EP1911868A1 - Installation et procéssus pour produire un tapis non-tissé mis en forme - Google Patents

Installation et procéssus pour produire un tapis non-tissé mis en forme Download PDF

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Publication number
EP1911868A1
EP1911868A1 EP06425700A EP06425700A EP1911868A1 EP 1911868 A1 EP1911868 A1 EP 1911868A1 EP 06425700 A EP06425700 A EP 06425700A EP 06425700 A EP06425700 A EP 06425700A EP 1911868 A1 EP1911868 A1 EP 1911868A1
Authority
EP
European Patent Office
Prior art keywords
filaments
protruding elements
mat
cylinder
walls
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.)
Withdrawn
Application number
EP06425700A
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German (de)
English (en)
Inventor
Rosaldo Fare'
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.)
Fare SpA
Original Assignee
Fare SpA
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 Fare SpA filed Critical Fare SpA
Priority to EP06425700A priority Critical patent/EP1911868A1/fr
Publication of EP1911868A1 publication Critical patent/EP1911868A1/fr
Withdrawn legal-status Critical Current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
    • 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
    • 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
    • D04H3/16—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 filaments produced in association with filament formation, e.g. immediately following extrusion

Definitions

  • the present invention relates to a device and a process for the production of high-relief mats of thermoplastic fibers fused together to form a non-woven fabric.
  • the present invention relates to a process and a device for the production of mats obtained by depositing mono- or multi-component fibers onto rotating rollers fitted with pyramids or other protruding elements which act to receive a plurality of filaments extruded by a spinneret located above the roller.
  • the extrusion head or spinneret generally extrudes a plurality of filaments with diameter inclusive between 0,1 mm and 1,5 mm at a controlled speed.
  • the filaments fall on a rotating roller under the spinneret where they are superimposed while still heated so as to fuse together to form a mat of thermo-welded fibers.
  • the roller is fitted with a plurality of elements protruding radially from the same, generally pointed or in the shape of a pyramidal frustum, to impart a three-dimensional structure to the mat.
  • a plurality of elements protruding radially from the same, generally pointed or in the shape of a pyramidal frustum, to impart a three-dimensional structure to the mat.
  • the mat is subjected to high compression stresses in use and the three-dimensional structure improves the strength of the structure and the continuity of the drainage function.
  • One problem of the known art is how to improve the technical characteristics of the known mats, particularly their resistance to compression and transverse forces with respect to the long direction of the mat (i.e. the direction perpendicular to the axis of the cylinder or roller forming and shaping the mat).
  • the structure has to conserve the characteristics of low weight, low density and the high number of spaces between the fibers necessary for use as a geomembrane or drainage membrane in general.
  • US-A-4212692 suggested that a base layer, obtained by an additional extrusion head and a supplementary roller, should be applied to the three-dimensional structure directly on the shaped roller for forming the mat.
  • the purpose of the present invention is to resolve the problems above discussed and to provide a non-woven mat produced by extruding filaments and collecting them on a rotating cylinder; the mat should have improved mechanical characteristics compared to known mats, without increasing the weight or the production cost.
  • the present invention relates to a device for the production of mats of non-woven fabric by extrusion of a plurality of filaments and collecting them and bonding them together on a rotating roller provided with a plurality of protruding elements to impart a three-dimensional structure to the said mat, characterized by there being present on at least part of the walls of said protruding elements means of retaining filaments in order to retain on them some of the filaments that come into contact with said walls.
  • the means of retaining the filaments is chosen from grooves, projections or steps that protrude from the walls of the protruding elements and are preferably tilted upward and to the outside of said protruding elements.
  • the elements protruding from the forming cylinder are chosen from either square-based pyramids or rectangular-based obelisks.
  • Pyramids and obelisks are provided with two quadrilateral bases, i.e. they have a major bottom base and a minor upper base.
  • each step or tooth defines a portion of a protruding element, each portion being different from the others in size and shape.
  • the horizontal width of the housings is at least one tenth of a millimeter and is preferably comprised in the range between 0,1 mm and 3,0 mm.
  • the invention furthermore relates to a process for the production of mats of non-woven fabric by the extrusion of a plurality of filaments, their collection and bonding together on a rotating cylinder provided with a plurality of protruding elements to impart a three-dimensional structure to the said mat, characterized by retaining on at least part of the walls of said protruding elements some of the filaments that come into contact with said walls by using a device of the described above type.
  • the retaining of filaments on the walls of the protruding elements results in the filaments being distributed more uniformly throughout the whole area of the product and, therefore, in a more uniform distribution of the mechanical characteristics over the whole structure of the mat produced and therefore with greater resistance to stress, particularly to compression.
  • the mat produced can more easily be attached to felts or other products, thanks also to the sinusoidal distribution of truncated tops of the protruding elements.
  • Figure 1 shows the forming cylinder 1 according to the present invention.
  • the cylinder 1 is located beneath an extrusion spinneret 2 in a way already known to the art and described in, for instance, the document US-A-4252590 quoted above, and carries a plurality of protruding elements 3 that project radially from cylinder 1.
  • the extrusion spinneret 2 presents a plurality of extrusion holes to extrude the chosen thermoplastic material in the form of filaments 4.
  • the extruded filaments are deposited on the roller to form a layer of interlaced filaments which fuse together to give a mat; the projections on the roller impart the required protrusions and depth to the mat.
  • the speed of rotation of the roller can be adjusted depending on the desired quantity of filaments per unit area of the mat, i.e. the faster cylinder 1 rotates, the lower the quantity and distribution of the filaments (and therefore the weight of the final product); the weight increases with decreasing speed of rotation.
  • At least some, preferably most, and most preferably all, of the protruding elements 3 are provided with means for the retaining of filaments 4; such means of retention are located on at least some of the walls of the protruding elements 3.
  • the protruding elements can be of various forms and dimensions, but they are preferably either pyramids and/or obelisks having major and minor polygonal bases, preferably quadrilateral.
  • the shown preferred embodiment includes a plurality of protruding elements constituted by obelisks having each a major and a minor rectangular bases, with their longest side parallel to the axis A of forming cylinder 1.
  • the means for retaining the filaments in the shown preferred embodiment include at least one filament retaining projection 5 on at least one of the sides of the element 3.
  • Such retaining projections, or housings, 5 of the filament 4 are in the form of grooves, projections, steps or notches, generally obtained by machining and removing successive layers from the walls of the element 3 so as to form a "stepped pyramid".
  • the pyramid (fig.2) extends from a base 6 that is preferably integral with cylinder 1 and comprises portions 3A-3C superimposed in one piece with walls staggered in different planes, narrowing at every filament retaining step 5.
  • the base 6 of the element (or pyramid) 3 is integral with the structure 8 of the cylinder 1 and is preferably by machining structure 8 so that the base line 7 of the protruding element 3 corresponds to the surface of the structure 8 of cylinder 1.
  • Fig. 2B shows a view from above of the visible part of a protruding element 3 mounted on the cylinder without showing the adjacent protruding elements.
  • Fig.2A shows in detail a filament retaining step 5, which is tilted (i.e. angled) upward and to the outside of the obelisk 3 so as to produce an inclination toward the center of the same and to favor the retaining of the filaments 4.
  • the steps 5 are located on at least one side of element 3, preferably on at least two and, more preferably, on all four sides.
  • the preferred embodiment shown is provided with two steps on two opposite sides 9A and 9B of the element 3, the sides 9A and 9B being positioned transversally to the axis A of the cylinder.
  • the element 3 is preferably flat-topped (truncated) and the upper surface 10 is preferably provided with a plurality of ridges or similar means for roughing its surface to favor retention of the filaments on the upper surface 10.
  • cylinder 1 includes a plurality of rings 11 united together on a shaft (not shown) to form a cylinder 1 with the desired dimensions.
  • On each ring 11 is provided a plurality of elements 3 that are aligned in single plane and that project radially from the support structure or base 8 of the same ring.
  • each ring can be arranged in a plurality of positions with respect to the adjacent rings to form the required overall layout of the protruding elements. For instance, in the embodiment shown the protruding elements of each ring are rotated through 0,5 - 15 degrees with respect to the initial ring, so that, going from left to right in Figs. 1 and 5, the sinusoidal arrangement seen in Fig. 5 is obtained.
  • rings 11 each carrying a single line of protruding elements 3 rings having two or more rows of elements 3 can be placed side by side, and it is also possible to produce the elements according to the present invention by working directly on a single cylinder.
  • the filaments arriving from the spinneret 2 contact the protruding elements and are retained at least temporarily by the means 5, i.e. they are retained for long enough to allow them to fuse with other filaments and to form a structure distributed substantially uniformly on the whole forming cylinder.
  • the protruding elements according to the invention can prevent that all the filaments flow down the sides of the pyramid or obelisk and accumulate in the grooves between one protruding element 3 and that adjacent to it.
  • the resultant mat will therefore have a more uniform structure than those known, with filaments distributed throughout the whole structure, but will not have large "holes” in the same.
  • the structure will therefore always have a "weave” provided by the interlaced filaments and it will be free of large spaces in between them.
EP06425700A 2006-10-11 2006-10-11 Installation et procéssus pour produire un tapis non-tissé mis en forme Withdrawn EP1911868A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP06425700A EP1911868A1 (fr) 2006-10-11 2006-10-11 Installation et procéssus pour produire un tapis non-tissé mis en forme

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP06425700A EP1911868A1 (fr) 2006-10-11 2006-10-11 Installation et procéssus pour produire un tapis non-tissé mis en forme

Publications (1)

Publication Number Publication Date
EP1911868A1 true EP1911868A1 (fr) 2008-04-16

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Family Applications (1)

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EP06425700A Withdrawn EP1911868A1 (fr) 2006-10-11 2006-10-11 Installation et procéssus pour produire un tapis non-tissé mis en forme

Country Status (1)

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EP (1) EP1911868A1 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
ITTV20090053A1 (it) * 2009-03-23 2010-09-24 Tema Technologies And Materials S Rl Impianto e procedimento per la produzione di materassini tecnici d'isolamento e drenaggio
ITMI20090657A1 (it) * 2009-04-21 2010-10-22 Marti S R L Metodo ed apparecchiatura per fabbricare una stuoia di tessuto non tessuto con elevato incrocio trasversale dei filamenti, elevato ingombro ed elevato volume vuoto

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4252590A (en) * 1975-07-09 1981-02-24 Akzona Incorporated Low density matting and process
JPH0838834A (ja) * 1994-07-28 1996-02-13 Nippondenso Co Ltd フィルタの製造方法
EP1241288A2 (fr) * 2001-03-13 2002-09-18 Toyoda Boshoku Corporation Tissu non-tissé tridimensionnel, méthode et moule pour le fabriquer
US20030201579A1 (en) * 2000-11-27 2003-10-30 Gordon Gregory Charles Electro-spinning process for making starch filaments for flexible structure

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4252590A (en) * 1975-07-09 1981-02-24 Akzona Incorporated Low density matting and process
JPH0838834A (ja) * 1994-07-28 1996-02-13 Nippondenso Co Ltd フィルタの製造方法
US20030201579A1 (en) * 2000-11-27 2003-10-30 Gordon Gregory Charles Electro-spinning process for making starch filaments for flexible structure
EP1241288A2 (fr) * 2001-03-13 2002-09-18 Toyoda Boshoku Corporation Tissu non-tissé tridimensionnel, méthode et moule pour le fabriquer

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
ITTV20090053A1 (it) * 2009-03-23 2010-09-24 Tema Technologies And Materials S Rl Impianto e procedimento per la produzione di materassini tecnici d'isolamento e drenaggio
ITMI20090657A1 (it) * 2009-04-21 2010-10-22 Marti S R L Metodo ed apparecchiatura per fabbricare una stuoia di tessuto non tessuto con elevato incrocio trasversale dei filamenti, elevato ingombro ed elevato volume vuoto

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