EP0060948B1 - Méthodes de formation de nappes fibreuses non-tissées - Google Patents

Méthodes de formation de nappes fibreuses non-tissées Download PDF

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Publication number
EP0060948B1
EP0060948B1 EP19810301272 EP81301272A EP0060948B1 EP 0060948 B1 EP0060948 B1 EP 0060948B1 EP 19810301272 EP19810301272 EP 19810301272 EP 81301272 A EP81301272 A EP 81301272A EP 0060948 B1 EP0060948 B1 EP 0060948B1
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Prior art keywords
velocity
fibers
forming surface
velocity component
web
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Expired
Application number
EP19810301272
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German (de)
English (en)
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EP0060948A1 (fr
Inventor
Sheila E. Widnall
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Georgia Pacific Consumer Products LP
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James River Dixie Northern Inc
James River Norwalk Inc
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Priority to EP19810301272 priority Critical patent/EP0060948B1/fr
Priority to DE8181301272T priority patent/DE3169320D1/de
Publication of EP0060948A1 publication Critical patent/EP0060948A1/fr
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    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/70Non-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
    • D04H1/72Non-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
    • D04H1/732Non-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
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/70Non-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
    • D04H1/72Non-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

Definitions

  • This invention relates to methods for forming nonwoven fibrous webs, wherein a layer of fibers is deposited from a gaseous suspension of fibers onto a moving foraminous forming surface. More specifically, this invention provides improvements in methods of achieving high speed production of nonwoven fibrous webs.
  • the prior art has generally disclosed systems which form an air suspension of fibers and direct the suspended fibers toward a moving foraminous forming surface upon which the fibers from the suspension are condensed-to form the nonwoven web.
  • Various apparatuses exist for generating the air suspension of fibers.
  • the fibers for example, can be produced by a lickerin, a hammermill, or by other apparatus known in the art.
  • the fibers can be dispersed in a gaseous medium by a variety of methods, and conveyed to a forming surface in an air stream operating generally as a pressure flow system, a vacuum system or a closed loop system.
  • This rippling effect becomes more pronounced as the speed of the forming surface increases, with the spacing between the thicker portions of the web becoming greater and with the web becoming more varied along its surface as to basis weight. This rippling effect worsens with increased speed and eventually renders webs commercially unacceptable at some higher speed.
  • This invention has sought to alleviate significantly the detrimental ripple effect. We have determined that there exists a critical relationship between the velocity of the fibers relative to the velocity of the moving forming surface as the fibers are being deposited onto the forming surface. We have found that the detrimental ripple effect can be controlled by controlling the ratio of the tangential velocity of the fibers relative to the moving forming surface, as compared to the velocity of the fibers normal to the moving surface.
  • Prior art concerned with obtaining higher production speeds in the production of air laid webs includes U.S. Patent No. 4,004,323 wherein it is taught that speeds in excess of 200 feet per minute (1.01 m/sec) and even in excess of 400 feet per minute (2.03 m/sec) can be achieved by inclining a duct, which carries a stream of fibers, at an angle to a forming surface.
  • the patent teaches a range of angles of incidence of the duct relative to the forming surface of from about 10° to about 30°.
  • the patent fails, however, to report the high speed formation defect termed herein the rippling effect, and does not teach the criticality of the velocity ratios as between the fibers and the forming surface in alleviating the detrimental rippling effect.
  • the present invention teaches that there are combinations of fiber stream velocities and forming surface velocities for which ducts aligned as recommended in Gotchel will produce unacceptable webs with pronounced ripples.
  • This invention relates to methods for forming a nonwoven fibrous web on a foraminous forming surface moving at a speed in excess of about 500 feet per minute (2.54 m/sec).
  • the methods include dispersing the fibers uniformly in a gaseous medium to form a gaseous suspension of fibers.
  • the gaseous suspension of fibers is conveyed in a stream to the moving forming surface onto which the fibers from the gaseous suspension are deposited to form a nonwoven fibrous web.
  • the detrimental high-speed forming phenomenon termed the rippling effect is alleviated by controlling the critical relationship between the velocity of the fibers being deposited onto the moving forming surface, relative to the velocity of the latter.
  • a method for forming a nonwoven fibrous web from fibers of a papermaking length generally less than inch (6.35 mm), wherein the fibers are distributed in a gaseous medium to form a gaseous suspension of fibers and are thereafter deposited from the gaseous suspension onto a moving foraminous forming surface to form the nonwoven fibrous web characterised by the steps of
  • the forming surface onto which the fibers are deposited need not be planar, but could be curved, in which case it will have a tangential velocity V o greater than 500 feet per minute (2.54 m/sec), the fiber velocity component V, being directed in the same direction as the motion of the curved forming surface.
  • the air-laid product When the velocities meet this ratio of 3:1 or less, the air-laid product is generally acceptable in terms of the ripple effect; outside this ratio the air-laid product generally is unacceptable as having excessive ripple characteristics.
  • V' the magnitude of the relative velocity component of the gaseous stream tangential to the forming surface, V' is equal to the square root of the quantity (V o - V 1 ) 2 plus (V 3 ) 2 .
  • the velocity V' should be less than about three (3) times the fiber velocity V 2 .
  • the normal fiber velocity V 2 can be increased, for example by increasing the amount of suction pulling the gaseous stream through the moving surface.
  • the gaseous stream can be deflected to impinge upon the forming surface at an oblique angle, thereby increasing the velocity component Vl- of the gaseous stream in the direction of motion of the forming surface while maintaining velocity V 2 constant by increasing the amount of suction.
  • the ratio of the velocity of the fibers relative to the velocity of the moving forming surface, compared to the component of the fiber velocities normal to the forming surface can be varied to produce more acceptable pro - ducts having more uniform web characteristics.
  • This invention aims at alleviating the detrimental ripple effect by controlling certain critical relationships between the velocity of fibers in a gaseous stream being condensed on a moving foraminous forming surface, relative to the velocity of the moving surface.
  • FIGs 2A and 2B illustrate two conditions of air laid web formation under two different velocity conditions as viewed relative to the surface 12.
  • typical fiber paths, 10, illustrate fibers approaching a forming surface 12 at an overall relative velocity V (relative), relative to the surface 12.
  • V (relative) is how an oncoming fiber would be viewed from a stationary point riding on the moving surface 12.
  • the relative velocity therefore, is the vector sum of the actual fiber velocity, here shown as V (actual) which has vector components V 2 normal to the forming surface and V, parallel to the forming surface 12.
  • V o When viewed relative to the forming surface 12 moving at a velocity V o , the velocity V, component is subtracted from V o to obtain the fiber velocity V' relative to the surface 12.
  • V o - V therefore represents the relative velocity of the oncoming fiber in a direction along the forming surface
  • V 2 represents the velocity of the oncoming fiber in the direction normal to the forming surface.
  • a critical parameter in the formation of a web as illustrated in Figure 1A is the ratio of V' to the fiber velocity V 2 normal to the surface.
  • this ratio must be maintained below about 3:1 to obtain acceptable product in terms of uniformity of the web, i.e. in terms of the inherent ripple effect.
  • Figure 2A further illustrates this ripple effect and our present belief of the reasons for the nonuniform web formation.
  • Figure 2A illustrates a nonwoven web 14 formed of fibers deposited, as illustrated, along fiber paths 10. As the fibers are deposited on the forming surface 12, the fibers approach the surface at an oblique angle as viewed in a coordinate system moving with the forming surface.
  • the ripple is believed to be primarily caused by a "shadowing" effect caused by the oblique approach of the fibers to the surface 12. This shadowing begins with the first fiber deposits, which occur randomly on the surface 12. These fiber deposits cause "shadows" directly downstream from their positions generally preventing oncoming fibers from falling in the areas of the shadows.
  • Fiber continues to accumulate directly upstream from these initial deposits such as in thicker web portions 13 until the shadowing influence of a neighboring upstream deposit interferes.
  • this shadowing phenomenon produces the ripple effect with thicker web portions 13 alternating with thinner web portions 15.
  • Further fiber deposition only increases the ripple characteristic of the web without changing the ripple wavelength.
  • no fiber bouncing or slipping has been observed in the formation of webs below a velocity ratio of about 3:1.
  • fiber bouncing or slippage was observed to be a more significant forming phenomenon, with the resulting web exhibiting extremely nonuniform web characteristics.
  • Figures 2A and 2B illustrate the relation between the nonuniformity of web formation, i.e. the ripple effect, and the ratios between the fiber and forming surface velocities.
  • V' the difference between velocity V o of the moving surface 12 and velocity component V, of the fibers in the direction of motion of the surface, is about one and three tenths (1.3) times the velocity V 2 of the fibers normal to the moving surface, i.e. a velocity ratio- of 1.3.
  • the resulting web, 14, is relatively uniform with closely spaced thicker web portions 13.
  • the difference V' between velocity V o of the moving surface 12 B and velocity component V, of the fibers in the direction of motion of the surface is about four times that of velocity V 2 of the fibers normal to the moving surface 12g, (a velocity ratio of 4:1) and the-resulting web 14 B is much less uniform than the web 14 of Figure 2A, with a more pronounced ripple effect, i.e. with the thicker portions 13 B of the web more widely spaced and of greater relative basis weight than in the web 14 of 2A.
  • FIGS 2A and 2B illustrate fiber velocities only having components V, in the direction of motion of the forming surface and V 2 normal to the forming surface.
  • No fiber velocity components in the cross-machine direction, i.e. perpendicular both to velocity component V, and to velocity component V 2 have been illustrated since such velocity components are generally undesirable in the manufacture of air laid webs.
  • V 3 may affect the web formation since those cross-machine velocity components will increase the relative velocity V' by the following formula, V' is equal to the square root of (V o - V,) 2 + (V3)2, and thereby. affect the velocity ratio V':V 2 .
  • Such cross machine velocities V 3 may deleteriously affect the web, requiring corresponding adjustments to reduce V' or increase V 2 in those affected web areas.
  • Figures 1A and 1B are plan views of webs formed at velocity ratios of 2.5:1 and 3.5:1, respectively.
  • the web produced is relatively uniform, exhibiting the ripple effect to a minor, but acceptable degree.
  • Some variation in fiber deposit is evident, with recurring heavier deposits at, for example, 17A, 17B, 17C.
  • the distances between these uniformly recurring heavier deposits 17A, 17B, 17C can be measured and are termed the "wavelength" of the "ripples”.
  • web formed at a velocity ratio of 3.5:1 exhibits a ripple effect of far greater wavelength with thicker portions 19A, 19B, 19C, interspersed with thinner portions 19D and 19E.
  • the web of Figure 1B is far less uniform in basis weight than the web of Figure 1A and is generally unacceptable.
  • Figure 3 is a graph illustrating experimental results of studies as to the ripple effect, for velocity ratios (V 0 ⁇ V 1 : V 2 ) ranging from 1:1 to 5:1. These studies were conducted using softwood Kraft and included studies of other variables in the air laid forming process in order to verify the criticality of this velocity ratio parameter.
  • the actual ratio at which the fibrous product is produced for commercial application can be varied to obtain a desired product.
  • fibrous product comprised substantially of softwood Kraft fibers at a velocity ratio of 2.5:1 for commercial purposes since that product would exhibit more uniform web characteristics than if produced at a 3:1 velocity ratio.
  • the fibrous product could be varied as to its composition, varying the fiber sizes to vary the ripple effect at a given velocity ratio.
  • a mixture of hardwood and softwood fibers might constitute commercially acceptable fibrous product at a higher velocity ratio than for a product produced primarily of softwood fibers.
  • the wavelength of the ripple effect is independent of the overall basis weight of the deposited web.
  • the spacing between the thicker portions of the web (the ripple wavelength) is established early during the deposition of the fibers, and further fiber deposition only increases the web thickness without affecting this ripple wavelength.
  • a lower weight web such as a tissue product, might be produced at a lower velocity ratio to shorten the ripple wavelength, obtaining a more satisfactory commercial product in terms of minimizing the effect of the thinner web portions 15. It is believed that this invention can be used to produce air laid webs at least in the range of from about 7 to about 75 pounds (3.17 to 34.01 kg) per 3000 square feet of web (278.7 sq. meters).
  • the weight of fibers distributed over this area can be in the range 25 to 70 pounds (11.3 to 31.7 kg), for instance 30 to 45 pounds (13.6 to 20.4 kg).
  • the apparatus of Figure 4 illustrates an application of this invention to enable the production of acceptable air-laid web at a higher speed of production than previously possible.
  • apparatus 18 comprises a conventional fiber distributor 20 positioned above a moving foraminous forming surface 22 moving from left to right in the drawing in the direction shown, with cellulosic fibers being impelled from the bottom 24 of the distributor 20 to form an air suspension of fibers directed toward the forming surface 22.
  • a suction box 26 is positioned below the forming surface 22, offset somewhat in the downstream direction relative to the distributor 18, the suction box 26 in use creating a moving air stream downwardly through the forming surface 22 and out via an exhaust pipe 28 to a fan (not shown).
  • the air stream fibers flow from the bottom 24 of the distributor box to the portion of the moving surface 22 above the suction box 26 where the fibers are deposited in the form of an air laid web 29.
  • the individual fibers are brought onto the moving surface 22 at an oblique angle by means of both the action of the offset position of the suction box 26 as well as by air turning foils 30.
  • the turning foils 30 are positioned adjacent the upstream end of the distributor 20 and generally serve to introduce a horizontal air stream into the stream of fibers flowing from the distributor 20 to the forming web 22.
  • Sealing roll 32 is positioned along the downstream end of distributor 20 substantially to seal the space between the distributor 20 and the forming surface 22. Side seals, not shown, seal the sides of the apparatus. These seals reduce air loss and minimize air turbulence within the apparatus.
  • the horizontal air stream introduced by the turning foils 30 coacts with the offset suction box 26 to impart a horizontal component of velocity to the fibers within the airstream.
  • the dashed lines L in Fig. 4 indicate typical probable paths of fibers and illustrate that the fibers approach the moving surface 22 at an oblique angle having a velocity component in the direction of movement of the moving wire 22, thereby enabling the production of an acceptable air laid web at a higher speed of the forming surface 22 in accordance with this invention.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Nonwoven Fabrics (AREA)

Claims (9)

1. Procédé pour former une nappe fibreuse non tissée à partir de fibres d'une longuer pour papeterie, généralement inférieure à 6,35 mm (
Figure imgb0001
inch) dans lequel les fibres sont distribuées dans un milieu gazeux pour former une suspension gazeuse de fibres, et sont ensuite déposées de la suspension gazeuse sur une surface poreuse de mise en forme en mouvement pour former la nappe fibreuse non tissée, caractérisé en ce qu'il consiste:
(a) à déplacer la surface de mise en forme à une vitesse Vo non inférieure à 2,54 m/s (500 feet par minute), et
(b) à transporter la suspension gazeuse de fibres en un courant vers la surface de mise en forme en mouvement, le courant gazeux ayant une composante de vitesse V, dans la direction du mouvement de la surface de mise en forme et une composante de vitesse V2 normale à la surface de mise en forme, l'amplitude de la différence entre la vitesse Vo de la surface de mise en forme, et la composante de vitesse V, étant inférieure à trois fois la composante V2 de vitesse des fibres.
2. Procédé selon la revendication 1, caractérisé en ce que l'amplitude de la différence relative entre la vitesse Vo et la composante de vitesse V, est inférieure à 2,5 fois la composante V2 de vitesse des fibres.
3. Procédé selon la revendication 1 ou la revendication 2, caractérisé en ce que les fibres sont appliquées sur une surface de mise en forme qui est une toile constituée de 40 fils de laiton, chacun de 0,317 mm (0,0125 inch), transversaux à la direction du mouvement de la toile, et 60 fils de laiton, chacun de 0,284 mm (0,0112 inch), dans ladite direction.
4. Procédé selon la revendication 1, 2 ou 3, caractérisé en ce que les fibres sont déposées sur la surface de mise en forme pour former une nappe fibreuse non tissée ayant une force dans la plage de 3,17 à 34,01 kg (7 à 75 pounds) par 278,7 m2 (3000 square feet) de nappe.
5. Procédé selon la revendication 4, caractérisé en ce que les fibres sont déposées pour former une nappe fibreuse non tissée ayant une force dans la plage de 11,3 à 31,7 kg (25 à 70 pounds) sur ladite surface de la nappe.
6. Procédé selon la revendication 4, caractérisé en ce que les fibres sont déposées pour former une nappe fibreuse non tissée ayant une force de 13,6 à 20,4 kg (30 à 45 pounds) sur ladite surface de la nappe.
7. Procédé selon l'une quelconque des revendications 1 à 6, caractérisé en ce que la différence relative entre la vitesse Vo et la composante de vitesse V1 est inférieure au double de la composante de vitesse normale V2 des fibres.
8. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce que le courant gazeux possède une autre composante de vitesse V3 dans une direction perpendiculaire à la fois à la composante de vitesse V, et à la composante de vitesse V2; l'amplitude de la racine carrée de (V0 ― V1)2 + (V3)2 étant inférieure à trois fois la composante de vitesse normale V2 des fibres.
9. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce que les fibres sont déposées sur une surface incurvée de mise en forme qui possède une composante de vitesse tangentielle Vo supérieure à 2,54 m/s (500 feet par minute), la composante de vitesse V, des fibres étant dirigée dans la même direction que le mouvement de la surface incurvée de mise en forme.
EP19810301272 1981-03-25 1981-03-25 Méthodes de formation de nappes fibreuses non-tissées Expired EP0060948B1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP19810301272 EP0060948B1 (fr) 1981-03-25 1981-03-25 Méthodes de formation de nappes fibreuses non-tissées
DE8181301272T DE3169320D1 (en) 1981-03-25 1981-03-25 Methods for forming nonwoven fibrous webs

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP19810301272 EP0060948B1 (fr) 1981-03-25 1981-03-25 Méthodes de formation de nappes fibreuses non-tissées

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EP0060948A1 EP0060948A1 (fr) 1982-09-29
EP0060948B1 true EP0060948B1 (fr) 1985-03-20

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CN110965204B (zh) * 2019-12-10 2024-10-18 广东五源新材料科技集团有限公司 吸覆与自由降落形成自调匀整的成网装置及方法和制品

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US3755856A (en) * 1971-04-23 1973-09-04 Kimberly Clark Co Method and apparatus for the formation of fiber fluff
FI760157A (fr) * 1976-01-23 1977-07-24 Risto Tiitola

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EP0060948A1 (fr) 1982-09-29

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