CA1278659C - Process for manufacturing spunbonded webs - Google Patents
Process for manufacturing spunbonded websInfo
- Publication number
- CA1278659C CA1278659C CA000509539A CA509539A CA1278659C CA 1278659 C CA1278659 C CA 1278659C CA 000509539 A CA000509539 A CA 000509539A CA 509539 A CA509539 A CA 509539A CA 1278659 C CA1278659 C CA 1278659C
- Authority
- CA
- Canada
- Prior art keywords
- filament
- filaments
- yarn
- crimped
- mass
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
Classifications
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
- D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01D5/00—Formation of filaments, threads, or the like
- D01D5/08—Melt spinning methods
- D01D5/098—Melt spinning methods with simultaneous stretching
- D01D5/0985—Melt spinning methods with simultaneous stretching by means of a flowing gas (e.g. melt-blowing)
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H5/00—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
- D04H5/06—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by welding-together thermoplastic fibres, filaments, or yarns
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H5/00—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
- D04H5/08—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of fibres or yarns
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Mechanical Engineering (AREA)
- Nonwoven Fabrics (AREA)
- Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
- Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
- Glass Compositions (AREA)
- Artificial Filaments (AREA)
Abstract
ABSTRACT OF THE DISCLOSURE:
A process is disclosed for manufacturing spunbonded webs from spun fibers or filaments or both by blow-spinning a melt or solution of a spinnable polymeric material by means of a die head with die openings, and a collector. In the area between the die heads and the collector, crimped monofilament or crimped filament yarn or a plurality thereof having a modulus of at least 1 cN/dtex are applied or introduced under tension to or into the mass of the spun fibers or filaments forming the spunbonded webs by blowing using filament or filament yarn feed nozzles.
The crimped monofilament or filament yarn product added in the process has the main effect of imparting to the spunbonded webs a low and uniform density and an improved gas, vapor and liquid permeability. Elasticity is also improved.
A process is disclosed for manufacturing spunbonded webs from spun fibers or filaments or both by blow-spinning a melt or solution of a spinnable polymeric material by means of a die head with die openings, and a collector. In the area between the die heads and the collector, crimped monofilament or crimped filament yarn or a plurality thereof having a modulus of at least 1 cN/dtex are applied or introduced under tension to or into the mass of the spun fibers or filaments forming the spunbonded webs by blowing using filament or filament yarn feed nozzles.
The crimped monofilament or filament yarn product added in the process has the main effect of imparting to the spunbonded webs a low and uniform density and an improved gas, vapor and liquid permeability. Elasticity is also improved.
Description
786t59 The present invention relates to a process for manufacturing spunbonded webs from spun fibers or filaments by blow-spinning a mel~ or a solution of a ~pinnable polymeric material by means of a die head which has one or more die openings, and a collector.
German OfEenlegungsschrift No. 1,964,060 discloses manufacturing spunbonded webs by blow-spinning a polypro-pylene melt. Spunbonded web manufacture by blow-spinining also includes, incidentally, the conventional process as disclosed for example in French Patent No. 1,364,9160 German Offenlegungsschrift No. 1,900,265 likewise discloses a process for manufacturing spunbonded webs by spray-spinning (blow-spinning) fiber-forming polymers. It is pointed out in this publication that any organic polymer which is processable by melt-spinning or solvent-spinning can be used as the fiber-Eorming polymers in the process.
Polyolefins, for example polypropylene and polyethylene, and also cellulose acetate and triacetate, polyamides, polyacetals, polyesters and acrylic polymers are mentioned.
However, the spunbonded webs made from spun fibers or filaments using these known processes have the following disadvantages:
- for purposes such as thermal insulation their density is too high, in particular when they consist of microfibers or filaments;
- for use as a filter material; and - as a consequence of their high density - their gas, vapor and liquid permeability are too low.
It is known from U.S. Patent No. 4,11~,531 to reduce the density of spunbonded webs produced by blow-spinning microfibers - and hence to increase their bulk - by blowing crimped spun fibers (staple fibers), that is to say fibers of limited length, into the stream of blow-spun microfibers. However, such a process has the disadvantage, ~ G ~
~;~7865~
inter alia, that it is not possible to distribute the crimped spun fibers uniEormly in the spunbonded web, because, o~,in~ to their limited length and their crimp, they become tangl~d with one anot~er in the course of blowing-in.
5 This leads to ~gglomerations of these crimped spun fibers and hence to spunbonded webs of non-uniforM density.
It is the objec~ of ~he present invention to provide a process of the ~ype described at the beginning whereby it is possible, without the need for additional process steps after that of blow-spinning, to produce spunbonded webs which have a low and in particular uniform density and, for use as a filter material, an improved, that is to say increased, gas, vapor and liquid permeability.
According to the present invention, there is provided a process for manufacturing spunbonded webs from fibers and filaments by blow-spinning a melt or a solution of a spinnable polymeric material using a die head which has one or more die openings, and a collector, w here in inthe area between the die opening(s) and the collector, at least one crimped monofilament or at least one crimped filament yarn or both are applied or introduced under tension to or into a mass of the spun fibers and filaments which form the spunbonded webs by blowing, using filament or filament yarn feed nozzles, the monofilaments and fi lam ent yarns having a modulus of at least 1 cN/dtex.
The advanta~3e of blowing monofilaments or filament yarns on or in a spunbonded web using filament or filament yarn feed nozzles is that therewith the monofilaments and filament yarns can be applied to or introduced into the mass of the spun fibers or filaments forming the spunbonded webs in a controlled manner, as a result of which, it is possible to obtain an even better, that is to say, even more uniform, distribution of the monofilaments and filament yarns on or in the mass of the spun fibers or filaments and ~' hence on or in the spunbonded web For the purposes of the invention, the spinable polymeric materials used ~an be all those which are processable by melt-spinning or solvent-spinning (dry-spinning). Thus, polyole~ins, such as polyethylene andpolypropylerle, polyesters, such as polyethylene terephtha-late, polyamides, such as nylon-6.6 and nylon-6, cellulose esters, such as secondary acetate rayon and cellulose triacetate, and acrylic polymers, such as polyacrylonitrile are suitable.
Suitable crimped monofilaments and filament yarns are for example those which have been given a crimp by false-twist crimping, air-jet crimping or stufferbox crimping.
The monofilaments and filament yarns can consist for example of polyolefins, such as polyethylene and poly-propylene, polyesters, such as polyethylene terephthalate, polyamides, such as aromatic polyamides, nylon-6 and nylon-6.6, cellulose esters, such as secondary acetate rayon and cellulose triacetate, and acrylic polymers, such as polyacrylonitrile.
Specific examples are a false-twist crimped five-filament 22-dtex nylon-6.6 yarn and a false-twist crimped 13-filament 44-dtex nylon-6.6 yarn. The monofilaments and filament yarns, however, can also have a much lower or higher linear titer.
As above indicated, the monofilaments and filament yarns have a modulus of at least 1 cN/dtex.
The modulus (also referred to as modulus of elasticity or initial modulus) is obtained from the slope of the tangent to the first - linear -part of the stress-strain curve in which the stress per dtex is plotted on the Y-axis against the strain on the X-axis. The stress-strain curve is in each ~ase d~te~mined by a tensile test in accordance with DIN 53834.
Illustxative embodiments of the invention are further e~plained hereinafter by refer~nce to the drawings, in which Fig. 1 schematically depicts an apparatus for carrying out the process according to the invention in cross-section. This illustration shows the embodiment whereby crimped - monofilaments or - crimped - filament yarns are 2pplied to the mass of the spun fibers or filaments or both forming the spunbonded web, by means of deflecting rollers S;
Fig. 2 schemati¢ally depicts an apparatus for carrying out the process according to the invention in cross-section. This illu~tration shows the embodiment whereby -crimped - monofilaments or crimped - filament yarns are blown onto the mass of the spun fibers or filaments or both forming the spunbonded web, by means of filament and filament yarn feed nozzles 8 respectively;
Fig. 3 schematically depicts-an apparatus for carrying out the process according to the invention in cross-~ection. This illustration shows the embodiment whereby -crimped - monbfilaments or - crimped - filament yarns are introduced into the mass of the spun fibers or filaments or both forming the spunbonded web, by means of deflecting rollers 5;
Fig. 4 schematically depicts an apparatus for carrying out the process according to the invention in cross-section. This illustration shows the embodiment whereby -crimped - monofilaments or - crimped - fila~ent yarns are blown 3L~786~9 into the ~ass of the spun fibers or filaments or both forming the spunbonded web, by means of filament and filament yarn feed nozzles 8 respectively; and ig. 5 shows a view of the appara~us according to the invention in direction A of Figure 3 from the cross-sectional plane indicated there. This illustratio~ shows that the deflecting rollers 5 according to Figure 3 are each axranged - I
centrally - between two adjaoent die openings 2 underneath a die head 1.
The apparatus of Figure 1 has a die head 1 with die openings 2, a collector 3 and deflecting rollers 5. The deflecting rollers 5 are arranged so close ~o the side of the 'I
mass 6 of the spun fibers or filaments which emerge from the die openings 2 and which form the spunbonded web 7 that the crimped monofilaments 4 or crimped filament yarns 4 or both which are supplied via these deflecting rollers 5 are carried along by the gas stream which is caused by the blow-spinning and accompanies the mass 6 of the spun fibers or filaments and i5 referred to as the primary gas stream and are conveyed onto the mass 6 of the spun fibers or filaments. The crimped monofilaments or filaments may be applied transverse to the direc~ion of flow of the mass of spun fibers and filaments which form the web.
The apparatus of Figure 2 has a die head 1 with die openings 2, a collector 3 and filament and filament yarn feed nozzles 8. The feed nozzles 8 are arranged at the side of the mass 6 of the spun fibers or filaments which emerge from the die openings 2 and form the spunbonded web 7. By means of the _ 5 _ feed noz~les 8, which can ~e oper~ted with c~mpressed air ~r s~me other pressurized gas, the c:rimped monofilaments 4 or the crimped filament yarns 4 are supplied to the mass 6 of the SpUn fibers or filaments. For this, the pressure of this air or gas is set in s~ch a way that the monofilaments 4 or the filament yarns 4 are blown onto the mass 6 of the spun fibers or fila-ments, that is to say they do not penetrate into this mass 6, whereafter ~hey are carried along by the ga~ stream which is caused by the blow-spinning and accompanies the mass 6 of the s~un fibers or filaments and is referred to as the primary gas stream.
The apparatus of Figure 3 comprises a die head 1 with die openings 2, a collector 3 and deflecting rollers 5. The deflec~ing rollers 5 are each arranged underneath the die head 1 centrally between two neighboring die openings 2, so that the crimped monofilaments 4 or crimped filament yarns 4 fed via these deflection rollers 5 are introduced into the interior of the mass 6 of the spun fibers or filaments emerging from the die openings 2 and forming the spunbonded web 7. Thereafter they are carried along ~y the gas stream which is caused by the blow-spinning and accompanies the mass 6 of the spun fibers or filaments and is referred to as the primary gas siream.
The apparatus of Figure 4 has a die head 1 with die openings 2, a collector 3 and filament and filament yarn feed nozzles 8. The feed nozzles 8 are arranged to the side of the mass 6 of the spun fibers or filaments which emerge from the die openings 2 and form the spunbonded web 7. By means of the feed nozzles 8, which can be operated with compressed air or some other pressurized gas, the crimped monofilaments 4 or the 1~7E~6~rj9 crimped fi~amellt yarns 4 are supplied to the mass 6 of the Spun fib~s or fi.laments. Fo~ this, the pressure of this air or of -the yas is se~ in such a way that the monofilarnents 4 or the filame~Zt yarns 4 ar~ blown into the interior of the mass 6 of ~he spun fibers or filaments. Thereafter, they are carried along by the gas stream which is caused by the ~low-spinning and accompanies the mass 6 of the spun fibers or filaments and is referred to as the primary g~s stream.
The invention will now be described with reference to the followi.ng examples which are not oonsidered to limit the invention.
E~TnD1~ 1 (Comparative Example) This example was performed on the apparatus of Figure 4, except that the filament and filament yarn feed nozzles 8 were not in operation, so that no crimped monofilament 4 or crimped filament yarns 4 or both were blown into the mass 6 of the spun fibers or filaments emerging from the die openings 2 and forming the spunbonded web 7.
Polypropylene having a melt flow index at 230C/2.16 kg of 13 g/10 min, a density at 23C of 0.902 g/cm3 and a melting range of 165-170C was meited and spun (blow-spun) by means of die head 1, which was similar to that o f G e r m a n P a t e n t 2 , 5.5 0, 4 6 3, t h o u g h t h e die openings 2 to gi~e spun fibers and filaments which had an a~erage diameter of 1.0 ~m. The spun fibers and filaments were laid onto the collector 3, which consisted of a rotating drum, to form the spunbonded web.
36~5~3 The web o~ained had a weight per unit area of 170 g/m , a thickness oE 6 mm and an air pe~meability of 600 m3/m2.h at a differential pressure of 490.35 Pa.
Example 2 This example was likewise carried out using the same apparatus and the same polymer as in Example 1. The conditions corresponded to those of Example 1 except that in addition one of the filament or filamen-t yarn feed nozzles 8, which was similar to the nozzle described in German Utility Model 7,306,18~ published on May 17, 1973 and having as a~plicant Farbwerke Hoechs-t AG, vormals Meister Lucius und srueniny, was in operation. using this one feed nozzle 8, which was operated with compressed air, a false-twist crimped five-filament 22-dtex nylon-6.6 yarn having a modulus of 21 cN/dtex was supplied to the mass 6 of spun fibers and filaments, at an angle of 45 to the direction of flow of this mass 6. For this, the air pressure with which the feed nozzle 8 was operated had been adjusted in such a way that the nylon-6.6 filament yarn was blown into the interior of the mass 6 of spun fibers and filaments. The nylon-6.6 filamen-t yarn was carried along by the primary gas stream (a hot air s-tream) accompanying the mass 6 of fibers and filaments and randomly distributed within the mass 6 of spun fibers and filamen-ts.
The mass 6 of spun fibers and filaments including the nylon-6.6 filament yarn was laid on the collecting drum 3, the speed of rotation of which was the same as in Example 1, to form a spunbonded web.
the web obtained has a weight per unit area of 251 g/m2 and a thickness of 15 mm. The measurement of air ~78165~
pærme~bility on this web gave a value of 1,200 m3/m2.h at a slifferential pressure of 490.35 Pa.
~xa~ple 3 Example ~ was repeated, except ~hat the one feed nozzle 8 was used to blow not the false-twist ~rimped 5-filament 22~dtex nylon-6.6 yarn but a false twist crimped 13-, filament 44-dtex nylon-6.6 yarn having a modulus of 24 cN/dtex in~o the interior of the mass 6 of spun fibers and filaments, ; ~gain at an angle of 45 ~o ~he direction of flow of this mass I¦ 6, This 13-filament 44-dtex nylon-6.6 yarn was likewise ¦I carried along by the primary gas stream accompanying the mass 6 of spun fibers and filaments an~ randomly distributed within ,j the mass 6 of spun fibers and filaments.
The spunbonded web removed from the rotating ¦ collecting drum 3 had a weight per unit area of 230 g/m~ and a thickness of ~2 mm. The measurement of air permeability on this web gave a value of l,800 m3/m2.h at a differential pressure of 490.35 Pa.
1, It is also possible for the filament or filament yarn ii feed nozzles 8, which were arranged fixedly for carrying out ' Examples 2 and 3, to be arranged pivotably. The same is true of the deflecting rollers 5. It is thereby possible to obtain I, an even better, that is to say, even more uniform, distribution il of the monofilaments or filament yarns or both on or in the ~punbonded web.
Example 4 To describe the elastic properties of melt-blown webs ~I with introduced or applied crimped filament yarns according to ¦ the present in~ention, the elastic extensi~ility was measured ,, _ g _ ,. I
~ :78~
and compared with that of a similar conventional melt-blown web. Example 2 was repeated with the exceptions noted belo~ ~o make the samples.
Experimental Sa~ples:
Sample 1: Melt-blown polypropylene web according to the invPntion, with a ~lown-in textured ~4-dtex 13-filament nylon yarn, having a basis weight of about 380 g/m2 and weld dots at intervals of 40 mm.
Sample 2: (Comparative Sample) 1'l Melt-blown polypropylene web having a basis l! weight of about 350 g/m2 and an average fiber , diameter of 2.5 - 3.0 m.
Measured Results II TABLE
¦I Total extensibilitv E tot; Elastic extensibility E elast.
Sample 1 SamPle 2 10~ 9% 2%
1 25% 17% 5%
! so~ 34% Total extension 1, by 50% not possible The elastic extensibility E elast. is obtained by the formula j E tot. = E elast. + E irrev., jl where the irreversible extension E irrev. was mea ured under ¦ the following conditions: -il .
Il ., '' - 10-.
~L27~36 Time under load~ 45 ~lin Samplin~ ; 1st sample on removal of load 2nd sample 60 min ~fter removal of load 3rd sample 1~0 min after removal l~f load The table shows that melt~blown webs according to the inven~ion are approximately four times more elasti~ than conv~ntiofial melt-blo~m webs without crimped filament yarns.
If crimped monofilaments or the ~rimped filament yarns are applied to or introduced into the mass of the spun fibers or filaments or both which form the spun~onded wehs by blowing on or in by means of filament or filament yarn feed nozzles under tension, the following further unexpected results Il are obtained: I
,~ 1. a high elasticity of the ready-produced spun- !
bonded webs; and 2. a more three-dimensional arrangement of the spun fibers or filaments or both in the ready- ¦
produced spunbonded web.
By being blow in or on under tension the monofilaments or filament yarns are initially elasticall~ (not plastically) extended, so that at the instance of the blowing j' in or on the crimp is - temporarily - no longer present. The I crimp on the monofilaments or filament yarns reappears at or i within the spunbonded web its~lf, because the filaments or filament yarns were only elastically extended. The result is a high elasticity of the ready-produced spunbonded webs. Such a high elasticity is very important for exa~ple if ~.he spunbonded . , ~q~86~9 ~i webs obtained according to the invention are used for textile p~lrposes, for example as interlinings for apparel. This is because such interlinings are used to avoid the bulging of pieces of clothing, for example at the elbow.
As already explained above, by performing the blowing in or on under tension the monofilaments or filament yarns are initially extended elastically, so that the crimp is temporarily no longer present. The fact that according to our invention the crimp reappears within or at the spunbond~d we~
jl makes the rather ~wo-dimensional arrangement of the spun fibers !i or filaments or both in a prior art spunbonded web more three- !
dimensional or uniform density.
Another factor is that, in the known two-dimensional arrangement, the spun fibers or filaments are preferentially oriented in one direction, namely in machine direction. By j! contrast, the present invention makes it possible, for example !I by transverse blowing in or on of the crimped monofilaments or - l¦ filament yarns, to arrange the spun fibers or filaments or both of the spunbonded web themselves in various directions (that is I not only in machine direction).
! Finally, it is also important that the more three- !
dimensional arran~ement of the spun fibers or filaments or both in the ready-produced spunbonded web according to the invention l~ also results in a more or less pronounced surface structure (a ! "figured surface"~. This is important for example when the spunbonded webs according to the invention are used for the production of artificial leather.
1.
., .
; - 12 -': i ~7~ ;9 The invention has the following advantages:
~ y means of the process according to the invention it is possible to manufacture spunbonded webs which ha~e a lvw and uniform density and an increased gas~ vapor and liquid permeability without additional process steps after the blow-spinning step. Elasticity is also improved.
German OfEenlegungsschrift No. 1,964,060 discloses manufacturing spunbonded webs by blow-spinning a polypro-pylene melt. Spunbonded web manufacture by blow-spinining also includes, incidentally, the conventional process as disclosed for example in French Patent No. 1,364,9160 German Offenlegungsschrift No. 1,900,265 likewise discloses a process for manufacturing spunbonded webs by spray-spinning (blow-spinning) fiber-forming polymers. It is pointed out in this publication that any organic polymer which is processable by melt-spinning or solvent-spinning can be used as the fiber-Eorming polymers in the process.
Polyolefins, for example polypropylene and polyethylene, and also cellulose acetate and triacetate, polyamides, polyacetals, polyesters and acrylic polymers are mentioned.
However, the spunbonded webs made from spun fibers or filaments using these known processes have the following disadvantages:
- for purposes such as thermal insulation their density is too high, in particular when they consist of microfibers or filaments;
- for use as a filter material; and - as a consequence of their high density - their gas, vapor and liquid permeability are too low.
It is known from U.S. Patent No. 4,11~,531 to reduce the density of spunbonded webs produced by blow-spinning microfibers - and hence to increase their bulk - by blowing crimped spun fibers (staple fibers), that is to say fibers of limited length, into the stream of blow-spun microfibers. However, such a process has the disadvantage, ~ G ~
~;~7865~
inter alia, that it is not possible to distribute the crimped spun fibers uniEormly in the spunbonded web, because, o~,in~ to their limited length and their crimp, they become tangl~d with one anot~er in the course of blowing-in.
5 This leads to ~gglomerations of these crimped spun fibers and hence to spunbonded webs of non-uniforM density.
It is the objec~ of ~he present invention to provide a process of the ~ype described at the beginning whereby it is possible, without the need for additional process steps after that of blow-spinning, to produce spunbonded webs which have a low and in particular uniform density and, for use as a filter material, an improved, that is to say increased, gas, vapor and liquid permeability.
According to the present invention, there is provided a process for manufacturing spunbonded webs from fibers and filaments by blow-spinning a melt or a solution of a spinnable polymeric material using a die head which has one or more die openings, and a collector, w here in inthe area between the die opening(s) and the collector, at least one crimped monofilament or at least one crimped filament yarn or both are applied or introduced under tension to or into a mass of the spun fibers and filaments which form the spunbonded webs by blowing, using filament or filament yarn feed nozzles, the monofilaments and fi lam ent yarns having a modulus of at least 1 cN/dtex.
The advanta~3e of blowing monofilaments or filament yarns on or in a spunbonded web using filament or filament yarn feed nozzles is that therewith the monofilaments and filament yarns can be applied to or introduced into the mass of the spun fibers or filaments forming the spunbonded webs in a controlled manner, as a result of which, it is possible to obtain an even better, that is to say, even more uniform, distribution of the monofilaments and filament yarns on or in the mass of the spun fibers or filaments and ~' hence on or in the spunbonded web For the purposes of the invention, the spinable polymeric materials used ~an be all those which are processable by melt-spinning or solvent-spinning (dry-spinning). Thus, polyole~ins, such as polyethylene andpolypropylerle, polyesters, such as polyethylene terephtha-late, polyamides, such as nylon-6.6 and nylon-6, cellulose esters, such as secondary acetate rayon and cellulose triacetate, and acrylic polymers, such as polyacrylonitrile are suitable.
Suitable crimped monofilaments and filament yarns are for example those which have been given a crimp by false-twist crimping, air-jet crimping or stufferbox crimping.
The monofilaments and filament yarns can consist for example of polyolefins, such as polyethylene and poly-propylene, polyesters, such as polyethylene terephthalate, polyamides, such as aromatic polyamides, nylon-6 and nylon-6.6, cellulose esters, such as secondary acetate rayon and cellulose triacetate, and acrylic polymers, such as polyacrylonitrile.
Specific examples are a false-twist crimped five-filament 22-dtex nylon-6.6 yarn and a false-twist crimped 13-filament 44-dtex nylon-6.6 yarn. The monofilaments and filament yarns, however, can also have a much lower or higher linear titer.
As above indicated, the monofilaments and filament yarns have a modulus of at least 1 cN/dtex.
The modulus (also referred to as modulus of elasticity or initial modulus) is obtained from the slope of the tangent to the first - linear -part of the stress-strain curve in which the stress per dtex is plotted on the Y-axis against the strain on the X-axis. The stress-strain curve is in each ~ase d~te~mined by a tensile test in accordance with DIN 53834.
Illustxative embodiments of the invention are further e~plained hereinafter by refer~nce to the drawings, in which Fig. 1 schematically depicts an apparatus for carrying out the process according to the invention in cross-section. This illustration shows the embodiment whereby crimped - monofilaments or - crimped - filament yarns are 2pplied to the mass of the spun fibers or filaments or both forming the spunbonded web, by means of deflecting rollers S;
Fig. 2 schemati¢ally depicts an apparatus for carrying out the process according to the invention in cross-section. This illu~tration shows the embodiment whereby -crimped - monofilaments or crimped - filament yarns are blown onto the mass of the spun fibers or filaments or both forming the spunbonded web, by means of filament and filament yarn feed nozzles 8 respectively;
Fig. 3 schematically depicts-an apparatus for carrying out the process according to the invention in cross-~ection. This illustration shows the embodiment whereby -crimped - monbfilaments or - crimped - filament yarns are introduced into the mass of the spun fibers or filaments or both forming the spunbonded web, by means of deflecting rollers 5;
Fig. 4 schematically depicts an apparatus for carrying out the process according to the invention in cross-section. This illustration shows the embodiment whereby -crimped - monofilaments or - crimped - fila~ent yarns are blown 3L~786~9 into the ~ass of the spun fibers or filaments or both forming the spunbonded web, by means of filament and filament yarn feed nozzles 8 respectively; and ig. 5 shows a view of the appara~us according to the invention in direction A of Figure 3 from the cross-sectional plane indicated there. This illustratio~ shows that the deflecting rollers 5 according to Figure 3 are each axranged - I
centrally - between two adjaoent die openings 2 underneath a die head 1.
The apparatus of Figure 1 has a die head 1 with die openings 2, a collector 3 and deflecting rollers 5. The deflecting rollers 5 are arranged so close ~o the side of the 'I
mass 6 of the spun fibers or filaments which emerge from the die openings 2 and which form the spunbonded web 7 that the crimped monofilaments 4 or crimped filament yarns 4 or both which are supplied via these deflecting rollers 5 are carried along by the gas stream which is caused by the blow-spinning and accompanies the mass 6 of the spun fibers or filaments and i5 referred to as the primary gas stream and are conveyed onto the mass 6 of the spun fibers or filaments. The crimped monofilaments or filaments may be applied transverse to the direc~ion of flow of the mass of spun fibers and filaments which form the web.
The apparatus of Figure 2 has a die head 1 with die openings 2, a collector 3 and filament and filament yarn feed nozzles 8. The feed nozzles 8 are arranged at the side of the mass 6 of the spun fibers or filaments which emerge from the die openings 2 and form the spunbonded web 7. By means of the _ 5 _ feed noz~les 8, which can ~e oper~ted with c~mpressed air ~r s~me other pressurized gas, the c:rimped monofilaments 4 or the crimped filament yarns 4 are supplied to the mass 6 of the SpUn fibers or filaments. For this, the pressure of this air or gas is set in s~ch a way that the monofilaments 4 or the filament yarns 4 are blown onto the mass 6 of the spun fibers or fila-ments, that is to say they do not penetrate into this mass 6, whereafter ~hey are carried along by the ga~ stream which is caused by the blow-spinning and accompanies the mass 6 of the s~un fibers or filaments and is referred to as the primary gas stream.
The apparatus of Figure 3 comprises a die head 1 with die openings 2, a collector 3 and deflecting rollers 5. The deflec~ing rollers 5 are each arranged underneath the die head 1 centrally between two neighboring die openings 2, so that the crimped monofilaments 4 or crimped filament yarns 4 fed via these deflection rollers 5 are introduced into the interior of the mass 6 of the spun fibers or filaments emerging from the die openings 2 and forming the spunbonded web 7. Thereafter they are carried along ~y the gas stream which is caused by the blow-spinning and accompanies the mass 6 of the spun fibers or filaments and is referred to as the primary gas siream.
The apparatus of Figure 4 has a die head 1 with die openings 2, a collector 3 and filament and filament yarn feed nozzles 8. The feed nozzles 8 are arranged to the side of the mass 6 of the spun fibers or filaments which emerge from the die openings 2 and form the spunbonded web 7. By means of the feed nozzles 8, which can be operated with compressed air or some other pressurized gas, the crimped monofilaments 4 or the 1~7E~6~rj9 crimped fi~amellt yarns 4 are supplied to the mass 6 of the Spun fib~s or fi.laments. Fo~ this, the pressure of this air or of -the yas is se~ in such a way that the monofilarnents 4 or the filame~Zt yarns 4 ar~ blown into the interior of the mass 6 of ~he spun fibers or filaments. Thereafter, they are carried along by the gas stream which is caused by the ~low-spinning and accompanies the mass 6 of the spun fibers or filaments and is referred to as the primary g~s stream.
The invention will now be described with reference to the followi.ng examples which are not oonsidered to limit the invention.
E~TnD1~ 1 (Comparative Example) This example was performed on the apparatus of Figure 4, except that the filament and filament yarn feed nozzles 8 were not in operation, so that no crimped monofilament 4 or crimped filament yarns 4 or both were blown into the mass 6 of the spun fibers or filaments emerging from the die openings 2 and forming the spunbonded web 7.
Polypropylene having a melt flow index at 230C/2.16 kg of 13 g/10 min, a density at 23C of 0.902 g/cm3 and a melting range of 165-170C was meited and spun (blow-spun) by means of die head 1, which was similar to that o f G e r m a n P a t e n t 2 , 5.5 0, 4 6 3, t h o u g h t h e die openings 2 to gi~e spun fibers and filaments which had an a~erage diameter of 1.0 ~m. The spun fibers and filaments were laid onto the collector 3, which consisted of a rotating drum, to form the spunbonded web.
36~5~3 The web o~ained had a weight per unit area of 170 g/m , a thickness oE 6 mm and an air pe~meability of 600 m3/m2.h at a differential pressure of 490.35 Pa.
Example 2 This example was likewise carried out using the same apparatus and the same polymer as in Example 1. The conditions corresponded to those of Example 1 except that in addition one of the filament or filamen-t yarn feed nozzles 8, which was similar to the nozzle described in German Utility Model 7,306,18~ published on May 17, 1973 and having as a~plicant Farbwerke Hoechs-t AG, vormals Meister Lucius und srueniny, was in operation. using this one feed nozzle 8, which was operated with compressed air, a false-twist crimped five-filament 22-dtex nylon-6.6 yarn having a modulus of 21 cN/dtex was supplied to the mass 6 of spun fibers and filaments, at an angle of 45 to the direction of flow of this mass 6. For this, the air pressure with which the feed nozzle 8 was operated had been adjusted in such a way that the nylon-6.6 filament yarn was blown into the interior of the mass 6 of spun fibers and filaments. The nylon-6.6 filamen-t yarn was carried along by the primary gas stream (a hot air s-tream) accompanying the mass 6 of fibers and filaments and randomly distributed within the mass 6 of spun fibers and filamen-ts.
The mass 6 of spun fibers and filaments including the nylon-6.6 filament yarn was laid on the collecting drum 3, the speed of rotation of which was the same as in Example 1, to form a spunbonded web.
the web obtained has a weight per unit area of 251 g/m2 and a thickness of 15 mm. The measurement of air ~78165~
pærme~bility on this web gave a value of 1,200 m3/m2.h at a slifferential pressure of 490.35 Pa.
~xa~ple 3 Example ~ was repeated, except ~hat the one feed nozzle 8 was used to blow not the false-twist ~rimped 5-filament 22~dtex nylon-6.6 yarn but a false twist crimped 13-, filament 44-dtex nylon-6.6 yarn having a modulus of 24 cN/dtex in~o the interior of the mass 6 of spun fibers and filaments, ; ~gain at an angle of 45 ~o ~he direction of flow of this mass I¦ 6, This 13-filament 44-dtex nylon-6.6 yarn was likewise ¦I carried along by the primary gas stream accompanying the mass 6 of spun fibers and filaments an~ randomly distributed within ,j the mass 6 of spun fibers and filaments.
The spunbonded web removed from the rotating ¦ collecting drum 3 had a weight per unit area of 230 g/m~ and a thickness of ~2 mm. The measurement of air permeability on this web gave a value of l,800 m3/m2.h at a differential pressure of 490.35 Pa.
1, It is also possible for the filament or filament yarn ii feed nozzles 8, which were arranged fixedly for carrying out ' Examples 2 and 3, to be arranged pivotably. The same is true of the deflecting rollers 5. It is thereby possible to obtain I, an even better, that is to say, even more uniform, distribution il of the monofilaments or filament yarns or both on or in the ~punbonded web.
Example 4 To describe the elastic properties of melt-blown webs ~I with introduced or applied crimped filament yarns according to ¦ the present in~ention, the elastic extensi~ility was measured ,, _ g _ ,. I
~ :78~
and compared with that of a similar conventional melt-blown web. Example 2 was repeated with the exceptions noted belo~ ~o make the samples.
Experimental Sa~ples:
Sample 1: Melt-blown polypropylene web according to the invPntion, with a ~lown-in textured ~4-dtex 13-filament nylon yarn, having a basis weight of about 380 g/m2 and weld dots at intervals of 40 mm.
Sample 2: (Comparative Sample) 1'l Melt-blown polypropylene web having a basis l! weight of about 350 g/m2 and an average fiber , diameter of 2.5 - 3.0 m.
Measured Results II TABLE
¦I Total extensibilitv E tot; Elastic extensibility E elast.
Sample 1 SamPle 2 10~ 9% 2%
1 25% 17% 5%
! so~ 34% Total extension 1, by 50% not possible The elastic extensibility E elast. is obtained by the formula j E tot. = E elast. + E irrev., jl where the irreversible extension E irrev. was mea ured under ¦ the following conditions: -il .
Il ., '' - 10-.
~L27~36 Time under load~ 45 ~lin Samplin~ ; 1st sample on removal of load 2nd sample 60 min ~fter removal of load 3rd sample 1~0 min after removal l~f load The table shows that melt~blown webs according to the inven~ion are approximately four times more elasti~ than conv~ntiofial melt-blo~m webs without crimped filament yarns.
If crimped monofilaments or the ~rimped filament yarns are applied to or introduced into the mass of the spun fibers or filaments or both which form the spun~onded wehs by blowing on or in by means of filament or filament yarn feed nozzles under tension, the following further unexpected results Il are obtained: I
,~ 1. a high elasticity of the ready-produced spun- !
bonded webs; and 2. a more three-dimensional arrangement of the spun fibers or filaments or both in the ready- ¦
produced spunbonded web.
By being blow in or on under tension the monofilaments or filament yarns are initially elasticall~ (not plastically) extended, so that at the instance of the blowing j' in or on the crimp is - temporarily - no longer present. The I crimp on the monofilaments or filament yarns reappears at or i within the spunbonded web its~lf, because the filaments or filament yarns were only elastically extended. The result is a high elasticity of the ready-produced spunbonded webs. Such a high elasticity is very important for exa~ple if ~.he spunbonded . , ~q~86~9 ~i webs obtained according to the invention are used for textile p~lrposes, for example as interlinings for apparel. This is because such interlinings are used to avoid the bulging of pieces of clothing, for example at the elbow.
As already explained above, by performing the blowing in or on under tension the monofilaments or filament yarns are initially extended elastically, so that the crimp is temporarily no longer present. The fact that according to our invention the crimp reappears within or at the spunbond~d we~
jl makes the rather ~wo-dimensional arrangement of the spun fibers !i or filaments or both in a prior art spunbonded web more three- !
dimensional or uniform density.
Another factor is that, in the known two-dimensional arrangement, the spun fibers or filaments are preferentially oriented in one direction, namely in machine direction. By j! contrast, the present invention makes it possible, for example !I by transverse blowing in or on of the crimped monofilaments or - l¦ filament yarns, to arrange the spun fibers or filaments or both of the spunbonded web themselves in various directions (that is I not only in machine direction).
! Finally, it is also important that the more three- !
dimensional arran~ement of the spun fibers or filaments or both in the ready-produced spunbonded web according to the invention l~ also results in a more or less pronounced surface structure (a ! "figured surface"~. This is important for example when the spunbonded webs according to the invention are used for the production of artificial leather.
1.
., .
; - 12 -': i ~7~ ;9 The invention has the following advantages:
~ y means of the process according to the invention it is possible to manufacture spunbonded webs which ha~e a lvw and uniform density and an increased gas~ vapor and liquid permeability without additional process steps after the blow-spinning step. Elasticity is also improved.
Claims (9)
1. A process for manufacturing spunbonded webs from fibers and filaments by blow-spinning a melt or a solution of a spinnable polymeric material using a die head which has one or more die openings, and a collector, wherein in the area between the die opening(s) and the collector, at least one crimped monofilament or at least one crimped filament yarn or both are applied or introduced under tension to or into a mass of the spun fibers and filaments which form the spunbonded webs by blowing, using filament or filament yarn feed nozzles, the monofilaments and filament yarns having a modulus of at least 1 cN/dtex.
2. The process according to claim 1, wherein the crimped monofilaments or filament yarns are blown transverse to the direction of flow of the mass of the spun fibers and filaments which form the spunbonded webs.
3. The process according to claim 1, further comprising a density of about 0.01 gram per cubic centimeter.
4. The process according to claim 1, wherein the yarn is 44 dtex 13-filament polyamide yarn.
5. The process according to claim 1, wherein the yarn is 44 dtex polyamide 6.6 yarn having a modulus of 24 cN/dtex.
6. The process according to claim 1, wherein the yarn is 22 dtex polyamide 6.6 yarn.
7. The process according to claim 1, wherein the filament or yarn is of polyolefin, polyester, polyamide, cellulose ester or acrylic polymer.
8. The process according to claim 7, wherein the filament or yarn is of polyethylene, polypropylene, polyethylene terephthalate, aromatic polyamide, secondary acetate rayon, cellulose triacetate, or polyacrylonitrile.
9. The process according to claim 1, wherein the fibers or filaments are blown in or at an angle of 45° to the direction of flow of the mass of the spun fibers and filaments which form the webs.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DEP3521221.7 | 1985-06-13 | ||
| DE19853521221 DE3521221A1 (en) | 1985-06-13 | 1985-06-13 | METHOD FOR PRODUCING SPINNING FLEECE |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1278659C true CA1278659C (en) | 1991-01-08 |
Family
ID=6273190
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000509539A Expired - Lifetime CA1278659C (en) | 1985-06-13 | 1986-05-20 | Process for manufacturing spunbonded webs |
Country Status (7)
| Country | Link |
|---|---|
| EP (1) | EP0205736B1 (en) |
| JP (1) | JPS61289164A (en) |
| AT (1) | ATE72272T1 (en) |
| CA (1) | CA1278659C (en) |
| DE (2) | DE3521221A1 (en) |
| ES (1) | ES8702960A1 (en) |
| NO (1) | NO861034L (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109943980A (en) * | 2017-12-20 | 2019-06-28 | 财团法人纺织产业综合研究所 | Nonwoven fabric construct and its production method |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE3787775T2 (en) * | 1986-08-22 | 1994-04-28 | Minnesota Mining & Mfg | Durable sheet-like material of the melt-blown type. |
| US5685757A (en) * | 1989-06-20 | 1997-11-11 | Corovin Gmbh | Fibrous spun-bonded non-woven composite |
| DE19609143C1 (en) * | 1996-03-08 | 1997-11-13 | Rhodia Ag Rhone Poulenc | Melt-blown fleece, process for its production and its uses |
Family Cites Families (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB772628A (en) * | 1953-11-23 | 1957-04-17 | Owens Corning Fiberglass Corp | Improved method for producing laminated sheet material from plastic or mineral fibres |
| NL295177A (en) * | 1963-11-29 | |||
| GB1213441A (en) * | 1968-01-04 | 1970-11-25 | Celanese Corp | Improvements in fibrous products |
| CA995430A (en) * | 1968-12-23 | 1976-08-24 | Robert R. Buntin | Non-woven polypropylene mats by melt blowing |
| CA1073648A (en) * | 1976-08-02 | 1980-03-18 | Edward R. Hauser | Web of blended microfibers and crimped bulking fibers |
| JPS53114974A (en) * | 1977-03-15 | 1978-10-06 | Toa Nenryo Kogyo Kk | Method and apparatus for making nonnwoven structure |
-
1985
- 1985-06-13 DE DE19853521221 patent/DE3521221A1/en not_active Ceased
-
1986
- 1986-02-14 DE DE8686101924T patent/DE3683691D1/en not_active Expired - Fee Related
- 1986-02-14 EP EP86101924A patent/EP0205736B1/en not_active Expired - Lifetime
- 1986-02-14 AT AT86101924T patent/ATE72272T1/en not_active IP Right Cessation
- 1986-03-18 NO NO861034A patent/NO861034L/en unknown
- 1986-03-19 ES ES553159A patent/ES8702960A1/en not_active Expired
- 1986-04-01 JP JP61072623A patent/JPS61289164A/en active Pending
- 1986-05-20 CA CA000509539A patent/CA1278659C/en not_active Expired - Lifetime
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109943980A (en) * | 2017-12-20 | 2019-06-28 | 财团法人纺织产业综合研究所 | Nonwoven fabric construct and its production method |
| CN109943980B (en) * | 2017-12-20 | 2021-02-23 | 财团法人纺织产业综合研究所 | Non-woven fabric structure and manufacturing method thereof |
Also Published As
| Publication number | Publication date |
|---|---|
| ES553159A0 (en) | 1987-01-16 |
| NO861034L (en) | 1986-12-15 |
| EP0205736B1 (en) | 1992-01-29 |
| DE3521221A1 (en) | 1986-12-18 |
| EP0205736A3 (en) | 1989-09-06 |
| EP0205736A2 (en) | 1986-12-30 |
| DE3683691D1 (en) | 1992-03-12 |
| ATE72272T1 (en) | 1992-02-15 |
| JPS61289164A (en) | 1986-12-19 |
| ES8702960A1 (en) | 1987-01-16 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| US3509009A (en) | Non-woven fabric | |
| US3441468A (en) | Process for the production of non-woven webs | |
| US4048364A (en) | Post-drawn, melt-blown webs | |
| US3565729A (en) | Non-woven fabric | |
| US4950529A (en) | Polyallylene sulfide nonwoven fabric | |
| US3528129A (en) | Apparatus for producing nonwoven fleeces | |
| US5993943A (en) | Oriented melt-blown fibers, processes for making such fibers and webs made from such fibers | |
| US5562986A (en) | Polytetrafluoroethylene fibers, polytetrafluoroethylene materials and process for preparation of the same | |
| US4988560A (en) | Oriented melt-blown fibers, processes for making such fibers, and webs made from such fibers | |
| US3156607A (en) | Lobed filament | |
| US3630816A (en) | Nonwoven sheets made from rectangular cross section monofilaments | |
| US20080287025A1 (en) | Nonwovens, Method for the Production Thereof and the Use Thereof | |
| KR20100014567A (en) | Splittable conjugate fiber, aggregate thereof, and fibrous form made from splittable conjugate fibers | |
| GB2053078A (en) | Method of producing melt-spun crystalline filaments which are stretched to orientate the molecules | |
| CA2076726C (en) | Paper machine felt and method for the manufacture thereof | |
| US4943481A (en) | Polyether imide fibers | |
| CA1278659C (en) | Process for manufacturing spunbonded webs | |
| EP0780498A1 (en) | Melt spun acrylonitrile olefinically unsaturated fibers and a process to make fibers | |
| US3707838A (en) | Process for the production of staple fibers | |
| EP1749916A1 (en) | Nonwoven fabrics and methods for making the same | |
| CA2451134A1 (en) | Filament draw jet apparatus and process | |
| US3268084A (en) | Bulked non-wovens | |
| KR100680373B1 (en) | Non-woven fabric and preparation thereof | |
| EP0581909A1 (en) | Oriented melt-blown fibers, processes for making such fibers, and webs made from such fibers. | |
| JPS589185B2 (en) | Japanese sagebrush |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKLA | Lapsed |