CN1106470C - 一种用于生产塑料纤维和纤维素纤维的纤维网的设备 - Google Patents

一种用于生产塑料纤维和纤维素纤维的纤维网的设备 Download PDF

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CN1106470C
CN1106470C CN98810150A CN98810150A CN1106470C CN 1106470 C CN1106470 C CN 1106470C CN 98810150 A CN98810150 A CN 98810150A CN 98810150 A CN98810150 A CN 98810150A CN 1106470 C CN1106470 C CN 1106470C
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延斯·奥勒·布勒克纳·安德森
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Abstract

一种用于生产纤维网的设备，所使用的纤维包括合成纤维和吸湿纤维；合成纤维例如塑料纤维，吸湿纤维如粘胶纤维和纤维素纤维。所述设备包括一成形头(1)，该成形头主要用来在一网状线材(9)上均匀、平滑地铺设一纤维层(16)；一水缠结工位(3)，其液体喷嘴(25)以强大的液体射流处理成形头(1)中形成的纤维层，该纤维层包括合成纤维和吸湿纤维；一炉子，在受作用的区域以交联的方式热粘结合成纤维。最后纤维网被卷绕成卷轴(32)。本发明设备生产纤维网的速度比现有设备高，而且更便宜，生产的纤维网更好、结构更均匀。

Description

一种用于生产塑料纤维 和纤维素纤维的纤维网的设备
本发明涉及用合成纤维如塑料纤维以及吸湿纤维(absorbentfibres)、例如粘胶纤维和纤维素纤维生产纤维网的设备，该设备至少包括将合成纤维加热到至少一个预定温度的热处理工位，和至少一个水缠结工位，该水缠结工位的喷嘴将一系列强大的液体射流喷向由合成纤维和吸湿纤维组成的纤维层。
在这种已知的设备中，长的、梳理过的例如聚丙烯或者聚乙烯等合成纤维在一个网状的环形线材(托持帘网)的上部组织上侧铺设成网状的一层，环形线材的上部组织在指向设备出口的方向同时运转。在同一线材上或在随后的线材上，纤维层被导引着通过一炉子，纤维在炉中被加热到高温，从而在受作用的区域通过交联(cross bond)连接在一起。
现在已形成了一种热粘结纤维层，其用作吸湿纤维的骨架和支撑网。所述吸湿纤维例如粘胶纤维和/或纤维素纤维，所述纤维可以作为一个网从一个卷轴上退绕或者利用已知的成形头通过空气流敷设。
此后，一闭合的结网线材将支撑网和敷设的纤维传送通过一组喷水嘴，这些喷水嘴将强大的水射流向下喷向纤维，驱使纤维有效地进入下置的骨架状支撑网中。
当水射流接触闭合的结网线材时，部分水受撞击而向着支撑网返回，由此将敷设的纤维环绕在交联的合成纤维上，并紧紧地贴着纤维网的下侧，这样就形成了一个光滑而平齐的表面。
上述通过水使纤维暴露在技术上称作水缠结或射流喷网。下面将使用水缠结这个术语。
水缠结的网在炉中烘干，最后卷绕成一个卷轴。
以这种方式生产的纤维网例如可以用于抹布、纸巾、帘布和睡衣等产品。
上述工艺可以各种方式变化，但通常都是从梳理过的纤维层开始。通常，所述纤维层是聚丙烯、聚乙烯、或者粘胶纤维或这些纤维的混合纤维。
梳理过的支撑网柔软、而适合于吸收，并且与敷设的纤维紧密地连接。在纵向，纤维网的强度使加工过程不存在纤维网断裂的巨大危险，这种断裂会导致昂贵的生产中断和材料的损失。
另一个优点在于，在水缠结过程中在纤维之间形成氢键，由此避免了在使用和加工时成品的凝絮和瑕疵。
然而梳理过程比随后的过程慢，因此不能以优选的容量进行，这意味着生产率被降低到由梳理过程设定的一个水平。由于这种设备非常昂贵，因此造成了严重的损失，使大部分的现有设备不能最大限度地被使用。
除了梳理过程需要精确的检测和控制以外，由于例如在操作过程中需要拉伸梳理过的纤维，所以设备的操作困难而且复杂。
构成支撑网的合成纤维也比纤维素纤维贵很多，由于现有过程要求使用基本上等量的两种纤维，最终产品变得昂贵。
即便使用上述含量的合成纤维，完成的纤维网也存在下述的主要缺陷，即分别在纵向和横向强度之间存在巨大的差异。该强度比例通常为5∶1。利用这种纤维网制造的产品在使用过程中可能会侧向分开。因此很容易用一根手指戳穿该产品。
另一缺陷在于，由于在现有设备中梳理过程不适合于生产夹层网，梳理过的纤维在这种情况下变成了几层中的一部分。因此，现有设备不能用来生产当今需求很大的一种产品，这种产品由两非织造纤维层和一中间气流铺设纤维层构成，中间层通过水缠结与其它两层连接在一起。
本发明的目的是提供一种具有一开始提到的特征的设备，其结构简单、便宜，容易操纵并且经济，与现有设备相比可以用更大的转换速度生产。
本发明的另一个目的是提供一种具有一开始提到的特征的设备，通过该设备能够制造分别在纵向和横向的强度之间具有平衡的比例的一种纤维网。
本发明的第三个目的在于提供一种具有一开始提到的特征的设备，该设备考虑了价格和特性，使生产纤维网的各种纤维的数量之间具有优选的比例。
本发明的第四个目的是提供一种具有一开始提到的特征的设备，通过该设备制造的纤维网比现有的纤维网具有更均匀和精确的纤维分布。
本发明的第五个目的是提供一种具有一开始提到的特征的设备，通过该设备可以制造具有比现有纤维网更高精度的公差的纤维网。
本发明的第六个目的是提供一种具有一开始提到的特征的设备，其可以容易地制造夹层纤维网。
根据本发明的具有新颖性的特殊的设备实现了上述目的。所述设备包括：一气流铺网工位，这一部分包括在操作过程中，产生在主要垂直运转的网状环形线材上以任意速率穿过其上部组织的主要垂直下降的气流的装置，所述装置在向气流中连续地供应至少合成纤维时将纤维光滑、均匀地在线材的上部组织的上侧分布成网状层；此时线材的上部组织向着设备出口的方向运行。
当现有设备的梳理过程这样由一个可靠而经济的气流铺网过程代替时，设备其余装置就可以按优选的速度运转了；同时，生产过程也变得容易控制了。纤维能够均匀而精确地分布，在各个方向具有相等的取向；这样最终的纤维网在纵向和横向获得了基本相等的强度，并且有可能以紧密的公差(tight tolerance)制造。
现在，本发明的过程不需要在纵向巨大的强度，这样昂贵的合成纤维在很大程度上可以用更便宜的纤维素纤维代替；由此完成的纤维网的吸湿特性显著地提高了，并降低了花费。
特别希望在气流铺网工位中添加合成纤维的同时添加吸湿纤维，因为纤维从一开始就紧密地混合，而支撑网在成形过程中成为整体。
为此目的可以使用一成形头，该成形头包括：一个在线材上部组织下方的抽吸箱。该抽吸箱与一个真空气泵连接；一个在线材上方的带有一个或多个纤维入口的外壳，一个在外壳中位于线材上方的许多旋转叶片，所述叶片在操作时在线材上部组织的上侧将纤维分布成平齐的一层。
所述设备的一种简单而便宜的结构形式包括一个合成纤维和吸湿纤维的成形头，一个水缠结工位、一个具有足够高的处理温度的炉子，其用于在受作用的区域热粘结合成纤维。
通过这种设置，合成纤维在同一炉中进行热粘结，该炉子也用于烘干水缠结的纤维网。当一个特殊的热粘结炉插入成形头和水缠结工位之间时，本过程可以被精确地控制，因为分别在热粘结炉和随后的烘干炉中的温度可以调整到用于各自过程的优选值。另外，纤维网通过水缠结过程而得到稳定，因此能得到优选的效果而没有大量浪费松散的纤维。
当使用三个一个接着另一个的成形头代替根据本发明设备的上述两种结构形式之一的单个成形头时，所述设备可以被成功地用于生产夹层纤维网；中间成形头主要供以例如纤维素纤维，而另外两个成形头被供以合成纤维或者合成纤维和纤维素纤维。
本发明还涉及一种纤维网，该纤维网包含合成纤维和吸湿纤维，并由本发明的上述设备制造。根据上述生产过程，所述纤维网的结构在所有方向具有均匀取向的纤维，并且分别在纵向和横向的强度具有良好的平衡。
当合成纤维是双组分纤维时，能够获得有效地连接的坚固的纤维网；每根纤维由第一种塑料的纤维芯和另一种塑料的纤维鞘构成，后一种塑料的熔点高于第一种塑料的熔点。当使用这种合成纤维时，稳定了纤维相遇的各个位置的联结，而不会使纤维芯同时熔融，否则会丧失粘结的特性。
根据本发明的设备制造的纤维网的纤维素纤维的百分含量在50％到95％之间，主要在60％到90％之间，尤其在75％到85％之间；这样纤维网比这种类型的传统的纤维网更便宜。
下面对本发明进行详细地描述，其中根据附图对几种结构形式的例子进行了说明。
图1示意性地表示了根据本发明设备的第一种结构形式；
图2示意性地表示了根据本发明设备的第二种结构形式；
图3示意性地表示了根据本发明设备的第三种结构形式；以及
图4示意性地表示了根据本发明设备的第四种结构形式。
在图1中，可以看到根据本发明设备的第一种结构形式，其主要部件包括一个成形头1，一个传送装置2，一个水缠结工位3，一炉4和一个卷绕工位5。
成形头1由一个带有一个合成纤维入口7和一个例如纤维素纤维的纤维入口8的外壳6构成，所述合成纤维例如塑料纤维。
在外壳下面设有一个网状线材9，所述网状线材的上部组织10和下部组织11在辊12上运转。
紧挨着在线材的上部组织10下方设置了一个抽吸箱13，该抽吸箱13与一个真空泵14连接，在线材的上部组织10的上方的两侧设置了许多旋转叶片15。
在操作过程中，真空泵14通过抽吸箱13和外壳6提供了一股气流；从没有图示的合成纤维源和一个没有图示的例如是粘胶纤维的吸湿纤维源，所述气流将合成纤维和吸湿纤维分别通过纤维入口7和纤维入口8引导入外壳6。
气流通过线材的上部组织10向下吹，同时纤维被保持在上部组织的上侧，这些纤维通过旋转叶片15混合并分布成一平齐和均匀的纤维层16。所述混合和分布是随机的，并且在各个方向都具有纤维均匀的取向。
与此同时，线材9的上部组织10以箭头所示方向向设备卷绕工位5处的出口的方向运转，并将纤维网16传送给传送装置2。
传送装置2由线材17构成，它叠置在成形头的线材9上方并绕辊18运行。线材17的下部组织放置在纤维层16的上侧。
抽吸箱20与一个真空气泵21连接，并且放置在线材17的下部组织上方。该抽吸箱产生的负压将纤维层16保持在线材17的下部组织19上，从而将纤维层沿箭头所示方向运送到水缠结工位3。
上述水缠结工位3由一个相对闭合的结网线材22构成，它与传送装置2的线材17叠合。并且绕辊23运转。线材22的上部组织24位于纤维层16下侧。
在线材22的上部组织24上方设置了许多喷水嘴25，该喷水嘴对着纤维层16向下喷射强大的水射流26；纤维层16在此处被下置的抽吸箱27保持在所述网上，所述抽吸箱连接到一个真空气泵28。通过泵28将水和松散的纤维从抽吸箱27移走。
水射流将纤维网的不同纤维绕在一起而形成一种牢固的连结。一部分喷射的水在遇到闭合的结网线材22的上部组织24时向纤维网的下侧反射回，由此提供了一平齐而光滑的表面。
另外，通过水缠结作用，在纤维之间将形成氢键，这防止了在使用和加工时的凝絮和瑕疵。
在水缠结处理之后，现在相对强度大的和连结好的纤维网进入一炉4，该炉在一足够高的温度下工作，在一个受作用区域将合成纤维热粘结起来。同时，纤维网将被烘干。
在炉4中，旋转辊29装备有一穿孔的壁，以允许热气流通过。借助于风扇30使气流循环，如图中所示。
在通过炉4的过程中，纤维网16环绕辊31和沿箭头所指方向转动的辊29；热空气将被迫通过纤维网以烘干纤维网，同时在合成纤维之间、并且在一定程度上也在合成纤维和吸湿纤维之间的接触点形成交联。
最后，完成的纤维网将在卷绕工位卷绕成一个纤维网32的卷轴。所述卷绕工位基本上由一个卷绕装置33构成，该卷绕装置33具有一个被驱动辊34和一个惰辊35。
图2表示了根据本发明的一种设备的另一结构形式，它与图1中所示的如上所述的第一种结构形式的不同点在于，在传送装置2和水缠结工位3之间插入了一个特殊的热粘结炉36，在图中用相同的参考标号表示相似的部件。
热粘结炉36是一个连续的炉，其上部组织37通过一线材38上方，线材38绕辊39运行。风扇40的目的是使空气再循环穿过纤维网16和线材38的上部组织，在上部组织上携带着纤维网。
热粘结炉36的工作温度足够高，以便在受作用区域将合成纤维粘结在一起，但不会使纤维显著地熔融。
当使用双组分纤维时，在热粘结炉中的过程最容易控制。当纤维例如具有180℃的熔点时，纤维鞘具有例如135℃的熔点。在炉中的温度必须被保持在这两个温度之间的一点，以便在被作用的区域有效地交联合成纤维而不会使纤维芯同时也熔融。
利用这种特殊的热粘结炉36获得的一个优点在于，纤维网16被预先保持稳定，这样随后的水缠结过程将具有增加的确定性，并具有较少的废纤维，废纤维必须在废水中被带走。
另一个优点在于，炉4只需要用作烘干炉，因此能够在一预先确定的较低的温度下工作，其尺寸并不重要。
图3表示了根据本发明的一种设备的第三种结构形式，它与上述结合图1说明的第一种结构形式的区别在于，现在不只有一个成形头，而具有三个成形头41，42和43一个放在另一个后面。每个这些成形头与第一种结构形式的成形头1以相同的方式构成。类似的部件用相同的参考标号表示。
当所述设备以这种方式设置了三个成形头时，它可用来生产夹层纤维网，这种纤维网通常由一柔软的热粘结的顶层和底层以及一吸湿夹芯构成。夹层纤维网例如具有如下的组合。
例1
底层15GSM
合成纤维和吸湿纤维如纤维素纤维之间的比例是10-5。这意味着67％的底层由合成纤维构成，而33％的底层由吸湿纤维构成。
中间层30GSM
合成纤维和吸湿纤维、例如纤维素纤维之间的比例是3-27。这意味着10％的中间层由合成纤维构成，90％的中间层由吸湿纤维构成。
顶层15GSM
合成纤维和吸湿纤维，如纤维素纤维之间的比例是7-8。这意味着47％的顶层由合成纤维构成，53％的顶层由吸湿纤维构成。
上述过程按照下述一种方式进行，第一成形头41被供给形成底层的纤维，另一成形头42被供给形成中间层的纤维，第三成形头43被供给形成顶层的纤维。这样所述三层将在每一层的单独的成形头41、42、43中形成，并顺序地一个在另一个上面形成。随后，该过程以与第一种结构形式相同的方式继续。
在图4中所示的根据本发明的设备的第四种结构形式与图3所示的上述第三种结构形式的区别在于，类似于其它结构形式，如同图2中所示，在传送装置和水缠结工位3之间插入了一个特殊的连续的热粘结炉36。因此相似的部件以相同的参考标号表示。
利用根据本发明的第四种结构形式的设备，可以获得如同结合其它结构形式说明的相同的优点。
下表表明了分别用于梳理过的产品和根据本发明的产品的一些数据，以便使所述优点更加明显，这些通过本发明可以获得。
例2
产品特征 经过梳理过程的产品 根据本发明的产品
热粘结纤维的含量纤维素纤维的含量热粘结纤维的长度粘胶纤维的长度纤维素纤维的长度替换纤维(例如吸湿纤维)的长度干强度、纵向干强度，横向湿强度、纵向湿强度、横向*)克重 50％50％12-60mm6-60mm0-6mm100N/50mm*)20N/50mm*)100N/50mm*)20N/50mm*)65g/sqm  5％-45％95％-55％2-25mm0-6mm2-25mm25-50N/50mm*)15-30N/50mm*)19N/50mm*)11N/50mm*)65g/sqm
可以看出，在传统的经过梳理过程的产品中大部分昂贵的合成纤维用比较便宜的纤维素纤维代替了，通过这种方式可以制造此传统产品价格低的多的产品。
同时，本发明产品的强度在纵向和横向仍然相等，而传统产品的对应强度的比率为5-1。
必须指出，上面结合附图描述的结构形式只是作为一个例子表示了本发明设备的设置方式。
以这种方式，在本发明的保护范围内，本发明的设备可以根据需要设置两个，四个、或更多的成形头。除此之外，也不必将成形头一个在另一个之后而排成一列。
另外，在生产线上可以根据处理纤维希望的质量插入一个或几个生产工位。

Claims (8)

1.用于生产一种非织造织物的一种设备，所述织物至少由合成纤维例如塑料纤维和吸湿纤维、例如粘胶纤维和纤维素纤维构成，所述设备包括：
至少一气流铺网工位，该工位包括，一环形线材，一个与一真空泵连接的、位于所述线材下方的抽吸箱，一个具有一个或多个纤维入口的在上线材部分上方的外壳，一些在线材上方、在外壳中可转动地设置的叶片，所述叶片在操作过程中将纤维以非织造网的形式分配在上线材部分上；
至少一个热处理工位，其位于所述至少一个气流铺网工位的下游，其目的是通过加热所述非织造网粘结合成纤维；
至少一个水缠结工位，其位于所述至少一个热处理工位的下游，其目的是将一些强大的液体射流指向粘结的网；以及
用于连续地将上述网传送通过设备的装置。
2.如权利要求1所述的一种设备，其特征在于，在水缠结工位的下游设置了至少一个用于烘干水缠结的非织造网的烘干工位。
3.如权利要求2所述的一种设备，其特征在于，在烘干工位以足够高的温度作用于水缠结非织造网、以便进一步粘结合成纤维。
4.如权利要求2或3所述的一种设备，其特征在于，所述烘干工位包括一个旋转滚筒，该旋转滚筒具有穿孔的壁，在操作过程中所述滚筒支撑着一段水缠结的非织造网，同时允许气流通过。
5.如权利要求1-4任一项所述的一种设备，其特征在于，所述设备包括至少三个依次排列的气流铺网工位。
6.一种非织造织物，其至少由合成纤维如塑料纤维和吸湿纤维、例如粘胶纤维和纤维素纤维构成，所述织物在这样一种设备上生产，该设备包括：
至少一个气流铺网工位，包括，与一个真空泵连接的、在所述线材下方的抽吸箱，一个具有一个或多个纤维入口的在上线材部分上方的外壳，一些在所述线材上方的在所述外壳中可旋转地设置的叶片，所述叶片在操作过程中将纤维以非织造网的形式分布在上线材部分的上方；
至少一个热处理工位，其位于至少一个气流铺网工位的下游，以便通过加热所述非织造网而粘结合成纤维；
至少一个水缠结工位，其位于至少一个热处理工位的下游，用来将一些强大的液体射流指向粘结的非织造网；以及
用于连续地将所述网传送通过所述设备。
7.如权利要求6所述的一种非织造织物，其特征在于，至少部分合成纤维是双组分纤维，每根纤维由第一种塑料的纤维芯构成，在所述第一种塑料的纤维芯包围着第二种塑料，且后者的熔点高于第一种塑料的熔点。
8.如权利要求6和7所述的一种非织造织物，其特征在于，纤维素纤维的含量为50％到95％，主要为60％到90％，尤其在75％到85％。
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CN1276028A (zh) 2000-12-06
AU9434298A (en) 1999-05-03
DK1023478T3 (da) 2011-06-20
EP1023478B1 (en) 2011-03-02
CA2306186C (en) 2008-09-23
DE69842152D1 (de) 2011-04-14
CA2592610A1 (en) 1999-04-22
EP1023478A1 (en) 2000-08-02
CA2306186A1 (en) 1999-04-22
ATE500367T1 (de) 2011-03-15
US6375773B1 (en) 2002-04-23
CA2592610C (en) 2010-09-28
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USRE42765E1 (en) 2011-10-04
JP2001520326A (ja) 2001-10-30

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