EP1712667B1 - Verfahren zur Herstellung einer Faservlies sowie danach hergestelltes Produkt - Google Patents

Verfahren zur Herstellung einer Faservlies sowie danach hergestelltes Produkt Download PDF

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Publication number
EP1712667B1
EP1712667B1 EP05425203A EP05425203A EP1712667B1 EP 1712667 B1 EP1712667 B1 EP 1712667B1 EP 05425203 A EP05425203 A EP 05425203A EP 05425203 A EP05425203 A EP 05425203A EP 1712667 B1 EP1712667 B1 EP 1712667B1
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EP
European Patent Office
Prior art keywords
web
protuberances
rollers
fibers
points
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EP05425203A
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English (en)
French (fr)
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EP1712667A1 (de
Inventor
Carmine Di Benedetto
Antonio Caira
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Pantex International SpA
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Pantex International SpA
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Publication date
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Priority to EP05425203A priority Critical patent/EP1712667B1/de
Priority to AT05425203T priority patent/ATE494408T1/de
Priority to DE602005025728T priority patent/DE602005025728D1/de
Priority to ES05425203T priority patent/ES2356919T3/es
Publication of EP1712667A1 publication Critical patent/EP1712667A1/de
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Publication of EP1712667B1 publication Critical patent/EP1712667B1/de
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    • 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
    • D04H1/559—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 the fibres being within 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
    • D04H1/44—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
    • 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
    • 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
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • 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
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding

Definitions

  • This invention relates to a method for producing a layer or web of textile material, and more specifically a nonwoven fabric.
  • the invention relates to a method for producing a nonwoven fabric by means of thermal consolidation of the fibers.
  • the invention also relates to a nonwoven fabric obtained with said method.
  • Nonwoven fabrics are used increasingly in various industrial and domestic sectors.
  • webs of nonwoven fabric are used to produce disposable sheets, disposable garments and above all in the sector of hygiene and sanitary products and products for infants, such as sanitary napkins, incontinence pads and baby diapers.
  • Nonwoven fabrics can be manufactured with various techniques. Essentially, the process to form the web of nonwoven fabric entails a phase to form a web of continuous filaments or discontinuous fibers (staple fibers), which are then consolidated according to various techniques, to bond the web and obtain the actual nonwoven fabric.
  • the web of fibers can, for example, be a web of carded fibers, or a layer of continuous filaments delivered from extrusion heads.
  • the bonding techniques can be of various types, such as mechanical (needle-punching), hydraulic (hydro-entanglement), gluing or thermal bonding.
  • the unconsolidated, i.e unbonded, web is fed through a calender, comprising a smooth cylinder and an engraved cylinder, i.e. provided with protuberances.
  • the two cylinders are pressed against each other at high pressure and at least one of the two is heated, to cause at least partial localized melting of the fibers which are (in this case) one-component or bicomponent thermoplastic fibers.
  • WO-A-9855295 describes a procedure for producing a composite material composed of two or three textile layers, wherein the fibers forming the textile layers are bonded and the layers are bonded to one another by means of a calender comprising a pair of engraved rollers.
  • the rollers are produced and controlled for tip-to-tip operation, i.e. with all the protuberances of one roller in phase with the protuberances of the other roller and form a pattern of bonding spots with a density corresponding to the density of the protuberances on the two rollers.
  • WO-A-0004215 describes a method for producing a nonwoven fabric by means of thermal consolidation of a web of fibers or filaments, such as a web of textile fibers, made of a thermoplastic material such as polypropylene. Bonding or consolidation is obtained through calendering with a roller provided with protuberances, the configuration of which forms the specific object of the invention described in that publication, and which cooperates with a smooth roller.
  • WO-A-9925911 (corresponding to US-A-6395211 ) describes a device and a procedure for producing a perforated nonwoven fabric.
  • the web of textile fibers is pre-bonded to form a nonwoven fabric.
  • This is then fed through a calender with a smooth cylinder coated in a yielding material and a cylinder provided with protuberances. Perforation of the nonwoven fabric is obtained by applying sufficient pressure and heat between the rollers.
  • WO-A-03064001 describes techniques for producing vacuum bags. These bags are formed of several components joined to one another, including a layer of nonwoven fabric. This is produced by hot calendering a web of fibers between a smooth roller and a roller provided with protuberances.
  • WO-A-03086709 describes a procedure for producing a non-woven fabric by lamination of a web of carded fibers in a calender comprising a smooth roller and a roller provided with protuberances.
  • WO-A-03021024 describes a device and a procedure for consolidating webs of textile fibers, wherein consolidation or bonding is obtained by calendering the web between a smooth roller and a roller provided with a high density distribution of protuberances.
  • WO-A-9713909 describes a procedure and a system for producing a semi-finished product in the form of a composite web of fibers having the function of acquisition and distribution layer in a sanitary napkin or baby diaper. Consolidation of a web of carded fibers is obtained by hot calendering between two rollers. To reduce pull on the web, i.e. the difference between the speed at which the web of fibers is fed to the calender and the peripheral rotation speed of the calender rollers, an air current is produced to press the web against one of the two rollers.
  • WO-A-0186050 describes a procedure for producing a composite web of nonwoven fabric by hot calendering and point bonding. The configuration of the calender rollers is not described in detail.
  • DE-A-3416004 describes a procedure and a device for producing a perforated nonwoven fabric.
  • a web of unconsolidated fibers is fed to a calender formed by a smooth roller and by a roller provided with protuberances.
  • the two heated rollers are pressed against each other to cause consolidation of the web and perforation thereof according to a distribution of holes corresponding to the protuberances of the roller.
  • DE-A-19750459 describes a method and a device for perforating a web of textile fibers again by smooth roller and a roller provided with protuberances.
  • US-A-5656119 describes a procedure for producing a multi-layer article with a plastic film interposed between two webs of fibers.
  • the three components are fed to a calender formed of two engraved cylinders, arranged and phased tip-to-tip, which cause adhesion of the fibers and perforation of the interposed film.
  • US-A-2003168194 describes a device and a procedure for embossing a web of textile fibers by means of a calender comprising two rollers, which can both be engraved, and with the engravings kept in phase.
  • EP-A-1418094 describes a procedure for producing a nonwoven fabric, wherein a web of fibers is initially pre-bonded by needle punching and subsequently bonded further by a heat process in a calender.
  • the object of this invention is to provide a method for producing a nonwoven fabric, which has improved characteristics in terms of thickness, coverage and softness, aspects that can be present separately or can coexist.
  • the object of a particular embodiment of the invention is to provide a method for producing an embossed, perforated, or perforated and embossed, nonwoven fabric, which can also include a subsequent calendering phase.
  • the invention relates to a method for processing a web of fibers and for producing a nonwoven fabric, wherein an essentially unbonded web of thermoplastic fibers is bonded by bonding points which are distributed according to concentrated areas; these areas of concentrated bonding points are combined with areas devoid, either partially or totally, of bonding points.
  • the web of unbonded fibers is fed between two counter-rotating rollers both provided with protuberances; during rotation in the nip between the two rollers, part of the protuberances of a first roller are carried opposite corresponding protuberances of a second roller, while part of the protuberances of said first roller are disposed opposite depressions between the protuberances of the second roller.
  • the bonding points are formed between pairs of protuberances opposite each other and at least partially coinciding.
  • the distance between the bonding areas is in any case suitable to guarantee sufficient bonding of the fibers or filaments.
  • the bonding points in the areas in which these are concentrated have a density ranging from 5 to 200 points/cm 2 , preferably from 30 to 100 points/cm 2 and even more preferably in the order of 30 to 70 points/cm 2 , while the distance between bonding areas is in the order of 5 to 30 mm and preferably 8-20 mm, but in any case chosen to guarantee (also as a function of the density and of the length of the fibers) adequate bonding, i.e. adequate cohesion between fibers of the web, reducing the welding points to a minimum to obtain a particularly soft and thick web.
  • the fibers can have a count ranging from 1 to 15 dtex, although these values must be considered preferred but not binding.
  • the fibers can be composed of: polyethylene, polypropylene, polyester or biodegradable PLA fibers.
  • the fibers or filaments can also be bicomponent, i.e. with a core and sheath formed of different polymers. For example, the following combinations can be used: polypropylene-polyethylene; polyester-polyethylene; polyester-copolyester; PLA-coPLA.
  • the web is formed of discontinuous fibers. According to an advantageous embodiment, the web is formed of discontinuous carded fibers.
  • the consolidated web with bonding points distributed in areas can be used in this form as a component of a final article, such as a sanitary napkin, a baby diaper.
  • the web bonded in this way can also be subjected to further processes, such as a supplementary bonding process, an embossing process, a perforation process, or a combination of these.
  • the bonded web of fibers as described can be joined to a plastic film or to another component to form a composite semi-finished material. This semi-finished product can be embossed or perforated and subjected to both embossing and perforation, or also to other additional processes.
  • the invention relates to a web of thermoplastic textile fibers bonded by point bonding according to claim 22.
  • Figure 1 schematically shows a possible configuration of a line for producing a nonwoven fabric according to the invention.
  • a carding machine is indicated with 1, which produces a textile web V of carded and unbonded fibers.
  • the web V can also be formed by superimposing more than one web produced by more than one carding machine.
  • the web V is composed of fibers, also bicomponent, with a core composed of a first thermoplastic material and a sheath composed of a second thermoplastic material, where the second thermoplastic material has a lower softening temperature than the material forming the core of the fiber.
  • the optionally bicomponent fibers and the materials with which they can be produced are known to those skilled in the art and not described herein.
  • the fibers can typically have a length in the order of 10-100 mm, preferably 20-80 mm and even more preferably 25-50 mm, with a count ranging, for example, from 1 dtex to 15 dtex.
  • the weight of the web V ranges, for example, from 5 g/m 2 to 150 g/m 2 , preferably from 10 to 35 g/m 2 and even more preferably from 15 to 30 g/m 2 . Although currently preferred, the values indicated must not be considered as binding and limiting.
  • the web V of carded and unconsolidated textile fibers is fed to a first calender 5, comprising a first bottom roller 7 and a second top roller 9, made of steel or another sufficiently hard material.
  • a first calender 5 comprising a first bottom roller 7 and a second top roller 9, made of steel or another sufficiently hard material.
  • the two rollers 7 and 9, counter-rotating as indicated by the arrows in the drawing, are both provided with respective protuberances 7P and 9P, as shown schematically in the enlargement in Figure 2 .
  • the protuberances are obtained for example by mechanical engraving or chemical etching, by laser engraving or in another suitable way. Typically, they will have a truncated cone or truncated pyramid shape, although other configurations of the protuberances would also be possible.
  • the protuberances 7P and 9P are disposed with a density which can typically be in the order of 5-200 protuberances/cm 2 , preferably in the order of 30-100 protuberances/cm 2 and even more preferably in the order of 30-70 protuberances/cm 2 .
  • the height of the protuberances can be in the order of 0.1-5 mm.
  • the dimension of the front surface of the protuberances and the density with which they are distributed are such that the front surface of the protuberances of each of the two rollers occupies a percentage ranging from 5 to 40% and preferably from 15 to 30% of the total cylindrical surface enveloping the respective roller.
  • the protuberances are disposed in such as way that only some protuberances of the roller 7 are opposite to and aligned with the protuberances of the roller 9, i.e. in a tip-to-tip arrangement.
  • the other protuberances are out of phase with one another. This effect can be obtained in various ways.
  • the engraving of the rollers can essentially be the same but the peripheral speeds of the rollers may differ slightly from each other, or the pitch of the protuberances on one roller may not be identical to the pitch of the protuberances on the opposed roller; or yet again, the protuberances may be disposed aligned according to helical alignments chosen so as to obtain said partial correspondence between the tips of one roller and the tips of the other. These different methods could also be combined to obtain non-correspondence of all the tips of the two rollers along the nip of the calender.
  • the diameters of the two rollers could be slightly different, also so that with each revolution of the rollers, the protuberances disposed in a tip-to-tip arrangement change to distribute wear of the protuberances evenly throughout the entire surface of the rollers 7 and 9.
  • Distribution, dimension and density of the protuberances 7P, 9P and reciprocal difference in phase therebetween are chosen so that the average bonded surface of the web preferably ranges from 1% to 15%, preferably from 3 to 10% and even more preferably from 4% to 8% of the total surface of the web.
  • the distance between centers of the rollers 7 and 9 is advantageously chosen so that the front surfaces of the protuberances in the tip-to-tip arrangement only press against each other with modest pressure.
  • the force per unit of length, i.e. the linear pressure, in the nip between the two rollers (without the web interposed) could be equal to or less than 30 N/mm against the conventional 75 N/mm.
  • the distance between centers of the rollers can be chosen so that, in the absence of a web of fibers, there is no contact between these rollers, but rather the protuberances in tip-to-tip arrangement are spaced apart, for example, by an amount above 0 mm but below 1 mm, preferably in the order of 0.02-0.8 mm and even more preferably between 0.05 and 0.5 mm.
  • the web V of unbonded fibers is fed into the nip between the rollers 7 and 9, the web is compressed and the thickness thereof is essentially calibrated by the rollers of the calender.
  • the rollers are heated to a temperature close to the softening or melting temperature of the fibers and when these are bicomponent, melting of the sheath of the fibers is obtained. This melting takes place in the areas in which the protuberances 7P and 9P are in the tip-to-tip arrangement, while in areas in which said reciprocal correspondence between protuberances is absent, bonding takes place purely through the action of heat.
  • the bonding points produced on the web V1 delivered from the calender 5 are distributed in a discontinuous and inconstant manner.
  • Figure 3 schematically shows the distribution of these bonding points S in a possible configuration. It must be understood that the design or distribution of the bonding points of the fibers is not binding and does not require to be determined precisely a priori, as it can vary due, for example, to more or less marked slipping between the rollers, said slipping which can even be of a non-negligible extent, especially when the rollers 7 and 9 are not in reciprocal contact.
  • the bonding points S are distributed according to discrete zones or areas A and that the areas are spaced apart to an extent essentially greater than the pitch between the protuberances on one or on the other of the two rollers, but sufficiently close to guarantee adequate overall bonding of the fibers of the web V.
  • the product delivered from the calender 5 is a bonded or partially bonded, i.e. consolidated or partially consolidated, web, which differs substantially from thermally bonded webs of the conventional type.
  • the latter are bonded according to a very dense and even distribution of points throughout the entire extension of the web, with a pitch of bonding points corresponding to the pitch of the protuberances on the engraved roller of the calender.
  • the product obtained with the method according to this description is characterized by discontinuity in the distribution of bonding points and therefore uneven distribution of said points, with large surface zones (surrounding the areas A), in which the fibers are partially free, i.e. devoid of bonding by pressure.
  • the product thus obtained is essentially softer and more voluminous than the web bonded by conventional thermal bonding.
  • the fibers are staple fibers, they are sufficiently bonded, or consolidated, as the areas A in which the bonding points are concentrated are spaced apart from each other by a distance generally below the average length of the fibers.
  • the areas A can be spaced apart from one another by an extent of, for example, between 5 and 20 mm. Consequently, each fiber is statistically affected by at least two bonding points S or in general by several bonding points S, thereby guaranteeing adequate consolidation of the fibers.
  • the web V initially having a high thickness (10-20 mm) when fed into the calender 5, when delivered therefrom also has a calibrated thickness.
  • This thickness is in the order of 0.20-1.00 mm and preferably from 0.25 to 0.50 mm.
  • the consolidated web delivered from the calender 5 is essentially thicker than the web obtained with conventional point bonding.
  • the increase in thickness with the same basis weight has been quantified in the order of about 20-80% according to the basis weight and the operating conditions of the calender.
  • the basis weight of the bonded web V1 typically ranges from, for example, 10 to 40 g/m 2 , preferably from 12 to 35 g/m 2 , and even more preferably from 15 to 30 g/m 2 .
  • the air current which is produced causes disturbance in the feed of the web and disarranges the fibers.
  • the peripheral speed of the rollers greater than the advance speed of the web being fed compensates this effect.
  • the thermal bonding procedure using a pair of rollers provided with protuberances partially out of phase allows a reduction in linear pressure between the rollers, i.e. the force per unit of axial length of the rollers.
  • linear pressure i.e. the force per unit of axial length of the rollers.
  • the consolidated web V1 delivered from the calender 5 can be used as is, for example (although not exclusively) to produce topsheets for sanitary napkins or diapers, or as an intermediate layer for the acquisition and/or distribution of body fluids immediately below a topsheet which can, for example, be made of a perforated plastic material.
  • the web V1 consolidated by the calender 5 can be subjected to further processing.
  • it is fed to a second calender 15 composed of a counter-rotating bottom roller 17 and top roller 19, both, for example, made of steel.
  • the roller 17 has a smooth surface, i.e. without protuberances, while the roller 19 is provided with protuberances 19P.
  • the distance between the centers of the two rollers 17, 19 of the second calender 15 is such that the protuberances 19P press against the smooth surface of the roller 17 (see the schematic enlargement in Figure 4 of the nip of the second calender).
  • the pressure between the two rollers can be essentially greater than the pressure between the rollers 7 and 9.
  • the linear pressure can, for example, in this case be between 50 N/mm and 200 N/mm.
  • One or other or both of the rollers 17, 19 can be heated to a temperature in proximity and preferably greater than the softening temperature of the fibers forming the web V1.
  • the peripheral speed of the two rollers is the same.
  • the web V1 already consolidated in the first calender 5
  • the protuberances 19P The result is indicated schematically in Figure 5 , where E indicates the depressions produced by the protuberances 19P.
  • E indicates the depressions produced by the protuberances 19P.
  • Figure 5 schematically indicates the areas A of concentration of the bonding points.
  • the embossed web V2 obtained is considerably softer and thicker than those obtained with conventional technologies.
  • the web V1 bonded in the first calender 5 is perforated in the calender 15. This can be obtained, for example, with a combined effect of pressure, temperature and reciprocal slipping between the rollers 17, 19, in a manner known to those skilled in the art.
  • Figure 6 schematically shows a section of a web V2 thermally bonded in points (S) and perforated (P).
  • the thickness and softness obtained on the perforated web V2 are greater with respect to those of webs obtained with conventional thermal bonding systems.
  • a second component such as a plastic film F, fed from a reel B, can also be joined to the web V1.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Absorbent Articles And Supports Therefor (AREA)
  • Preliminary Treatment Of Fibers (AREA)
  • Treatment Of Fiber Materials (AREA)

Claims (34)

  1. Verfahren zum Verarbeiten einer Bahn aus Fibern zum Erzeugen eines Vliesstoffs für Hygieneprodukte und Produkte für Kleinkinder wie Monatsbinden, Inkontinenzeinlagen, Babywindeln, wobei eine ungebundene und nicht konsolidierte Bahn von thermoplastischen Stapelfasern in einen Spalt zwischen ein Paar gegenläufig rotierenden Walzen eingebracht wird, wobei die Walzen mit Vorsprüngen versehen sind und zumindest eine der Walzen geheizt wird, wobei die Fibern durch thermische Verbindungspunkte, die durch die Vorsprünge gebildet werden, konsolidiert werden, dadurch gekennzeichnet, dass in dem Spalt, der zwischen den Walzen definiert ist, die Vorsprünge derart angeordnet sind, dass einige Vorsprünge einer Walze In einer Spitze-zu-Spitze-Anordnung mit den Vorsprüngen der anderen Walze sind, während die anderen Vorsprünge der beiden Walzen in dem Spalt zueinander außer Phase sind, derart, dass die Verbindungspunkte entsprechend konzentrierten Bereichen verteilt sind und dass die Bereiche der konzentrierten Verbindungspunkte mit Bereichen mit deutlich geringerer Dichte von Verbindungspunkten kombiniert sind.
  2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass die Verbindungspunkte in diskreten Bereichen konzentriert sind, die von Bereichen umgeben sind, die vollständig ohne Verbindungspunkte sind.
  3. Verfahren nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass während der Drehung in dem Spalt zwischen den beiden Walzen Teile der Vorsprünge einer ersten Walze zumindest teilweise gegenüber entsprechenden Vorsprüngen einer zweiten walze getragen werden, während ein Teil der Vorsprünge der ersten Walze entsprechend Vertiefungen zwischen den Vorsprüngen der zweiten Walze angeordnet sind, wobei die Verbindungspunkte zwischen Paaren von Vorsprüngen, die einander gegenüber liegen, gebildet werden.
  4. Verfahren nach Anspruch 1, 2 oder 3, dadurch gekennzeichnet, dass die Bereiche von konzentrierten Verbindungspunkten voneinander durch Bereiche getrennt sind, die zumindest teilweise ohne Verbindungspunkte sind.
  5. Verfahren nach Anspruch 1, 2 oder 3, dadurch gekennzeichnet, dass die Bahn eine Bahn aus diskontinuierlichen kardierten Fibern ist.
  6. Verfahren nach Anspruch 4 und 5, dadurch gekennzeichnet, dass der Abstand zwischen den Bereichen, in denen die Verbindungspunkte konzentriert sind, unterhalb der mittleren Länge der Fibern liegt.
  7. Verfahren nach einem oder mehreren der vorstehenden Ansprüche, dadurch gekennzeichnet, dass die Bahn, die mittels der Verbindungspunkte verbunden ist, anschließend geprägt wird.
  8. Verfahren nach Anspruch 7, dadurch gekennzeichnet, dass die Bahn in einem Kalander geprägt wird, der eine Walze aufweist, die mit Vorsprüngen ausgestattet ist, die mit einer Glattwalze kooperiert, wobei zumindest eine der beiden Walzen vorzugsweise geheizt ist und die beiden Walzen gegeneinander gepresst werden.
  9. Verfahren nach einem oder mehreren der Ansprüche 1 bis 6, dadurch gekennzeichnet, dass die mit den Verbindungspunkten verbundene Bahn anschließend perforiert wird.
  10. Verfahren nach Anspruch 9, dadurch gekennzeichnet, dass die Bahn in einem Kalander perforiert wird, der eine Walze aufweist, die mit Vorsprüngen versehen ist und mit einer Glattwalze zusammenwirkt, wobei zumindest eine der beiden Walzen vorzugsweise geheizt ist und die beiden Walzen gegeneinander gepresst werden.
  11. Verfahren nach einem oder mehreren der vorstehenden Ansprüche, dadurch gekennzeichnet, dass die Bahn aus Fibern oder Filamenten mit einer zweiten Schicht eines Materials verbunden wird, um ein Verbundprodukt zu bilden.
  12. Verfahren nach Anspruch 11, dadurch gekennzeichnet, dass die zweite Materialschicht ein Kunststofffilm ist.
  13. Verfahren nach einem oder mehreren der vorstehenden Ansprüche, dadurch gekennzeichnet, dass in den Bereichen, in denen die Verbindungspunkte konzentriert sind, die Punkte eine Dichte im Bereich von 5 bis 200 Punkte/cm2 aufweisen, vorzugsweise von 30 bis 100 Punkte /cm2 und noch vorzuziehender in der Größenordnung von 30 bis 70 Punkte /cm2.
  14. Verfahren nach einem oder mehreren der vorstehenden Ansprüche, dadurch gekennzeichnet, dass die Bereiche, die mit konzentrierten Verpunkten versehen sind, voneinander um einen Abstand getrennt sind, der im Bereich von 5 bis 30 mm und vorzugsweise von 8 bis 20 mm liegt.
  15. Verfahren nach einem oder mehreren der vorstehenden Ansprüche, dadurch gekennzeichnet, dass die Bahn aus Fibern gebildet ist, die eine Nummer von 1 bis 15 dtex aufweisen.
  16. Verfahren nach einem oder mehreren der vorstehenden Ansprüche, dadurch gekennzeichnet, dass eine Bahn aus Fibern mit einer Länge im Bereich von 10 bis 100 mm, vorzugsweise von 20 bis 80 mm und noch mehr vorzuziehen von 25 bis 50 mm gebildet wird.
  17. Verfahren nach einem oder mehreren der vorstehenden Ansprüche, dadurch gekennzeichnet, dass die gebundene Bahn ein Grundgewicht im Bereich von 10 bis 40 g/m2, vorzugsweise 12 bis 35 g/m2 und noch mehr vorzuziehen von 15 bis 30 g/m2 aufweist.
  18. Verfahren nach einem oder mehreren der vorstehenden Ansprüche, dadurch gekennzeichnet, dass der verbundene Bereich von 1 % bis 15 %, vorzugsweise von 3 % bis 10 % und noch mehr vorzuziehen von 4 % bis 8 % der Gesamtfläche der Bahn beträgt.
  19. Verfahren nach einem oder mehreren der vorstehenden Ansprüche, dadurch gekennzeichnet, dass die beiden Walzen mit einer Kraft pro Einheitslänge gleich oder weniger als 30 N/mm gegeneinander gepresst werden.
  20. Verfahren nach einem oder mehreren der vorstehenden Ansprüche, dadurch gekennzeichnet, dass der Abstand zwischen Mitten der beiden Walzen derart ist, dass der Abstand zwischen gegenüberliegenden Vorsprüngen der beiden Walzen in der Lücke zwischen ihnen weniger als 1 mm, vorzugsweise im Bereich von 0,02 bis 0,8 mm und noch mehr vorzuziehen von 0,05 bis 0,5 mm beträgt.
  21. Verfahren nach einem oder mehreren der vorstehenden Ansprüche, dadurch gekennzeichnet, dass die Dicke der Bahn, die aus dem Spalt zwischen den beiden Walzen geliefert wird, auf einen Wert von 0,20 bis 1,00 mm und vorzugsweise von 0,25 bis 0,50 mm eingestellt wird.
  22. Bahn aus thermoplastischen Textilstapelfibern, die durch Punktverbindung verbunden sind, zur Erzeugung eines Vliesstoffs für Hygieneprodukte und Produkte für Kleinkinder wie Monatsbinden, Inkontinenzeinlagen, Babywindeln, dadurch gekennzeichnet, dass die Verbindungspunkte in diskreten Bereichen konzentriert sind, die von Bereichen ohne Verbindungspunkte umgeben sind, wobei der Abstand zwischen den diskreten Bereichen von konzentrierten Verbindungspunkten unterhalb der mittleren Länge der Fibern liegt.
  23. Bahn nach Anspruch 22, dadurch gekennzeichnet, dass sie durch diskontinuierliche kardierte Fibern gebildet ist.
  24. Bahn nach einem oder mehreren der Ansprüche 22 oder 23, dadurch gekennzeichnet, dass sie nach dem Verbinden geprägt wird.
  25. Bahn nach einem oder mehreren der Ansprüche 22 bis 24, dadurch gekennzeichnet, dass sie perforiert ist.
  26. Bahn nach einem oder mehreren der vorstehenden Ansprüche, dadurch gekennzeichnet, dass sie mit einer zweiten Materialschicht verbunden ist, um ein Verbundprodukt zu bilden.
  27. Bahn nach Anspruch 26, dadurch gekennzeichnet, dass die zweite Materialschicht ein Kunststofffilm ist.
  28. Bahn nach einem oder mehreren der Ansprüche 22 bis 27, dadurch gekennzeichnet, dass in den Bereichen, in denen die Verbindungspunkte konzentriert sind, die Verbindungspunkte eine Dichte im Bereich von 5 bis 200 Punkte/cm2, vorzugsweise von 30 bis 100 Punkten/cm2 und noch mehr vorzuziehen im Bereich von 30 bis 70 Punkten/cm2 aufweist.
  29. Bahn nach einem oder mehreren der Ansprüche 22 bis 28, dadurch gekennzeichnet, dass die Bereiche, die mit den konzentrierten Verbindungspunkten versehen sind, voneinander um einen Abstand getrennt sind, der im Bereich von 5 bis 30 mm und vorzugsweise im Bereich von 8 bis 20 mm liegt.
  30. Bahn nach einem oder mehreren der Ansprüche 22 bis 29, dadurch gekennzeichnet, dass sie hauptsächlich aus Fibern mit einer Nummer im Bereich von 1 bis 15 dtex gebildet ist.
  31. Bahn nach einem oder mehreren der Ansprüche 22 bis 30, dadurch gekenntzeichnet, dass sie aus Fibern mit einer Länge im Bereich von 10 bis 100 mm, vorzugsweise von 20 bis 80 mm und noch mehr vorzuziehen von 25 bis 50 mm gebildet ist.
  32. Bahn nach einem oder mehreren der Ansprüche 22 bis 31, dadurch gekennzeichnet, dass sie ein Grundgewicht Im Bereich von 10 bis 40 g/m2, vorzugsweise von 12 bis 35 g/m2 und noch mehr vorzuziehen im Bereich von 15 bis 30 g/m2 aufweiset.
  33. Bahn nach einem oder mehreren der Ansprüche 22 bis 32, dadurch gekennzeichnet, dass der Verbindungsbereich von 1 % bis 15 %, vorzugsweise von 3 % bis 10 % und noch mehr vorzuziehen von 4 % bis 8 % der Gesamtfläche der Bahn beträgt.
  34. Bahn nach einem oder mehreren der Ansprüche 22 bis 33, dadurch gekennzeichnet, dass sie eine Dicke im Bereich von 0,20 bis 1,00 mm und vorzugsweise von 0,25 bis 0,50 mm aufweist.
EP05425203A 2005-04-11 2005-04-11 Verfahren zur Herstellung einer Faservlies sowie danach hergestelltes Produkt Active EP1712667B1 (de)

Priority Applications (4)

Application Number Priority Date Filing Date Title
EP05425203A EP1712667B1 (de) 2005-04-11 2005-04-11 Verfahren zur Herstellung einer Faservlies sowie danach hergestelltes Produkt
AT05425203T ATE494408T1 (de) 2005-04-11 2005-04-11 Verfahren zur herstellung einer faservlies sowie danach hergestelltes produkt
DE602005025728T DE602005025728D1 (de) 2005-04-11 2005-04-11 Verfahren zur Herstellung einer Faservlies sowie danach hergestelltes Produkt
ES05425203T ES2356919T3 (es) 2005-04-11 2005-04-11 Procedimiento para producir una tela no tejida y producto obtenido mediante dicho procedimiento.

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP05425203A EP1712667B1 (de) 2005-04-11 2005-04-11 Verfahren zur Herstellung einer Faservlies sowie danach hergestelltes Produkt

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EP1712667B1 true EP1712667B1 (de) 2011-01-05

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AU2001256989A1 (en) 2000-04-07 2001-10-23 The Procter And Gamble Company Apertured polymeric film webs and absorbent articles using such webs
CA2621211C (en) 2005-08-29 2012-05-15 James W. Cree Apertured laminate and method of making
US8664128B2 (en) 2008-01-30 2014-03-04 Advantage Creation Enterprise Llc Elastic laminate and method of making
PL2411210T3 (pl) 2009-03-24 2017-03-31 James W. Cree Tłoczone, teksturowane taśmy, urządzenie i sposoby ich produkcji
CN102762375B (zh) 2009-12-18 2016-01-06 优势创造实业有限责任公司 挤出涂覆的穿孔非纺织网和制造方法

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US3507943A (en) 1965-10-04 1970-04-21 Kendall & Co Method for rolling nonwoven fabrics
US4005169A (en) 1974-04-26 1977-01-25 Imperial Chemical Industries Limited Non-woven fabrics
US4493868A (en) * 1982-12-14 1985-01-15 Kimberly-Clark Corporation High bulk bonding pattern and method
DE3416004A1 (de) 1984-04-30 1985-10-31 Henkel KGaA, 4000 Düsseldorf Verfahren zum herstellen eines vliesstoffes mit lochstruktur und kalander zum durchfuehren des verfahrens
DE3700609A1 (de) * 1987-01-10 1988-07-21 Corovin Gmbh Verfahren und vorrichtung zum verfestigen eines faservlieses
FR2653793B1 (de) * 1989-10-30 1992-01-03 Kaysersberg Sa
US6093665A (en) * 1993-09-30 2000-07-25 Kimberly-Clark Worldwide, Inc. Pattern bonded nonwoven fabrics
US5567501A (en) 1994-06-15 1996-10-22 International Paper Company Thermally apertured nonwoven product
IT1278801B1 (it) * 1995-12-05 1997-11-28 Perini Fabio Spa Gruppo goffratore-laminatore per l'incollaggio dei veli goffrati, relativo metodo e prodotto ottenuto
DE19750459C2 (de) 1997-11-14 2002-03-07 Kuesters Eduard Maschf Kalander zum Perforieren einer Bahn
FR2774707B1 (fr) * 1998-02-06 2000-04-07 Fort James France Papier absorbant a usage domestique
US6554963B1 (en) 1998-11-02 2003-04-29 Albany International Corp. Embossed fabrics and method of making the same
DE10022292C2 (de) 2000-05-09 2002-03-28 Sebastian Sommer Verfahren zur Herstellung eines Vliesstoffes
DE10252034B4 (de) 2002-11-06 2004-12-16 Johns Manville Europe Gmbh Airbagschutzhülle

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EP1712667A1 (de) 2006-10-18
DE602005025728D1 (de) 2011-02-17
ATE494408T1 (de) 2011-01-15

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