CA2396976A1 - Method and device for bonding a non-woven fibre produced by the air-lay method - Google Patents
Method and device for bonding a non-woven fibre produced by the air-lay method Download PDFInfo
- Publication number
- CA2396976A1 CA2396976A1 CA002396976A CA2396976A CA2396976A1 CA 2396976 A1 CA2396976 A1 CA 2396976A1 CA 002396976 A CA002396976 A CA 002396976A CA 2396976 A CA2396976 A CA 2396976A CA 2396976 A1 CA2396976 A1 CA 2396976A1
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- Prior art keywords
- woven fabric
- air
- fibres
- lay method
- strengthening
- Prior art date
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- Abandoned
Links
- 238000000034 method Methods 0.000 title claims abstract description 59
- 239000000835 fiber Substances 0.000 title claims abstract description 13
- 239000010410 layer Substances 0.000 claims abstract description 44
- 239000002131 composite material Substances 0.000 claims abstract description 27
- 239000004745 nonwoven fabric Substances 0.000 claims description 56
- 238000005728 strengthening Methods 0.000 claims description 27
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 11
- 239000002344 surface layer Substances 0.000 claims description 7
- 239000002250 absorbent Substances 0.000 claims description 6
- 238000000465 moulding Methods 0.000 claims description 6
- 239000000853 adhesive Substances 0.000 claims description 5
- 230000001070 adhesive effect Effects 0.000 claims description 5
- 230000004927 fusion Effects 0.000 claims description 5
- 238000010438 heat treatment Methods 0.000 claims description 5
- 238000009423 ventilation Methods 0.000 claims description 4
- 229920003043 Cellulose fiber Polymers 0.000 claims description 3
- 238000003490 calendering Methods 0.000 claims description 2
- 229920000642 polymer Polymers 0.000 claims description 2
- 238000001035 drying Methods 0.000 claims 2
- 238000011144 upstream manufacturing Methods 0.000 claims 1
- 238000004519 manufacturing process Methods 0.000 abstract description 4
- 239000000203 mixture Substances 0.000 abstract description 3
- 238000007796 conventional method Methods 0.000 abstract 1
- 239000002365 multiple layer Substances 0.000 abstract 1
- 230000002745 absorbent Effects 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 230000005855 radiation Effects 0.000 description 1
- 238000007669 thermal treatment Methods 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
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
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
- D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
- D04H1/49—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation entanglement by fluid jet in combination with another consolidation means
-
- 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
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/407—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties containing absorbing substances, e.g. activated carbon
-
- 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
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/425—Cellulose series
-
- 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
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
- D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
-
- 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
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
- D04H1/498—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres entanglement of layered webs
-
- 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
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
-
- 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
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/556—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving by infrared heating
-
- 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
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
- D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
- D04H1/732—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged by fluid current, e.g. air-lay
-
- 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
- D04H13/00—Other non-woven fabrics
-
- 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
- D04H18/00—Needling machines
- D04H18/04—Needling machines with water jets
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Nonwoven Fabrics (AREA)
- Laminated Bodies (AREA)
- Treatment Of Fiber Materials (AREA)
- Reinforced Plastic Materials (AREA)
- Absorbent Articles And Supports Therefor (AREA)
- Preliminary Treatment Of Fibers (AREA)
Abstract
The conventional method for production of a multiple-layer, non-woven fibre is by means of the air-lay method, with thermal bonding using bonding fibres. The same method can be applied to a composite non-woven fibre with an intermediate pulp layer. This method of bonding does not reduce the later pilling wear and hardly influences the inner composition of the layers of the composite.
According to the invention, the outer non-woven fibre is preferably made from a bicomponent fibre and treated by hydrodynamic needling for bonding, such that not just the surface is bonded, but also the layers are bonded to each other.
According to the invention, the outer non-woven fibre is preferably made from a bicomponent fibre and treated by hydrodynamic needling for bonding, such that not just the surface is bonded, but also the layers are bonded to each other.
Description
08-03-2002: 864 Replacement page T" March, 2002 Method, device and composite non-woven fabric for strengthening a non-woven fabric produced according to the air-lay method WO 97/30223 makes known an air-lay method for producing a composite non-woven fabric, where a plurality of air-lay moulding heads of the type according to 772 are disposed one behind the other and produce a composite non-woven fabric from connecting fibres, then cellulose fibres and again connecting fibres.
This type of production has the advantage of higher achievable speed compared to the formation of card non-woven fabric. For strengthening, a calender and a through-ventilation unit are connected and the object of these is to attach the connecting fibres to one another using heat.
This type of strengthening does not create a non-woven fabric which meets the conditions in practice. The individual layers have no cohesive strength, the non-woven fabric components detaminate and split. The surfaces of the non-woven fabric are also liable to wear and tear.
The object of the invention is to find a method, the fibres from which should make up this type of non-woven fabric for the air-lay method and subsequently to find how this fabric should be strengthened to prevent, amongst other things, delaminating.
Proceeding from a method, where for the strengthening of a non-woven fabric, which has been produced according to the air-lay method, - comprising two outer layers made of cut, thermally activatable fibres and one layer of cellulose fibres, such a super-absorbent pulp, which is disposed between these outer layers, through continuous forming of initially the lower layer, then overlaying with the pulp layer and finally the top layer - simply one thermal treatment is provided, it is provided according to the invention to form initially the two outer layers of the composite non-woven fabric from fibres which are from 8 to 10 mm maximum in length and then to subject the three-layered non-woven fabric to a hydrodynamic needling process for strengthening, that is to say also for the intimate bonding of the layers, which are laid solely according to the air-lay method,. In an advantageous manner here, the multi-layered composite non-woven fabric comprises two outer layers, which are formed AMENDED SHEET
EBti488 2 08-03-2002: 864 Replacement page T" Maroh, 2002 according to the air-lay method from fusion adhesive fibres, such as more especially double-component fibres or and other fibres, such a high polymer fibres, between which layers is placed another layer of super-absorbent pulp, also produced solely according to the air-lay method, and whereby this composite non-woven fabric, which is produced solely according to the air-lay method, is subsequently strengthened by means of the hydrodynamic needling process.
This type of non-woven fabric composition for the surface Layers and the type of strengthening by means of the water needling process guarantees a surface which is free of pilling and tinting, but which, nevertheless, is porous to liquid and can also cover a stronger, absorbent pulp layer. The two outer layers of this type of non-woven fabric ate intensively strengthened by the water needling process and are also bonded to the pulp layer, which is what the dreaded laminating of the fibre types after strengthening prevents. For sufficient strengthening of the surface layers, both the layers are preferably treated with the water needling process, that is to say the composite non woven fabric is needled on both sides.
Solely hydrodynamic needling of a composite non woven fabric is made known by US-A-5 413 849. In this case however, the outer layers are deposited as card non-woven fabric, that is to say they are made from considerably longer staple fibres, and the central layer comprises resilient continuous fibres, which give the entire composite non-woven fabric a stability. The outer card non-woven fabric layers made of staple fibres can be replaced partially by the short pulp fibres, which can also be Paid using the air-lay method. The same is valid in conjunction with WO
92/08834. In this case, a mixture of staple fibres and pulp fibres are water needled, nothing being stipulated about the length of the fibres, however the fibres are not laid according to the air-lay method.
The fusion adhesive fibres should be treated for further bonding on each other and to each other by means of heat. The heat also influences the required surface finish of the non-woven fabric. In this respect, the double-component fibre is particularly advantageous because it remains preserved as original fibre during the heat treatment, whilst the normal fusion adhesive fibre can fuse and shrink, which is disadvantageous for the forming of the resistant surface. This measure of heating the fusion adhesive fibres is already known through US-A-5 240 764, however not in conjunction with the double-component fibres. The heat treatment can be effected in the most varied way; the essential point is the fibres bonding well on the surface and transversely through the surface non-woven fabric.
A device of the type according to the invention is represented as an example in the drawing. Further inventive details can be explained by way of this example. In which:
Figure 1 is the side view of a continuous system for the production and strengthening of a dry non-woven fabric, which has been laid according to the air-lay method, and Figure 2 is a system similar to Figure 1 with no thermo bonding according to the lay method.
The non-woven fabric is initially formed from staple fibres and pulp. The staple fibres must be cut short enough for them to be laid according to the air-lay method, i.e. they are from 8 to 10 mm maximum in length. The moulding head 1 is then ***
AMENDED SHEET
charged with the staple fibres for the base Layer of the non-woven fabric. The staple fibres are such that they can be b~aught to adhesion under the influence of heat.
More especially advantageous here are double-component fibres, which have the advantage that they do not shrink under the influence of heat, but remain preserved as fibre. Onto the base non-woven fabric formed with the moulding head 1 then comes the pulp layer with the moulding head 2, where applicable a thicker pulp layer again with another moulding head (not illustrated), and then the top surface layer made of staple fibres. This composite non-woven fabric 4 then has to be strengthened and up to now this has only been effected by means of thermo bonding.
According to the system in Figure 1, the non-woven fabric 4 is first pre-strengthened by means of heat in the device 5. This can be effected by means of hot air (through-ventilation), but also with the application of infrared radiation or with calendering.
This pre-strengthening measure has the advantage of obtaining better surface closure of the surface layers, which can prevent a greater loss of pulp during the subsequent needling process. The system shown in Figure 2 does not have this pre-strengthening under heat. Therefore, depending on the fibre and other conditions, the pre-strengthening measure can be left out.
The composite non-woven fabric 4 is then acted upon by the hydrodynamic needling process. As, in this case, we are talking about a non-woven fabric with surface layers on both sides, it is expedient to execute the strengthening process with the water jets on both sides. This is why the needling arrangement is represented in the Figures with two drums 6 and 7, which is only to indicate that the non-woven fabric is to be conveyed in a meander-shaped manner about the drums so that it can be acted upon on both sides by the water jets. This water jet strengthening process not only influences the surface of the composite non-woven fabric, but also the deeper cohesive strength of the layers such that a subsequent delaminating of the individual non-woven fabric layers no longer occurs.
After the strengthening of the composite non-woven fabric and also the bonding of the layers with each other by means of the water jets, the non-woven fabric must be dried. For this purpose, a through-ventilation drier 8, such as a sieve drum drier, is advantageously advantageous. Finally, the nan-woven fabric can be calibrated again by means of the arrangement 9, as is only represented in the system shown in Figure 2.
This type of composite non-woven fabric is very economical because it can be produced at high speeds, such as, for example, 400 - 500 mlmin. A very absorbent product of 40 -100 glm2 can be produced, as the pulp layer can be thick. At the same time, the surface layers should be thin in relation to the pulp layer, for example g/m2, whilst the pulp layer can be heavy at 60 g/m2. Through a combination of thermo bonding and water needling, the surface is not only essentially free of tinting and pilling, but the non-woven fabric is also strengthened through and through and this makes it difficult to separate the layers of the non-woven fabric.
This type of production has the advantage of higher achievable speed compared to the formation of card non-woven fabric. For strengthening, a calender and a through-ventilation unit are connected and the object of these is to attach the connecting fibres to one another using heat.
This type of strengthening does not create a non-woven fabric which meets the conditions in practice. The individual layers have no cohesive strength, the non-woven fabric components detaminate and split. The surfaces of the non-woven fabric are also liable to wear and tear.
The object of the invention is to find a method, the fibres from which should make up this type of non-woven fabric for the air-lay method and subsequently to find how this fabric should be strengthened to prevent, amongst other things, delaminating.
Proceeding from a method, where for the strengthening of a non-woven fabric, which has been produced according to the air-lay method, - comprising two outer layers made of cut, thermally activatable fibres and one layer of cellulose fibres, such a super-absorbent pulp, which is disposed between these outer layers, through continuous forming of initially the lower layer, then overlaying with the pulp layer and finally the top layer - simply one thermal treatment is provided, it is provided according to the invention to form initially the two outer layers of the composite non-woven fabric from fibres which are from 8 to 10 mm maximum in length and then to subject the three-layered non-woven fabric to a hydrodynamic needling process for strengthening, that is to say also for the intimate bonding of the layers, which are laid solely according to the air-lay method,. In an advantageous manner here, the multi-layered composite non-woven fabric comprises two outer layers, which are formed AMENDED SHEET
EBti488 2 08-03-2002: 864 Replacement page T" Maroh, 2002 according to the air-lay method from fusion adhesive fibres, such as more especially double-component fibres or and other fibres, such a high polymer fibres, between which layers is placed another layer of super-absorbent pulp, also produced solely according to the air-lay method, and whereby this composite non-woven fabric, which is produced solely according to the air-lay method, is subsequently strengthened by means of the hydrodynamic needling process.
This type of non-woven fabric composition for the surface Layers and the type of strengthening by means of the water needling process guarantees a surface which is free of pilling and tinting, but which, nevertheless, is porous to liquid and can also cover a stronger, absorbent pulp layer. The two outer layers of this type of non-woven fabric ate intensively strengthened by the water needling process and are also bonded to the pulp layer, which is what the dreaded laminating of the fibre types after strengthening prevents. For sufficient strengthening of the surface layers, both the layers are preferably treated with the water needling process, that is to say the composite non woven fabric is needled on both sides.
Solely hydrodynamic needling of a composite non woven fabric is made known by US-A-5 413 849. In this case however, the outer layers are deposited as card non-woven fabric, that is to say they are made from considerably longer staple fibres, and the central layer comprises resilient continuous fibres, which give the entire composite non-woven fabric a stability. The outer card non-woven fabric layers made of staple fibres can be replaced partially by the short pulp fibres, which can also be Paid using the air-lay method. The same is valid in conjunction with WO
92/08834. In this case, a mixture of staple fibres and pulp fibres are water needled, nothing being stipulated about the length of the fibres, however the fibres are not laid according to the air-lay method.
The fusion adhesive fibres should be treated for further bonding on each other and to each other by means of heat. The heat also influences the required surface finish of the non-woven fabric. In this respect, the double-component fibre is particularly advantageous because it remains preserved as original fibre during the heat treatment, whilst the normal fusion adhesive fibre can fuse and shrink, which is disadvantageous for the forming of the resistant surface. This measure of heating the fusion adhesive fibres is already known through US-A-5 240 764, however not in conjunction with the double-component fibres. The heat treatment can be effected in the most varied way; the essential point is the fibres bonding well on the surface and transversely through the surface non-woven fabric.
A device of the type according to the invention is represented as an example in the drawing. Further inventive details can be explained by way of this example. In which:
Figure 1 is the side view of a continuous system for the production and strengthening of a dry non-woven fabric, which has been laid according to the air-lay method, and Figure 2 is a system similar to Figure 1 with no thermo bonding according to the lay method.
The non-woven fabric is initially formed from staple fibres and pulp. The staple fibres must be cut short enough for them to be laid according to the air-lay method, i.e. they are from 8 to 10 mm maximum in length. The moulding head 1 is then ***
AMENDED SHEET
charged with the staple fibres for the base Layer of the non-woven fabric. The staple fibres are such that they can be b~aught to adhesion under the influence of heat.
More especially advantageous here are double-component fibres, which have the advantage that they do not shrink under the influence of heat, but remain preserved as fibre. Onto the base non-woven fabric formed with the moulding head 1 then comes the pulp layer with the moulding head 2, where applicable a thicker pulp layer again with another moulding head (not illustrated), and then the top surface layer made of staple fibres. This composite non-woven fabric 4 then has to be strengthened and up to now this has only been effected by means of thermo bonding.
According to the system in Figure 1, the non-woven fabric 4 is first pre-strengthened by means of heat in the device 5. This can be effected by means of hot air (through-ventilation), but also with the application of infrared radiation or with calendering.
This pre-strengthening measure has the advantage of obtaining better surface closure of the surface layers, which can prevent a greater loss of pulp during the subsequent needling process. The system shown in Figure 2 does not have this pre-strengthening under heat. Therefore, depending on the fibre and other conditions, the pre-strengthening measure can be left out.
The composite non-woven fabric 4 is then acted upon by the hydrodynamic needling process. As, in this case, we are talking about a non-woven fabric with surface layers on both sides, it is expedient to execute the strengthening process with the water jets on both sides. This is why the needling arrangement is represented in the Figures with two drums 6 and 7, which is only to indicate that the non-woven fabric is to be conveyed in a meander-shaped manner about the drums so that it can be acted upon on both sides by the water jets. This water jet strengthening process not only influences the surface of the composite non-woven fabric, but also the deeper cohesive strength of the layers such that a subsequent delaminating of the individual non-woven fabric layers no longer occurs.
After the strengthening of the composite non-woven fabric and also the bonding of the layers with each other by means of the water jets, the non-woven fabric must be dried. For this purpose, a through-ventilation drier 8, such as a sieve drum drier, is advantageously advantageous. Finally, the nan-woven fabric can be calibrated again by means of the arrangement 9, as is only represented in the system shown in Figure 2.
This type of composite non-woven fabric is very economical because it can be produced at high speeds, such as, for example, 400 - 500 mlmin. A very absorbent product of 40 -100 glm2 can be produced, as the pulp layer can be thick. At the same time, the surface layers should be thin in relation to the pulp layer, for example g/m2, whilst the pulp layer can be heavy at 60 g/m2. Through a combination of thermo bonding and water needling, the surface is not only essentially free of tinting and pilling, but the non-woven fabric is also strengthened through and through and this makes it difficult to separate the layers of the non-woven fabric.
Claims (13)
1. Method for strengthening a non-woven fabric, which has been produced according to the air-lay method, comprising two outer layers made of cut, thermally activatable fibres and one layer made of cellulose fibres, such as super-absorbent pulp, which is disposed between these outer layers, through continuous forming of initially the lower layer, then overlaying with the pulp layer and finally the top layer, characterised in that the two outer layers of the composite non-woven fabric are formed from fibres, which are from 8 to 10 mm maximum in length, and the three-layered non-woven fabric is subjected to a hydrodynamic needling process for the strengthening, that is to say also for the intimate bonding of the layers, which are laid solely according to the air-lay method.
2. Method according to claim 1, characterised in that in addition to the strengthening by means of the hydrodynamic needling process, the composite non-woven fabric, which is formed solely according to the air-lay method, is treated by means of a thermal strengthening process.
3. Method according to claim 2, characterised in that the term thermal strengthening includes the treatment of the non-woven fabric, which is formed solely according to the air-lay method, with every type of heat treatment, namely heat treatment, for example, with hot air, more especially through-ventilation, with infra-red, with calendering.
4. Method according to claim 2 or 3, characterised in that the composite non-woven fabric, which is formed solely according to the air-lay method, is thermally treated before and/or after the water needling process for strengthening.
5. Method according to one of the claims 2 - 4, characterised in that the thermal strengthening together with the drying of the non-woven fabric, which is formed solely according to the air-lay method, is executed after the water needling process.
6. Method according to one of claims 2 - 5, characterised in that at the end of the strengthening process, the composite non-woven fabric, which is formed solely according to the air-lay method, is calibrated again.
7. Method according to one of claims 1 - 6, characterised in that the hydrodynamic treatment is executed on both sides of the composite non-woven fabric, which is formed solely according to the air-lay method.
8. Device for executing the method in accordance with one of claims 1 - 7, comprising the following disposed one after the other in a line a) at least three moulding heads working according to the air-lay method, one for the first layer made of thermally activatable fibres with a fibre length from 8 to 10 mm maximum, one for the pulp and one for the top surface layer again for the thermally activatable fibres with a fibre length of from 8 to 10 mm maximum, and a b) non-woven fabric strengthening unit, which comprises a hydrodynamic needling device (6, 7) and a drier (8).
9. Device according to claim 8, characterised in that upstream of the device for the hydrodynamic needling of a composite non-woven fabric, which is formed solely according to the air-lay method, c) is disposed a device (5) for the thermal strengthening.
10. Device according to claim 8 or 9, characterised in that downstream of the device for the hydrodynamic needling of a composite non-woven fabric, which is formed solely according to the air-lay method, d) is disposed a device (8) for the thermal strengthening.
11. Device according to claim 10, characterised in that the device (8) for the thermal strengthening of a composite non-woven fabric, which is formed solely according to the air-lay method, is provided after the hydrodynamic needling initially for the drying of the non-woven fabric.
12. Device according to one of claims 8 -11, characterised in that a calibrating device (9) is provided as the last unit for treating the composite non-woven fabric, which is formed solely according to the air-lay method.
13. Multi-layered composite non-woven fabric comprising two outer layers, which are formed in accordance with the air-lay method from fusion adhesive fibres, which are from 8 to 10 mm maximum in length, such as more especially double component fibres or and other fibres, such as high polymer fibres, between which layers is laid a further layer made of super-absorbent pulp, which is also produced according to the air-lay method, wherein this composite non-woven fabric, which is formed solely according to the air-lay method, is strengthened by means of the hydrodynamic needling.
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE10001957.9 | 2000-01-18 | ||
DE10001957A DE10001957A1 (en) | 2000-01-18 | 2000-01-18 | Air laying non-wovens with melt adhesive fiber outer and cellulose inner layers includes bonding of all three layers by water jet needle punching |
PCT/EP2001/000406 WO2001053589A1 (en) | 2000-01-18 | 2001-01-16 | Method and device for bonding a non-woven fibre produced by the air-lay method |
Publications (1)
Publication Number | Publication Date |
---|---|
CA2396976A1 true CA2396976A1 (en) | 2001-07-26 |
Family
ID=7627904
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CA002396976A Abandoned CA2396976A1 (en) | 2000-01-18 | 2001-01-16 | Method and device for bonding a non-woven fibre produced by the air-lay method |
Country Status (13)
Country | Link |
---|---|
US (1) | US20030101556A1 (en) |
EP (1) | EP1294971B1 (en) |
JP (1) | JP2003527495A (en) |
KR (1) | KR20020071936A (en) |
CN (1) | CN1395636A (en) |
AT (1) | ATE291656T1 (en) |
BR (1) | BR0107670A (en) |
CA (1) | CA2396976A1 (en) |
DE (2) | DE10001957A1 (en) |
EA (1) | EA003594B1 (en) |
ES (1) | ES2239125T3 (en) |
IL (2) | IL150720A0 (en) |
WO (1) | WO2001053589A1 (en) |
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US6110848A (en) * | 1998-10-09 | 2000-08-29 | Fort James Corporation | Hydroentangled three ply webs and products made therefrom |
DE10008746A1 (en) * | 2000-02-24 | 2001-08-30 | Fleissner Maschf Gmbh Co | Method and device for producing composite nonwovens by means of hydrodynamic needling |
GB0013302D0 (en) * | 2000-06-02 | 2000-07-26 | B & H Res Ltd | Formation of sheet material using hydroentanglement |
GB0128692D0 (en) * | 2001-11-30 | 2002-01-23 | B & H Res Ltd | Formation of sheet material using hydroentanglement |
EP1325981A1 (en) * | 2002-01-05 | 2003-07-09 | The Procter & Gamble Company | Multiply tissue towel with super absorbent fibres |
EP1327716B1 (en) * | 2002-01-05 | 2006-10-25 | The Procter & Gamble Company | Multiply tissue product |
FR2838457B1 (en) * | 2002-04-12 | 2004-08-27 | Rieter Perfojet | DRUM FOR INSTALLATION FOR PRODUCING A NON-WOVEN TABLECLOTH, METHOD FOR PRODUCING A NON-WOVEN TABLECLOTH, AND NON-WOVEN TABLECLOTH OBTAINED |
WO2004005019A1 (en) * | 2002-07-05 | 2004-01-15 | Fleissner Gmbh | Product and method for producing a non-woven fabric by means of hydrodynamic needling |
US7416638B2 (en) | 2003-11-18 | 2008-08-26 | Georgia-Pacific Consumer Products Lp | Apparatus and method for manufacturing a multi-layer web product |
TW201420054A (en) * | 2012-11-21 | 2014-06-01 | Kang Na Hsiung Entpr Co Ltd | Hygroscopic non-woven fabric and fabricating method thereof |
EP3476988A4 (en) * | 2016-06-22 | 2019-07-17 | Toray Industries, Inc. | Production method for partially separated fiber bundle, partially separated fiber bundle, fiber-reinforced resin molding material using partially separated fiber bundle, and production method for fiber-reinforced resin molding material using partially separated fiber bundle |
CN106012295A (en) * | 2016-08-03 | 2016-10-12 | 江苏盛纺纳米材料科技股份有限公司 | Nano-fibre hot air hydrophilic non-woven material and preparation method |
US10415166B2 (en) * | 2017-05-15 | 2019-09-17 | Jacob Holm & Sons Ag | Hydroentangled airlaid process and industrial wipe products |
CN113004863A (en) * | 2021-01-25 | 2021-06-22 | 义乌壹统胶科技有限公司 | Green plate adhesive and manufacturing device thereof |
DE102021006353A1 (en) * | 2021-12-27 | 2023-06-29 | Mondi Ascania GmbH | Process for producing a nonwoven element for hygiene articles |
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US4640810A (en) * | 1984-06-12 | 1987-02-03 | Scan Web Of North America, Inc. | System for producing an air laid web |
US4808467A (en) * | 1987-09-15 | 1989-02-28 | James River Corporation Of Virginia | High strength hydroentangled nonwoven fabric |
US4894280A (en) * | 1987-12-21 | 1990-01-16 | Kimberly-Clark Corporation | Flexible, tear resistant composite sheet material and a method for producing the same |
US4931355A (en) * | 1988-03-18 | 1990-06-05 | Radwanski Fred R | Nonwoven fibrous hydraulically entangled non-elastic coform material and method of formation thereof |
DE3831496C2 (en) * | 1988-09-16 | 2001-03-22 | Fleissner Maschf Gmbh Co | Process for the thermal consolidation of nonwovens with binding powder |
FR2667622B1 (en) * | 1990-10-08 | 1994-10-07 | Kaysersberg Sa | HYDRAULICALLY LINKED MONTISSE AND MANUFACTURING METHOD THEREOF. |
SE469896B (en) * | 1990-11-19 | 1993-10-04 | Moelnlycke Ab | Method and apparatus for producing spun lace material and a material thus produced |
SE467499B (en) * | 1990-11-19 | 1992-07-27 | Moelnlycke Ab | PROCEDURES FOR HYDROENT ANGLING |
US5393599A (en) * | 1992-01-24 | 1995-02-28 | Fiberweb North America, Inc. | Composite nonwoven fabrics |
US5240764A (en) * | 1992-05-13 | 1993-08-31 | E. I. Du Pont De Nemours And Company | Process for making spunlaced nonwoven fabrics |
DE4408813C1 (en) * | 1994-03-16 | 1995-10-05 | Freudenberg Carl Fa | Process for making a nonwoven composite and interposed nonwoven composite |
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-
2000
- 2000-01-18 DE DE10001957A patent/DE10001957A1/en not_active Withdrawn
-
2001
- 2001-01-16 KR KR1020027008980A patent/KR20020071936A/en not_active Application Discontinuation
- 2001-01-16 ES ES01907450T patent/ES2239125T3/en not_active Expired - Lifetime
- 2001-01-16 AT AT01907450T patent/ATE291656T1/en not_active IP Right Cessation
- 2001-01-16 IL IL15072001A patent/IL150720A0/en not_active IP Right Cessation
- 2001-01-16 BR BR0107670-1A patent/BR0107670A/en not_active Application Discontinuation
- 2001-01-16 CA CA002396976A patent/CA2396976A1/en not_active Abandoned
- 2001-01-16 EA EA200200773A patent/EA003594B1/en not_active IP Right Cessation
- 2001-01-16 JP JP2001553443A patent/JP2003527495A/en active Pending
- 2001-01-16 DE DE50105700T patent/DE50105700D1/en not_active Revoked
- 2001-01-16 US US10/169,909 patent/US20030101556A1/en not_active Abandoned
- 2001-01-16 CN CN01803853A patent/CN1395636A/en active Pending
- 2001-01-16 WO PCT/EP2001/000406 patent/WO2001053589A1/en not_active Application Discontinuation
- 2001-01-16 EP EP01907450A patent/EP1294971B1/en not_active Revoked
-
2002
- 2002-07-11 IL IL150720A patent/IL150720A/en unknown
Also Published As
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EP1294971B1 (en) | 2005-03-23 |
IL150720A0 (en) | 2003-02-12 |
CN1395636A (en) | 2003-02-05 |
EA200200773A1 (en) | 2003-02-27 |
ES2239125T3 (en) | 2005-09-16 |
BR0107670A (en) | 2002-10-08 |
IL150720A (en) | 2007-07-04 |
ATE291656T1 (en) | 2005-04-15 |
EA003594B1 (en) | 2003-06-26 |
JP2003527495A (en) | 2003-09-16 |
DE10001957A1 (en) | 2001-07-19 |
DE50105700D1 (en) | 2005-04-28 |
EP1294971A1 (en) | 2003-03-26 |
WO2001053589A1 (en) | 2001-07-26 |
KR20020071936A (en) | 2002-09-13 |
US20030101556A1 (en) | 2003-06-05 |
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EEER | Examination request | ||
FZDE | Discontinued |