DE1111933B - Method and system for producing upholstery wadding from fiber layers - Google Patents

Description

GERMAN

PATENT OFFICE

C 9005 Vn / 56a

MARCH 9, 1954

REGISTRATION DAY:

NOTICE THE REGISTRATION AND ISSUE OF EDITORIAL: JULY 27, 1961

The invention relates to a method and an installation for the production of upholstery wadding from fiber layers, which are impregnated by a powdery impregnation agent are connected to one another, at least partially between the fibers with the aid of a gas stream with which the impregnating agent is introduced into the fibers, has been distributed.

There are already processes for the production and shaping of impregnated or glued fibrous nonwovens, Fabrics or the like. Known that lead to more or less compact masses, which to solid moldings, artificial leather, etc. can be processed. So these products are essentially practically impermeable.

It is also a method of making products such as B. upholstery wadding and the like, which are permeable, known. However, this method turned out to be because of the use of separate ones Spray nozzles as a disadvantage, one of which is a powdery binder on the lower side of the Fiber mat and the other blows on the upper side of the fiber mat. The fiber mat is made that they are in application of the method known from the art of a transport device to the heating devices a receiver can be fed, after passing through an intermediate zone consisting of a pair of perforated drum-like There is suction rollers which, in cooperation with the spray nozzles, result from the nozzles Suck out the air blown out together with the binder dust, the binder dust being removed from the Fiber mat is filtered out. It is obvious that the disadvantage of this procedure is the necessity a variety of conveying devices, such as. B. the feeding device and the individual drums, can be seen and that the failure of only one of the conveying elements is the implementation of the process severely hampered both in terms of time and in terms of costs. There Furthermore, the outlet openings of the spray nozzles are not covered, some of the binder dust gets into the atmosphere, thereby affecting the other parts of the apparatus can and in the same way annoy the workers operating this apparatus considerably will.

In order to avoid these disadvantages and difficulties, it is proposed in the method according to the invention to introduce the gas stream together with the entrained synthetic resin particles from one side into the fiber layer, while this is carried on a perforated conveyor belt through which the free gas process and plant for production
of upholstery wadding made of fiber layers

Applicant:

Chavannes Industrial Synthetics, Inc.,
New York, NY (V. St. A.)

Representative: Dr.-Ing. H. Ruschke, Berlin-Friedenau,

and Dipl.-Ing. K. Grentzenberg,
Munich 27, Pienzenauer Str. 2, patent attorneys

Marc Alfred Chavannes and James W. Howden,

New York, NY (V. St. A.),
have been named as inventors

current flows, advances. The part of the synthetic resin that is not filtered out is carried off by the gas flow opposite side of the fiber layer is introduced back into it without escaping into the surrounding Atmosphere takes place. After the fiber layer the usual heating and cooling stages has passed through and has been impregnated in this way, it is cut up and carded, like this that a new fluffy fiber layer is created, which is heated and cooled again.

Further features of the invention emerge from the following description in which the invention relates to Hand of the drawings is explained in more detail. In the drawings is

Fig. 1 is a plan view of the plant for performing the method according to the invention,

Fig. 2 is essentially a side view of part of the system shown there with a viewpoint 2-2 of Fig. 1,

Fig. 3 is a substantially vertical section, on an enlarged scale, of part of the system shown in FIGS. 1 and 2, the sectional plane running along the line 3-3 of FIG To direct cottonage,
FIG. 4 shows a vertical section along the line 4-4 of FIG. 1, of part of the system shown there, FIG. 5 shows an enlarged view of the upholstery wadding,

which can be made according to the invention;

109 649/28

cotton fibers are shown which are connected to one another by the synthetic resin.

The various figures are schematic.

In Fig. 1 in section A fibers or other material from which z. B. fibers can be formed by crushing, introduced and passed through section ^, where they are formed into a layer, and section C, where synthetic resin powder is introduced, continuously to the section!), Where the fibers are arranged in the form of several layers, wherein the synthetic resin is evenly distributed between the fibers. From section D , the fiber layer advances transversely to the original direction of movement, through section E, where it is slightly compressed and the edges are trimmed, through section F, where it is heated and slightly compressed, through section G, where it is cooled, and passes in section H as finished upholstery wadding from the apparatus.

In Fig. 1, 10 is a feeder with the box feeder 12 into which fibers are brought. These fibers can come from raw cotton, cotton waste, textiles, fibers of various types, including of the aforementioned, or a mixture of different substances. A suitable substance is made from a blend of American long staple cotton, Indian cotton and recycled cotton American waste fiber. According to another embodiment, material can also be used be brought into the box feeder, which was previously done by the apparatus according to the invention had gone.

At the bottom of the box feeder 12 there is a running spiked belt 14. From this there are quantities captured by fibers, passed through a lock 15 and taken over by another spiked belt 16 and brought up. From the spiked belt 16, the fibers go through a bat 18 and fall in the weighing apparatus 20. Means, not shown, are provided to the weighing apparatus 20 in certain Open time intervals, whereby amounts of fiber are brought down onto a spiked belt 24 will. The latter feeds the fibers into a machine 22 which transforms them into a substantially uniform one Processed position in which the fibers are roughly parallel to each other and parallel to their direction of movement lie. To carry out this operation as well as to fold in the transverse direction, which is later is described, one of a Garnettkrempelmaschine, z. B. a two-cylinder double comb roller Garnettkrempel, similar machine can be used.

The schematically illustrated machine designated in FIGS. 1 and 2 contains part of such a machine Garnett carding machine. Its two comb rollers are labeled 26 and 28. A cotton fiber layer occurs at each of these two comb rollers and is from them by combing devices, not shown combed. These two fiber layers are on a moving belt or apron conveyor 36 united into a single layer. The belt 36 is louvered so that air can pass through it can. In other embodiments it can also be provided with holes in a different way, through what air can pass through. The belt 36 is carried by rollers 38, 40, 42 and 44 carried by Axles are supported, which are mounted in a stationary frame 46.

In section C, as shown in FIG. 3, an air stream containing dry synthetic resin powder is in and to some extent blown through the fiber layer located on the belt 36.

For this purpose, a fan and a line, generally designated 47, are provided to circulate the air flow to steer. The main air flow enters the conduit at inlet 48. The synthetic resin powder is in a container 50. An additional stream of air enters the container 50 through line 52 and blows from it the synthetic resin powder via the line 54 into the main line 47. In line 47 are baffle plates 56 provided in order to ensure an even distribution of the same in the air flow.

The cross-section of the line 47 increases in the direction of that in the vicinity of the louvre-like strip 36 lying area 62. A part of the conduit 47 similar to a housing or box surrounds this Band 36. Openings are provided at both ends of the housing 64 for the band 36 to pass through.

The lower part of the housing 64 receives the air that passes through the fiber layer and tape 36 goes, and directs them up through the belt and the location on one with respect to their direction of movement back point around. In order to favor the air flow in this direction, they are directed upwards Guide plates 66 are provided. After going up through the belt and the Fiber layer has flowed through the line section 68 to the outside.

As shown in Fig. 2, the cotton fiber layer is then from the belt 36 on a transverse fold or reciprocating belt 70 carried by rollers 72 and 74. These roles will be in turn supported by a movable frame, not shown, which is located in a slot 76 in the Frame moved back and forth.

The cotton fiber layer becomes due to the reciprocating movement of the movable frame Folded crosswise onto a lower tape 78 into a multilayer sheet 80. The lower belt 78 moves in the horizontal direction at right angles to the previous horizontal direction of movement of the Cottonage away. This arrangement can be clearly seen in FIG. This creates the transverse fold of the layers on the lower band 78.

For the sake of clarity, the cotton fiber layer is shown only at that point in FIGS. 1 to 4 of the drawings where it is transversely folded onto the lower tape 78 in FIG. The fiber layer is in other places been omitted.

The lower belt 78 is carried by rollers 84 and 86 which run on fixed axles. The multilayer cotton layer with the resin distributed therein is conveyed onward by the lower belt 78 and goes through a series of pressure rollers 88, 90, 92, 94 and 96 which compress them somewhat. Then the situation goes through vertical, rotating knives 98 and a counter roller 100, which the Trim the edges or cut them lengthways into strips or narrow layers.

The cotton sheet is then conveyed by a belt 102 into a heating section which it is conveyed to a cooling section. It runs between a belt 110 and a other, 112. Belt 110 is carried by pulleys 114, 116 and 118 and is provided with a tension pulley

120 provided. Belt 112 is carried by rollers 122, 124, 126 and 128 and has tension roller 130.

The heating section lies between the rollers 122 and 128, the cooling section between the rollers 128 and 126. In the heating section, the two belts 110 and 112 slightly converge, so that the thickness of the multilayered cotton layer is continuously reduced. In the cooling section, the upper and lower surfaces of the cotton ply are kept approximately parallel, so that after the resin has hardened, the ply has an approximately constant thickness.

The belt 110 moves between the rollers 114 and 116 on a substantially flat, unfolded path. Various supports may be provided in this area to hold the tape flat. In the illustrated apparatus, the movement of belt 110 between rollers 114 and 116 can be viewed as horizontal. On the other hand, the belt 112 runs slightly downwards from roll 122 to roll 128 and continues horizontally from roll 128 to roll 126. This is achieved in that the common tangent to the circumference of the rollers 128 and 126 runs at the same distance from the belt 110 , whereas the underside of the roller 122 is somewhat further away from the belt 110.

The belts 110 and 112 are provided with openings through which air can be blown. For this purpose, they can be built like blinds, made of wire mesh or perforated.

In the heating section, hot air is blown through a line 132 via line-like air guide means 134 - hereinafter referred to as a guide - up through the belt 110 and the cotton and is sucked off via the guide 136 and through the line 138. In order to promote the passage of the air through the cotton, there is an overpressure in the line 132 and the guide 134; in the guide 136 and in the line 138, however, a negative pressure. This can be accomplished by connecting line 132 to the exit side of a fan and line 138 to the entry side of the same or another fan.

By a similar arrangement, hot air is blown downwardly through the cotton from a conduit 140 and evacuated through conduit 142 .

As can be seen, the heating section has a first, longer zone in which hot air rises is blown, and a second longer zone in which hot air is blown downwards, wherein the air passes through the cotton as it advances.

In the heating section, the resin is quickly heated to a temperature at which it becomes soft and soft becomes sticky. In a typical case and when using a copolymer of vinyl acetate and Vinyl chloride, the resin can be heated to about 177 ° C. A more general, typical temperature range, on which the resin can be heated is between 149 and 163 ° C. The correct temperature but depends on the resin used.

The cotton then moves through the cooling section. Cold air is blown from a conduit 144 upward through the belt and cotton via a guide 146 and is discharged via the guide 148 and a conduit 150. In a second zone, cold air is blown from line 152 through belt 112, cotton, and belt 110, and is evacuated through guide 154 .

An overpressure is maintained in the guides 146 and 152 by connection to the outlet side of a fan. A negative pressure is obtained in the guides 148 and 154 by connection to the inlet side of the same or another fan.

In the cooling section, the resin is cooled to a temperature at which it hardens, whereby at least some of the fibers stick together. When cooling, the upper and the The lower surface of the cotton layer is kept roughly parallel.

Of course, instead of air in the heating and cooling sections and also as a means of transport for the resin in the apparatus of Fig. 3 other gases can be used.

A heating system in which hot air is blown in and out of one side of the sheet opposite side is sucked off and put back into the circuit, is particularly advantageous, results a fast and even heating and guarantees a high thermal efficiency.

Various examples of the method according to the invention are given below:

According to a first example of the method, this includes the following operations: it becomes a set Made of cotton fibers in the form of loose wadding, a powdered copolymer of vinyl acetate and vinyl chloride mixed with an air stream, the air stream and the entrained resin powder passed into the fiber mass, the resin and the fibers are heated to about 171 ° C by an inevitable Hot air flow is passed into the fiber mass, the resin and the fibers to about 32 ° C through an inevitable stream of cooler air was cooled and the padding was cut into pieces without any substantial change of the same can be used or later changed to a desired shape can.

According to a second example of the method, this includes the following operations: fibers become placed in an advancing position, then dry, powdered, thermoplastic resin is applied brought the layer, folded the layer transversely, around a multilayer padding made of fibers with in between distributed resin, then the resin is heated to the softening point and subsequently cooled, while the upper and lower surfaces of the padding are kept approximately parallel. According to a third example of the method, this includes the following operations: it becomes cotton fibers partially aligned in a continuously advancing position, from one Side of the ply is an air stream with a dry, powdery, a copolymer of vinyl acetate and Vinyl chloride-containing resin is blown in and fed back into the other side of the sheet.

As an additive to the fibers is an amount of 1 part by weight Resin and 3 parts by weight of fibers are suitable. The next step is to get the location on folding an advancing carrier transversely to form thicker wadding than may be desired and then to condense them easily. Then hot air is blown into a surface of the upholstery wadding, while a suction is created on the other. This operation is done in reverse

repeatedly so that hot air is blown into the surface where the suction was previously. The upholstery wadding is slightly compressed during this heating process. After that, upholstery wadding and resin are used cooled with the opposing surfaces kept approximately parallel.

According to a fourth example of the method, it includes the following operations: Manufacture of the Upholstery wadding according to the operations of one of the above examples, cutting the upholstery wadding into small strips, production of new upholstery wadding by carding the strips with or without adding more Fibers, heating to a temperature at which the resin is soft and cooling to a temperature at which it hardens. If more fibers are added, the addition is an amount of 1 part by weight suitable for 4 parts by weight of the strips.

According to a fifth example of the method, it includes the following operations: Manufacture of the upholstery wadding according to the operations of the fourth example with the additional operation of impregnation the new upholstery wadding during or after carding with additional, powdered, thermoplastic Resin in a stream of air. For the addition of resin at this point is an amount of 5 parts by weight Resin suitable for 100 parts by weight of new upholstery wadding.

In Fig. 5 a part of the product according to the invention is shown schematically. It is about a number of cotton fibers that are melted, powdered, thermoplastic resin are connected to each other. The fibers shown form a small part of an upholstery wadding, the top and bottom surfaces of which are flat and parallel. This upholstery wadding can be used for production be used by padding in clothing and the like. In the production of such wadings can cut the upholstery wadding approximately in the desired shape and then using Heat and pressure are brought into the final shape.

Padding for garments, e.g. B. shoulder cushions, can be made from an inner, proportionate loose, elastic part and a denser, felt-like part on the outer surfaces. While According to the invention, both types of material can be produced, both for the inner part of the Shoulder pads, as well as those for their surface, is the invention for making the former Materials particularly advantageous.

A product made according to the invention and suitable as an insulating material or packaging means, This is also useful for subsequent shapes to form the inner part of such cotton padding suitable, consists of a loose elastic mass of cotton fibers, which only through melted, powdery particles of a copolymer of vinyl acetate and vinyl chloride bonded together that is evenly distributed in the mass. This product has a specificity not exceeding 0.04 Weight, so it does not weigh more than 40 g / l, and consists of at least 97% of its total volume Air.

In some respects the product is far superior to other types of upholstery wadding, and yet a significant fiber saving of e.g. 50% can be achieved, i.e. i.e., by adding powdered thermoplastic resin to the fibers according to the method described, it is possible to produce a product to achieve which, although containing fewer fibers, is strong one made from fibers alone is superior.

The above-mentioned product is molded with a specific gravity not exceeding 0.04 and beyond when compressed, as in the manufacture of an upholstered cushion, its specific weight can multiply, z. B. down to 0.26.

In some products according to the invention, the fibers must be partially oriented. she should therefore run in the same direction, but not be completely parallel. Some fibers run but in some other direction.

As shown in Fig. 5, the resin particles adhere to the fibers, some where the fibers meet cross, so that they connect them to each other, while others on other parts of the fibers.

A desirable characteristic of many types of wadding is that it is pliable, however, when the pressure is released, it returns to its original shape. With the elastic, according to the invention The upholstery wadding produced improves the melted, powdered thermoplastic resin and the cotton fibers together have the aforementioned property. The resin is used, among other things, to to form a number of semi-elastic connections between the fibers. Prevent this that the fibers move against each other when the cotton is compressed or deformed will. Every single, bent fiber strives to take on the old shape again, whereby the entire fiber layer, when it is no longer compressed or deformed, it tends to change the original To take shape again.

It can be seen from Fig. 5 that the molten particles of powdered resin are caused by surface tension are rounded because they have been heated until they soften and then solidified.

Regarding the size of the dry powdery resin particles to be used, for example Particles of a copolymer of vinyl acetate and vinyl chloride with a satisfactory result used with cotton fibers, the size distribution of which was as follows:

Percent of the particles Sieve number through which
the particles fall
(Openings / 25.4 mm ² ) 5 400 10 300 60 200 95 100 100 50

The numbers are of course examples. It might also prove desirable Use particles of a more uniform size than those listed.

According to one embodiment of the invention, the resin particles should be small enough to be before Melts become adsorbed on the individual cotton fibers when they are blown into the fiber mass will.

For the best results, especially when making a product that is used for padding

is eminently suitable in clothing and the like and is made of cotton and a copolymer of vinyl acetate and vinyl chloride, the weight of the resin in the finished product should not be less than 10% and do not exceed 50% of the weight of the fibers with the resin. The resin should be at a temperature soften or melt below the carbonization point of the fibers used, over approximately 121 ° C, so that it is not melted by steam if the wadding is a normal ironing process is subjected in cleaning establishments.

A suitable copolymer of vinyl acetate and vinyl chloride has an average molecular weight of about 6000 and consists of approximately 86 percent by weight Polyvinyl chloride and 14 weight percent polyvinyl acetate.

Alternatively, a copolymer of vinyl acetate and vinyl chloride can be used with satisfactory results used that is about 86 percent by weight of polyvinyl chloride, 13 percent by weight Polyvinyl acetate and 1 percent by weight interpoly-. meric dibasic acid (0.7 to 0.8 carboxyl) and has a molecular weight of approximately 6000.

While the product according to the invention is particularly suitable for the manufacture of padding for clothing or the like, it can also be used for many other purposes.

As mentioned, it can be used as a packaging material in the form of upholstery wadding without any further changes be used.

It can also be molded into various suitable shapes. With these forms there is presence of the molten resin particles randomly attached to the fibers to be formed additional connection points very useful.

A very advantageous method when using the product according to the invention as packaging material for certain objects is to use in on the surface of the padding to form cavities that correspond to the shape of the articles to be packaged correspond. Such shaped cavities can be created in that the padding by means of a hot die is pressed. In some cases this can be done in different ways Pieces of cotton wool corresponding to hollows are formed, which exactly on both sides of the packaged Fit the object.

Of course, in addition to the loose product that can be used for the inner parts of shoulder cushions and the like or as packaging, products can also be produced according to the invention which are significantly denser or more compact. One way of regulating the density of the finished product is to change the amount by which it is compressed in the heating section F.

In the finished product, the air volume can be only 70% or even 99V2% of the total volume. A very useful range is between 90 and 99%.

The degree of rigidity of the finished product can also be largely changed. General becomes the more resin is used, the stiffer the product.

Of course, the invention is not necessarily limited to continuous or semi-continuous Method, although it is desirable for the sake of higher efficiency, the various To carry out procedural steps continuously.

The parts of the description that go beyond the following patent application are for explanation purposes only and are not the subject of the invention.

Claims (7)

PATENT CLAIMS: 1. A method for producing upholstery wadding from fiber layers which are connected to one another by a powdered impregnation agent in the form of a thermoplastic synthetic resin which has been distributed at least partially between these fibers with the aid of a gas stream which supplies the impregnation agent, characterized in that the gas stream together with the entrained synthetic resin particles is guided into the fiber layer from one side, while it advances on a perforated conveyor belt through which the free gas flow flows, the synthetic resin being partially filtered out through the fibers and the gas flow from the other side back into the fiber layer is introduced, whereupon, after the usual heating and cooling steps, the impregnated fiber layer is cut and carded in order to then form a new fluffy fiber layer, which is heated and cooled again. 2. The method according to claim 1, characterized in that that the fiber layer after the introduction of the synthetic resin, but before cutting and carding is folded transversely and compacted. 3. The method according to claim 1 and 2, characterized in that the fiber layer is compressed while it is being heated. 4. Plant for performing the method according to claim 1 to 3, characterized by a machine (22) for producing a uniform layer of fibers and a downstream fan (47) for introducing the synthetic resin into the fiber layer, a perforated conveyor belt (36) for guidance the fiber layers to a transverse folding device (D) and through a heating and cooling device (140 and 144) for the impregnated fiber layers. 5. Plant according to claim 4, characterized by one provided above the conveyor belt (36) Suction line (68) with a suction chamber (64) underneath the conveyor belt (36) through the openings in this connected is. 6. Plant according to claim 4 and 5, characterized by provided with a housing (64) Baffles (66) that in turn control the air that has passed through the conveyor belt (36) guide through this and through the fiber layer; by a second belt (78) which is transverse to the direction of movement of the first volume promotes; further by a transverse folding device (70, 76) for the Fiber layer to transfer them from the first to the second tape, so that a multi-layer Fiber layer (80) is created, as well as by pressure rollers (88, 90, 92, 94, 96) to the strength of the multilayer Reduce fiber layer. 7. Plant according to claim 4 to 6, characterized in that the heating device consists of a hot air supply line (132, 134) and exhaust 109 649/28 suction (136, 138) , while the cooling device comprises a cold air supply line (144,146) and suction (148, 150) and also endless belts (110,112) are provided to keep the upper and lower sides of the advancing fiber layers approximately parallel. Considered publications: German Patent Specifications No. 812 610, 804 678; British Patent No. 555,800; U.S. Patent No. 2,622,308; "Textilpraxis" magazine, April issue 1953, p. to 302. 1 sheet of drawings