EP0105730B1 - Open mesh belt bonded fabric - Google Patents

Open mesh belt bonded fabric Download PDF

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Publication number
EP0105730B1
EP0105730B1 EP83305892A EP83305892A EP0105730B1 EP 0105730 B1 EP0105730 B1 EP 0105730B1 EP 83305892 A EP83305892 A EP 83305892A EP 83305892 A EP83305892 A EP 83305892A EP 0105730 B1 EP0105730 B1 EP 0105730B1
Authority
EP
European Patent Office
Prior art keywords
open mesh
fabric
mesh network
web
fibers
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
EP83305892A
Other languages
German (de)
English (en)
French (fr)
Other versions
EP0105730A3 (en
EP0105730A2 (en
Inventor
Annamaria Cesco Cancian
Charles J. Shimalla
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.)
Chicopee Inc
Original Assignee
Chicopee Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Chicopee Inc filed Critical Chicopee Inc
Priority to AT83305892T priority Critical patent/ATE45400T1/de
Publication of EP0105730A2 publication Critical patent/EP0105730A2/en
Publication of EP0105730A3 publication Critical patent/EP0105730A3/en
Application granted granted Critical
Publication of EP0105730B1 publication Critical patent/EP0105730B1/en
Expired legal-status Critical Current

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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
    • D04H1/54—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
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5412—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres sheath-core
    • 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

Definitions

  • a fibrous web is passed around a for- maminous roll while being subjected to forced air heat directed toward the outside surface of the roll.
  • This apparatus although originally used for drying fibrous webs, has been suggested for use in fusing fibrous webs comprising thermoplastic materials.
  • One modification of the apparatus and method comprises the use of a restraining belt extending about the roll, which belt is laid down atop the fibrous web to restrain the web against the surface of the roll during the bonding or drying process.
  • the foraminous surface of the roll creates a smooth fabric face.
  • an open mesh network is disposed about the surface of the roll or substituted for the surface of the roll. The open mesh network surface molds the fabric creating a puffed surface.
  • the present invention comprises an apparatus, method and fabric formed thereby for thermal bonding a web comprising at least 10 percent conjugate fibers.
  • an open mesh network comprises or is superimposed on a moving surface such as a rotating drum and a source of forced heated air is directed toward the open mesh network.
  • a fibrous web comprising conjugate fibers comprising a low melting point thermoplastic component is fed to and superimposed over the open mesh network rotating on the rotating drum. Forced heated air impinging on the web molds the web and puffs the fibers out of the plane of the fabric into the open areas of the open mesh network and fuses the low melting point component of the conjugate fibers in the web.
  • the fabric formed thereby is a very high loft fabric having patterned puffed regions on one surface thereof.
  • the method of the present invention may also be practiced using a restraining belt causing regions of densification between the puffed regions.
  • the use of a conventional smooth surfaced restraining belt compresses the web against the open mesh structure creating regions of densification between the puffed regions of the fabric and a smooth surface on the opposite side of the fabric. If the restraining belt is formed of another open mesh network, it will create densified regions as above, and will create a pattern of embossed type densified regions on the surface of the fabric opposite the puffed surface.
  • FIG. 1 illustrates schematically and in cross- section an apparatus according to the present invention.
  • the apparatus comprises a framework shown generally at 10 with a movable surface comprising in this embodiment a rotatable drum 12.
  • the apparatus had heating means (not shown) within the frame at 14.
  • the heating means directs forced heated air onto the outside of the movable surface.
  • the path of the movable surface comprise a curve when as in this embodiment, when it does, it is preferred to exhaust the confluence of forced air by drawing a vacuum from a point within the curve.
  • Most preferably the force of the impinging air and the vacuum are balanced, which balance is dependent on the web being processed.
  • an open mesh network 16 is superimposed on the movable surface.
  • the open mesh network may comprise an endless belt as shown, which extends away from the roll 12 and is transported back to the roll by means 18,20, and 22 for moving an endless belt open mesh structure to and from the movable surface.
  • the open mesh network may be wound tightly about just the drum.
  • the open mesh network may be used to form the surface of the drum or movable surface.
  • the endless belt open mesh network has two advantages. The endless belt open mesh network may be used to transport the web to a cooling station as will be described later; and may be easily replaced by another open mesh network of different configuration.
  • a portion of an open mesh structure for use in the apparatus and method according to the present invention is shown at 40 in Figure 2.
  • the open mesh structure has open areas 42 and also has a depth 44.
  • a web 24 comprising at least 10 percent conjugate fibers is disposed across a moving open mesh structure surface and the exposed side of the fabric is then subjected to forced heated air.
  • the fibers disposed across the open areas 42 are bent out of the plane of the web and into the open regions by the forced heated air thereby creating a fabric having a pattern of puffed regions of lesser density than the overall fabric created by the fibers bent out of the flame of the fabric.
  • the forced heated air also heats and fuses the low melting point component of the conjugate fibers of the web to fibers in the web.
  • the apparatus of the present invention may also comprise a cooling station (not shown) at 26 which in its preferred embodiment comprises forced cooled air.
  • a cooling station (not shown) at 26 which in its preferred embodiment comprises forced cooled air.
  • the means for carrying the endless belt open mesh away from the drum may. comprise means for carrying the open mesh network into the cooling station.
  • Figure 3 depicts a fabric formed according to the present invention.
  • the fabric shown generally at 50 has a very high loft and low density.
  • One face 52 of the fabric comprises a pattern of puffed regions 54 wherein the fibers are bent out of the.plane 55 of the fabric. As shown in Figure 3A, these puffs are formed in the open areas 42 of the open mesh structure by the forced heated air. These puffed regions have lower density than the overall fabric.
  • the other surface 56 of the fabric may have a pattern of recesses 58 corresponding to the puffed regions 54. At lower air velocities, the fabric formed has a substantially uniform density throughout, with puffed regions and recesses being matched to give a molded fabric wherein the entire fabric is moved into the open areas, 42, of the open mesh structure.
  • the nonwoven fabrics of the present invention are made from polyester/polyethylene conjugate fibers wherein at least about 50 percent of the surface of the individual fibers is polyethylene. It is preferred to employ sheath/core fibers with the polyethylene as the sheath and the polyester as the core. Either eccentric or concentric sheath/core fibers can be employed.
  • the fibers will usually have a denier within the range of from about 1 to about 6 (about 1.111 to about 6.666 dtex), and are in excess of about 1/4-inch (6.35 mm) in length, up to about 3 or 4 inches (7.6 or 10.2 cm) long.
  • the conjugate fibers employ high density polyethylene, that is, linear polyethylene that has a density of at least about 0.94, and a Melt Index ⁇ "M.)." by ASTM D-1238 (E) (190°C., 2160 gms.) of greater than 1, preferably greater than about 10, and more preferably from about 20 to about 50.
  • E 190°C., 2160 gms.
  • the fibers will be composed of about 40 to 60 weight percent, and preferably 45 to 55 weight percent, polyester, the remainder being polyethylene.
  • a minor proportion of other fibers preferably nonabsorbent staple fibers such as polyester fibers, can be used along with the polyester/ polyethylene conjugate fibers.
  • the fabrics of the invention are produced byfirst forming a fibrous web comprising a loose array of the conjugate fibers, as by carding, air laying, or the like.
  • the exact weight of the fibrous web has not been found to be narrowly critical, although useful weights have been found within the range from about 0.2 to about 4.2 ounces per square yard (about 6.78 to about ' 142.4 g/m 2 ).
  • the web comprising a loose array of polyester/ polyethylene conjugate fibers is laid on an open mesh network surface and passed underforced air heating means.
  • the forced heated air pushes the fibers in open areas of the mesh out of the plane of the fabric and fuses the polyethylene component of the conjugate fibers and form bonds at points of fiber-to-fiber contact.
  • Forced heated air at a face velocity of at least 100ft./min. (0.51 m/s) is applied to a circular drum with a vacuum drawn at three- tenths inch (7.6 mm) of water within the drum.
  • the exact temperatures employed will vary, depending upon the weight and bulk density of the web, and upon the dwell time employed in the heated zone. For instance, bonding temperatures within the range from about 130° to about 18o o e., have been found satisfactory. Dwell times in the heated zone will usually vary from about 2 seconds to about 1 minute, and more normally will be from about 3 to about 10 seconds.
  • an air permeable restraining belt 28 may be provided and carried along means 30 for causing said restraining belt to travel along with the open mesh network surface.
  • the restraining belt compresses the web against the open mesh network creating a fabric as shown at 60 in Figure 4.
  • the fabric has one surface 63 comprising puffed regions 64 wherein the fibers are bent out of the plane 65 of the fabric.
  • the puffed regions have very low density.
  • the fabric also comprises densified regions 66 which extend between and around the puffed regions. The densification is caused by the compression of the web against the open mesh structure by the belt 28.
  • the other surface of the fabric 68 formed next to the belt 28 is smooth.
  • the restraining belt may comprise an endless belt open mesh network.
  • a fabric formed thereby is shown in Figure 5.
  • the fabric shown generally at 70 comprises one face 72 which comprises puffed regions 74 wherein the fibers are puffed out of the plane 75 of the fabric, and densified regions 76 therebetween formed by the compression of the web against the open mesh network restraining belt.
  • the fabric also comprises embossed type densification at least at surface 78 introduced by the open mesh network retraining belt. The emboss-type densification gives an embossed type pattern to the other surface 78.
  • the open mesh networks 16 and 28' had the same configuration and were in registry; however, the present invention contemplates different open mesh networks used as the moving surface and as the restraining belt and also contemplates the belts being used when they are not in registry creating a fabric wherein the other surface 78 has embossed type densified regions which do not coincide with the densified regions created by compressing the web against the open web structure moving surface.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Chemical Or Physical Treatment Of Fibers (AREA)
EP83305892A 1982-09-30 1983-09-29 Open mesh belt bonded fabric Expired EP0105730B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AT83305892T ATE45400T1 (de) 1982-09-30 1983-09-29 Durch offenmaschiges band gebundener stoff.

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US43031082A 1982-09-30 1982-09-30
US430310 1982-09-30

Publications (3)

Publication Number Publication Date
EP0105730A2 EP0105730A2 (en) 1984-04-18
EP0105730A3 EP0105730A3 (en) 1987-01-21
EP0105730B1 true EP0105730B1 (en) 1989-08-09

Family

ID=23706978

Family Applications (1)

Application Number Title Priority Date Filing Date
EP83305892A Expired EP0105730B1 (en) 1982-09-30 1983-09-29 Open mesh belt bonded fabric

Country Status (24)

Country Link
EP (1) EP0105730B1 (xx)
JP (1) JPS5988959A (xx)
KR (1) KR840006024A (xx)
AR (1) AR231316A1 (xx)
AT (1) ATE45400T1 (xx)
AU (1) AU567115B2 (xx)
BR (1) BR8305380A (xx)
CA (1) CA1235292A (xx)
DE (1) DE3380359D1 (xx)
DK (1) DK449283A (xx)
ES (4) ES8502492A1 (xx)
FI (1) FI83099C (xx)
GB (1) GB2127864B (xx)
GR (1) GR79364B (xx)
HK (1) HK60786A (xx)
IE (1) IE54579B1 (xx)
IN (1) IN162882B (xx)
MX (1) MX157391A (xx)
MY (1) MY8600688A (xx)
NO (1) NO833548L (xx)
NZ (1) NZ205681A (xx)
PH (2) PH20888A (xx)
PT (1) PT77421B (xx)
ZA (1) ZA837298B (xx)

Families Citing this family (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NZ205683A (en) * 1982-09-30 1987-03-31 Chicopee Patterned,non-woven thermoplastics fabric;heat fused on open mesh carrier belt
DE3334787A1 (de) * 1983-09-26 1985-04-11 Fleißner GmbH & Co, Maschinenfabrik, 6073 Egelsbach Verfahren und vorrichtung zum waermebehandeln von vliesen
JPH0635697B2 (ja) * 1984-10-05 1994-05-11 井上金属工業株式会社 不織布製造方法及び不織布製造装置
JPS6340549A (ja) * 1986-08-05 1988-02-20 ユニ・チヤ−ム株式会社 吸収性物品の表面シ−トおよびその製造方法
US5382400A (en) 1992-08-21 1995-01-17 Kimberly-Clark Corporation Nonwoven multicomponent polymeric fabric and method for making same
US5405682A (en) 1992-08-26 1995-04-11 Kimberly Clark Corporation Nonwoven fabric made with multicomponent polymeric strands including a blend of polyolefin and elastomeric thermoplastic material
CA2092604A1 (en) 1992-11-12 1994-05-13 Richard Swee-Chye Yeo Hydrophilic, multicomponent polymeric strands and nonwoven fabrics made therewith
US5482772A (en) 1992-12-28 1996-01-09 Kimberly-Clark Corporation Polymeric strands including a propylene polymer composition and nonwoven fabric and articles made therewith
US5599420A (en) * 1993-04-06 1997-02-04 Kimberly-Clark Corporation Patterned embossed nonwoven fabric, cloth-like liquid barrier material and method for making same
US5399174A (en) * 1993-04-06 1995-03-21 Kimberly-Clark Corporation Patterned embossed nonwoven fabric, cloth-like liquid barrier material
DE10132563A1 (de) * 2001-07-10 2003-01-30 Fleissner Maschf Gmbh Co Verfahren zur farblosen Musterung einer Warenbahn und Vorrichtung zur Durchführung des Verfahrens
JP4623495B2 (ja) * 2004-08-13 2011-02-02 ユニチカ株式会社 パレット用プラスチック成型体の製造方法
DE202011004335U1 (de) * 2011-03-23 2012-03-26 Trützschler Nonwovens Gmbh Einrichtung zur Verfestigung eines textilen Produktes mittels heißen Gasen
JP5840100B2 (ja) * 2012-09-28 2016-01-06 ユニ・チャーム株式会社 不織布
DE102013114075A1 (de) * 2013-12-16 2015-06-18 TRüTZSCHLER GMBH & CO. KG Vorrichtung und Verfahren zum thermischen Verfestigen einer textilen Warenbahn
KR102433994B1 (ko) 2017-03-07 2022-08-19 가부시키가이샤 즈이코 부형 시트 및 그 제조 방법

Family Cites Families (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE1660791A1 (de) * 1966-05-31 1972-02-17 Vepa Ag Verfahren und Vorrichtung zum Verfestigen von Nadelfilz,Filz und aehnlichen Produkten
GB1237603A (en) * 1968-02-14 1971-06-30 Vepa Ag Process and device for strengthening felts and other non-woven fabrics
JPS4831954B1 (xx) * 1968-02-14 1973-10-03
US4103058A (en) * 1974-09-20 1978-07-25 Minnesota Mining And Manufacturing Company Pillowed web of blown microfibers
GB1524713A (en) * 1975-04-11 1978-09-13 Ici Ltd Autogeneously bonded non-woven fibrous structure
AR213851A1 (es) * 1976-07-12 1979-03-30 Kendall & Co Una tela no tejida biaxialmente orientada;y metodo y aparato para producirla
DE2644961B2 (de) * 1976-10-06 1978-10-05 Fa. A. Monforts, 4050 Moenchengladbach Verfahren zum kontinuierlichen thermischen Verfestigen von Vliesen
JPS5653257A (en) * 1979-10-02 1981-05-12 Toray Industries Elastic molded article substantially comprising fiber and method
JPS5924221B2 (ja) * 1980-03-26 1984-06-07 金井 宏之 衣料用芯地の製造方法
JPS56140153A (en) * 1980-04-01 1981-11-02 Asahi Chemical Ind Strong and flexible nonwoven fabric
ZA82846B (en) * 1981-02-27 1983-01-26 Dexter Ltd C H Method and apparatus for making a patterned non-woven fabric

Also Published As

Publication number Publication date
FI833521A0 (fi) 1983-09-29
GB2127864A (en) 1984-04-18
BR8305380A (pt) 1984-05-08
ATE45400T1 (de) 1989-08-15
IN162882B (xx) 1988-07-16
GB8326031D0 (en) 1983-11-02
PH20888A (en) 1987-05-27
ES281476Y (es) 1985-10-16
FI833521A (fi) 1984-03-31
ES281478Y (es) 1985-10-16
MX157391A (es) 1988-11-18
DE3380359D1 (en) 1989-09-14
GB2127864B (en) 1986-03-26
KR840006024A (ko) 1984-11-21
ES526136A0 (es) 1985-01-01
AU1975683A (en) 1984-04-05
JPS5988959A (ja) 1984-05-23
IE54579B1 (en) 1989-11-22
ZA837298B (en) 1985-05-29
ES281478U (es) 1985-03-01
DK449283A (da) 1984-03-31
PT77421A (en) 1983-10-01
HK60786A (en) 1986-08-29
IE832312L (en) 1984-03-30
AU567115B2 (en) 1987-11-12
NO833548L (no) 1984-04-02
DK449283D0 (da) 1983-09-29
NZ205681A (en) 1987-03-31
PH23429A (en) 1989-08-07
ES281477U (es) 1985-03-01
FI83099B (fi) 1991-02-15
EP0105730A3 (en) 1987-01-21
ES281476U (es) 1985-03-01
FI83099C (fi) 1991-05-27
PT77421B (en) 1986-04-17
EP0105730A2 (en) 1984-04-18
MY8600688A (en) 1986-12-31
ES8502492A1 (es) 1985-01-01
GR79364B (xx) 1984-10-22
ES281477Y (es) 1985-10-16
AR231316A1 (es) 1984-10-31
CA1235292A (en) 1988-04-19

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