Classifications

• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01G—PRELIMINARY TREATMENT OF FIBRES, e.g. FOR SPINNING
  • D01G25/00—Lap-forming devices not integral with machines specified above
• • 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
  • D04H1/70—Non-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
  • D04H1/72—Non-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
• • 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
  • D04H1/70—Non-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
  • D04H1/72—Non-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
  • D04H1/732—Non-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
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
  • D21H27/30—Multi-ply
  • D21H27/42—Multi-ply comprising dry-laid paper

Definitions

• the present invention relates to a forming head for dry forming a fibrous web, the forming head being positioned above a forming wire opposite a suction unit.
• the present invention also relates to a method of using said forming head.
• All revolving rollers in a distribution unit are preferably driven by a single engine and a synchronous transmission belt.
• Such an embodiment has the advantage that the revolving rollers can be placed closer to each other, whereby the fibres can be influenced by more than one spike at a time. This will provide a higher impact force on the agglomerates, lumps and/or shadows, enabling a better disintegration of the fibrous material.
• the revolving rollers can be placed so that the outer ends of the spikes describe circles that do not overlap each other. This is especially advantageously when the forming head according to the present invention handles long fibres, for instance with a length of 60 mm or more as the circles which define the outer ends of the spikes substantially just touch each other or are a little shifted from each other.
• the spikes on one revolving rollers are preferably placed very close to the spikes on a neighbouring roller, e.g. 2 mm .
• the spikes can be made of a non-flexible material.
• Such spikes will provide a higher force of impact, which is preferred for some kinds of fibre material.
• Using a non-flexible material for the spikes will thereby ensure that especially recalcitrant agglomerates, lumps and/or shadows are disintegrated.
• the at least one roller in at least one of the distribution unit are detachable mounted. Thereby is it possible to arbitrarily adjust e.g. the closeness of the spikes on the revolving rollers, the length of the spikes and/or the material the spikes are made of simply by replacing, removing or adding one or more of the revolving rollers in a distribution unit.
• the fixed bottom can preferably be in the form of a sieve, net or a grid arranged for placing the fibres and/or particles on the forming wire.
• the bottom can comprise wings, rollers or other scraping or brushing devices, which in an active manner removes fibres from the bottom.
• rollers in each layer can be placed on a row with their longitudinal axis oriented parallel or orthogonal on the movement direction of the forming wire.
• the longitudinal axis of the rollers can, however, also be oriented in the direction parallel with the movement direction of the forming wire. According to the invention is has been shown possible to form a fibrous product, where problems are avoided with the variation of the thickness over the width of the product formed on the forming wire.
• rollers in each distribution unit are adapted for being rotated around their longitudinal axes with the same rate of rotations, e.g. within an interval of between 200 and 5000 rpm, preferably about 2000-3000 rpm.
• rollers can in a different embodiment be adapted for having different rates of rotation in the different distribution steps or simply within a single distribution unit.
• rotational speed By allowing the rotational speed to be adjustable, each distribution unit can be made to work at an optimum, even if the unit at different times is supplied with different amounts of materials. In this respect it is also possible to design each distribution steps for materials having special physical properties .
• the axial distance between the spikes is between 3 and 20 mm, and that the thickness of the spikes is between 0,5 and 10 mm.
• the length of the spikes will be between 5 and 200 mm, preferably about 100 mm.
• rates of rotation, lengths of spike and thickness of spike which lie outside these intervals.
• spikes will cover an embodiment with largely thread-formed spikes.
• plate-formed elements which also can be designated as wings.
• Such plate-formed wings will primarily be formed with the expanse placed in a plane orthogonally on the rotation axis of the axle.
• the plates can be formed with a slope or be formed like propellers to bring about an upwards or downwards directed action on the fibre cloud.
• the wings can be provided with holes. Such holes can facilitate the passage of air. By appropriate choice of revolving speed and form of holes in the rollers the passage of fibres to such holes can be hindered or limited.
• the forming head comprises four distribution units, placed in succession starting from the distribution unit farthest from the forming wire. It has surprisingly been found that when the first distribution unit comprises one revolving roller, the second distribution unit comprises two revolving rollers, the third distribution unit comprises one revolving roller, and the forth distribution unit comprises a plurality of revolving roller arranged in a substantially horizontal plane, the fibrous material will be completely opened and free from lumps and shadows which again ensures a very even distribution of the fibres on the forming wire.
• the top distribution unit are preferably arranged to be able to transfer a relatively higher impact to the fibrous material.
• a single revolving roller having long spikes of e.g. between 50 and 130 mm in length is preferred.
• the first distribution unit can have the same or a smaller horizontal cross section than the underlying distribution unit(s) .
• the inventors have shown that a forming head having said construction provides a decidedly beneficial "shower effect" created by the difference in air fluxuation, that distributes and effectively spreads the fibres evenly onto the longer underlying distribution unit(s) .
• the product may also be made from or at least include a portion of synthetic fibres, such as polyamide, polyester, polyacrylic, polypropylene, bi-component or vermiculite fibres or the like as well as any kind of granular material.
• Fibreboards with such synthetic fibres may be used for providing the fibre product with certain properties, e.g. absorbent products.
• the fibres may be pre-treated with a fire retardant or a fire retardant may be supplied directly in the fibre mixture, which is blown into the forming box.
• Fig. 1 is a schematic perspective view of a forming head according to one embodiment of the invention.
• Fig. 2 shows a schematic side view, partly sectionally, of the forming head shown in fig. 1
• Fig. 3 shows a schematic side view, of the forth distribution unit shown in fig. 1
• Fig. 4 shows a schematic side view, of a different embodiment of the forth distribution unit in fig. 1, and
• Fig 5a shows a schematic side view of a forming head according to a second embodiment of the invention.
• the forming head according to the invention comprises four distribution units. This are of course in no manner intended to be limiting to the invention, and within the scope of the present invention the forming head can comprise from two to a plurality of distributions units.
• a forming head 1 according to a first embodiment of the invention is shown.
• the forming head comprises four independent interconnected distribution units 2, 3, 4 and 5 respectively. Fibres are supplied to the first distribution unit 2 via an inlet 6.
• a suction unit 7 is positioned beneath a forming wire 8, and the forming head is positioned above the wire. Fibres 9 are air laid on the forming wire 8 to form a web 10 in a dry forming process.
• the forming head is shown with the interior elements visible in the forth distribution unit 5.
• the housing walls may be made from transparent or opaque materials.
• each distribution unit 2 3,4,5 revolving rollers are provided with protruding spikes 12.
• the first distribution unit 2 comprises one revolving roller 11
• the second distribution unit 3 comprises two revolving rollers 12
• the third distribution unit 4 comprises one revolving roller 14
• the forth distribution unit 5 comprises five revolving rollers 15, 16, 17, 18, 19, placed in a substantially horizontal plane parallel to the forming wire 8.
• the five revolving rollers 15, 16, 17, 18, 19, which are placed within the forth distribution unit, can be said to make up the bottom of the forming head wherein three revolving rollers 15, 16, 17 are placed by one side wall of the distribution unit and two revolving rollers 18, 19 at the opposite side.
• Engines 20 arranged with the possibility for a variable revolution rate, drives each revolving roller, ensuring that it is possible to adjust the revolution rate of the engines dependent of choice of rollers, spikes and the product, which is to be formed.
• the revolving spike rollers are in the embodiment shown in fig. 1 placed so that the outer ends of the spikes describe circles that do not overlap each other.
• the fibres 9 are supplied to the forming head 1 via inlets 6. Said fibres will comprise agglomerates, lumps and/or shadows and when these comes into contact with the spikes 12, the agglomerates, lumps and/or shadows will be disintegrated or shred in order to ensure an even distribution of fibres 9 in the product 10 formed on the forming wire 8.
• Fibres are supplied in an airflow to the first distribution unit 2 via an inlet 6.
• the airflow can be created by means of transport blowers, which are linked with pipes that lead to the distribution unit, but other ways of obtaining the airflow known to the person skilled in the art are within the scope of protection .
• fibres are primarily led in from each side of the first distribution unit 2, but fibres could also be feed to the distribution unit by means of more inlet pipes on each side of said distribution unit or to several of the distribution units. It is hereby possible to vary the capacity of the forming head by opening and closing the inlet pipes.
• the fibres can be introduced to the distribution unit in question by blowing them into said distribution unit. This will ensure, that the fibres have a substantial velocity upon introduction to the unit, which provides that large concentrations variations throughout the forming head will be reduced or even eliminated, ensuring a more uniform distribution of powder to the web.
• the topmost first distribution unit 2 may or may not have a detachable lid 23 to allow inspection and maintenance of the forming head, and to provide the possibility of admitting false air so that a negative pressure does not build up in the forming head and obstructs the continuous flow towards the forming wire obtained by means of the suction unit.
• the lid 23 has an air inlet opening 24 for admitting the false air.
• the opening may be provided in the lid 23 or any other suitable site on the forming head, e.g. in the axial side of the first 2 and/or subsequent distribution unit, as well as more openings may be provided and favourable.
• the uniform distribution is furthermore increased as the revolving rollers retain fibres before they are gradually sucked down via the vacuum from the suction unit to the forming wire.
• the revolving rollers works as a kind of buffer zone, ensuring, that the fibres do not fall directly onto the forming wire.
• Fibres or other product which are to be part of the final web could also be are added to several of the distribution steps of the forming head according to the invention, increasing the capacity of the forming head.
• the fibre material comprising the agglomerates, lumps and/or shadows which requires the highest impact force can be feed to the first distribution step 2, and the fibre material which requires the lowest impact force to the forth distribution unit 5.
• Fig. 2 shows a schematic side view, partly sectionally, of the forming head shown in fig. 1.
• a partial section is shown for schematically illustrating the revolving rollers 11,12,13,14,15,16,17,18,19 and the left side of the picture shows the engines 20.
• the first distribution unit 2 and the third distribution unit 4 both comprises one revolving roller 11, 14 having spikes 12, which covers only about 65% of the sectional area of the distribution unit.
• the second distribution unit 3 has the two revolving rollers 12, 13, with spikes that substantially covers the entire area of the respective distribution units.
• the forth distribution unit 5 has five revolving rollers 15, 16, 17, 18, 19, placed in a substantially horizontal plane parallel to the forming wire 8. These revolving rollers with belonging spikes will cover the entire bottom of the forth distribution unit 5, through which the fibre material will be released to the forming wire. Since the spikes partly will retain the fibres against the effect from the suction of the suction unit the cloud of fibres, which has been formed inside the forming box of single fibres are split up and mixed in the air stream, are transferred down onto the underlying wire by application of the revolving spike rollers.
• Fig. 3 shows a schematic side view of a forth distribution unit 5, according to the invention wherein the spikes 22 on the revolving rollers 15,16,17,18,19 are placed so that the outer ends 23 of the spikes describe circles that do not overlap each other .
• Fig. 4 shows a different embodiment of the forth distribution unit 5, according to the invention to the invention described, wherein the spikes 22 on the revolving rollers 15,16,17,18,19 are be placed so that the outer ends 23 of the spikes describe circles that do overlap each other. As is clearly shown on the figure two adjacent spikes will engage with each other like toothed wheels.
• the embodiment shown in fig. 3 has the advantage that the revolving rollers 15,16,17,18,19 can be placed closer to each other, whereby the fibres can be influenced by more than one spike 12 at a time, providing a higher impact force on the agglomerates, lumps and/or shadows, enabling a better disintegration .
• Fig. 5a and 5b shows a second embodiment 25 of the forming head according to the invention.
• This embodiment basically corresponds to the first embodiment with a few modifications and for like parts same reference numbers are used.
• the forming head according to the invention comprises sixth distribution units. This are of course in no manner intended to be limiting for the invention, and the forming head can within the scope of the present invention comprise from two to a plurality of distributions units.
• the forming head shown in fig. 5a and 5b comprises six independent interconnected distribution units 26, 27, 28, 29, 30 and 31 respectively. Fibres are supplied to the first distribution unit 26 via an inlet 6. A suction unit 7 is positioned beneath a forming wire 8, and the forming head 25 is positioned above the wire. Fibres are air laid on the forming wire 8 to form a web in a dry forming process.
• the first, second and third distribution units 25, 26 and 27 have a smaller horizontal cross section than the underlying distribution units, i.e. the forth, fifth and sixth distribution unit 28, 29 and 30.
• the difference in the horizontal cross section ensures a fluxuation in the air flow between the distribution units having the smaller cross section and the distribution units with the larger cross section, whereby an un-even air flow is created that will ensure that the fibres are distributed and spread more homogenously onto the underlying distribution unit (s) .
• each distribution unit revolving rollers are provided with protruding spikes 12.
• the first distribution unit 26 comprises one revolving roller 32
• the second distribution unit 27 comprises two revolving rollers 33, 34
• the third distribution unit 28 comprises one revolving roller 35
• the forth distribution unit 29 comprises one revolving roller 36
• the fifth distribution unit 30 comprises two revolving rollers 37, 38
• the sixth distribution unit 28 comprises three revolving rollers 39, 40, 41 placed in a substantially horizontal plane parallel to the forming wire 8.
• the three revolving rollers 39, 40, 41, which are placed within the sixth distribution unit, can be said to make up the bottom of the forming head.
• Engines 20 arranged with the possibility for a variable revolution rate, drives each revolving roller, ensuring that it is possible to adjust the revolution rate of the engines dependent of choice of rollers, spikes and the product, which is to be formed.
• a single engine 20 drives all revolving rollers in a distribution unit.
• a synchronous transmission belt (not shown) is used to transmit the force from said engine to the respective revolving rollers.
• the beneficial effect that the revolving rollers can be placed so that the outer ends of the spikes describe circles that overlap each other e.g. meshes like toothed gear.
• This embodiment has the advantage that the revolving rollers can be placed closer to each other, whereby the fibres can be influenced by more than one spike at a time. This will provide a higher impact force on the agglomerates, lumps and/or shadows, enabling a better disintegration of the fibrous material.
• each distribution unit with attached motor in the forming head is a "plug and go” and can be pulled out and exchanged swiftly by hand, replaced by another distribution unit, removed completely or an additional distribution unit added to the forming head.

Landscapes

• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Nonwoven Fabrics (AREA)
• Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
• Preliminary Treatment Of Fibers (AREA)

Priority Applications (2)

Applications Claiming Priority (3)

Publications (2)

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• 2008
  • 2008-01-11 EP EP08150185A patent/EP2078769A1/de not_active Withdrawn
• 2009
  • 2009-01-12 WO PCT/EP2009/050273 patent/WO2009087236A1/en active Application Filing
  • 2009-01-12 NZ NZ587277A patent/NZ587277A/en unknown
  • 2009-01-12 RU RU2010132248/12A patent/RU2502837C2/ru active
  • 2009-01-12 PL PL09700432T patent/PL2238281T3/pl unknown
  • 2009-01-12 CA CA2711808A patent/CA2711808A1/en not_active Abandoned
  • 2009-01-12 EP EP09700432A patent/EP2238281B1/de active Active
  • 2009-01-12 CN CN2009801032115A patent/CN101925697B/zh active Active
  • 2009-01-12 US US12/812,346 patent/US20100283176A1/en not_active Abandoned
  • 2009-01-12 AU AU2009203705A patent/AU2009203705A1/en not_active Abandoned
  • 2009-01-12 AT AT09700432T patent/ATE535634T1/de active
  • 2009-01-12 BR BRPI0905731-5A patent/BRPI0905731A2/pt not_active Application Discontinuation
  • 2009-01-12 DK DK09700432.9T patent/DK2238281T3/da active
  • 2009-01-12 KR KR1020107017588A patent/KR20100116185A/ko not_active Application Discontinuation
• 2010
  • 2010-08-10 ZA ZA2010/05680A patent/ZA201005680B/en unknown

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