GB1604160A - Non-woven fabric - Google Patents

Description

(54) NON-WOVEN FABRIC (71) We, E. ILLINGWORTH & COM PANY (Bradford) LIMITED, a British Company of Shelf Mills, Shelf, Nr. Halifax, HX3 7PA, West Yorkshire, do hereby declare the invention for which we pray that a patent may be granted to us and the method by which it is to be performed, to be particularly described in and by the follow mg statement: This invention relates to a non-woven fabric of a pile-like structure particularly but not exclusively for use as a floor covering.

It is known to produce bonded web carpets by introducing between backing sheets a non-woven web concertina-folded across the width of the web, bonding the folds to the backing sheets and slitting the folded web between the bonded folds so as to produce simultaneously two pile-like fabrics. The products are not, however, completely satisfactory partly because of the difficulty of bonding at the folds and partly because the folded portions of web tend to open because of the resilience of the constituent fibres. Moreover, for optimum performance of the resultant fabnc it is desirable that the predominant fibre orientation is lengthwise of the "pile". This requires that the fibre orientation in the non-woven web should be along the length of the web which is a structure not readily produced. It is also known to cut strips off a web and to bond successive strips by their cut edges in face-to-face array transversely of an elongate backing sheet, but the method suffers from the disadvantage inherent in discontinuous processes. The present invention seeks to obviate the above mentioned disadvantages.

According to one aspect of the invention there is provided a method of forming a pile-like fabric comprising the steps of forming a plurality of elongate strips of fibrous matenal by progressively slitting an elongate fibrous web along its length, progressively turning each strip about its longitudinal axis, condensing the turned strips laterally and assembling the condensed strips in the form of a pile with a slit edge of each strip in a common plane. Preferably the strips are so coherent as not to require support during the turning.

The forming, turning, condensing and assembling of the strips Preferably take place simultaneously and continuously.

Adjacent strips may be turned in the same direction or m opposite directions. Preferably the edges of the strips arranged in a common plane and secured to a backing sheet.

Preferably opposed slit edges of the strips are arranged in two parallel planes, secured to a pair of backing sheets and divided between the said backing sheets to form two pile-like fabrics simultaneously.

Preferably the fibres of the web lie predominantly in the plane of the web and transverse to the direction of slitting.

According to a further aspect of the invention there is provided apparatus for producing pile-like fabrics comprising means for progressively slitting an elongate fibrous web along its length into strips, means for progressively turning the stnps about their longitudinal axis, means for condensing the turned strips laterally and means for assembling the sllt-edges of each strip in a common plane. The apparatus may further comprise means for securing the edges arranged in a common plane to a backing sheet.

Path length equalisation means may be provided for eliminating differences in path length on such closing up when the method is operated continuously. The apparatus may comprise means for securing the, strips between parallel backing sheets, and means for dividing the strips between the sheets.

According to yet a further aspect of the invention there is provided a pile-like carpet made by the method aforesaid.

Embodiments of the invention will now be described by way of example and with reference to the accompanying drawings of which: Figure I shows diagrammatically and in side elevation apparatus for the basic steps of the invention; Figure 2 shows diagrammatically and in plan apparatus for the initial steps of the method; Figure 3 shows diagrammatically and in perspective apparatus for the initial steps of the method; Figure 4 shows diagrammatically and in side elevation apparatus for all the processing steps; Figures 5 and 6 show in detail parts of the apparatus shown in Figure 4; A web 1 consisting predominantly of fibres 2 lying in the plane of the web and transverse to the longitudinal direction is formed as shown in Figure 3 by cross laying the output from a Garnet machine 4 by means of a cross folding lattice 5 and needling the same by means of a needle loom 6, although in other embodiments the web may be produced in other ways The web is advanced from where it is produced and progressively slit into strips 10 y means of a slitting device 11 which may comprise a pair of heated profiled rollers, a series of knife edges, heated wires or laser beams. Subsequently each strip is turned through 90" as it moves away from the slitting device as shown most clearly in Figure 3. In an embodiment not shown, adjacent strips are turned through 90" in opposite directions.

Because of the needling or other web production method, the strips are so coherent as to require no support during the turning which Is simply effected by feeding the strips from a reed of form 7A to a reed of form 7B as shown in Figure 5, with each strip passing through the gaps 12 between adjacent wires 13. The strips, though narrow, are wider than the web Is thick, and the twisting of the strips through 90" will result in their being spaced apart from one another, and the strips are thus closed so that they are substantially in face to face contact, this being achieved by passing the strips through a reed of form 7B wherein the gaps 12 are closer together.

It will be clear that some strips will undergo more lateral movement than others in the closing together of the strips slit from one web and thus travel over a slightly longer path. As it is envisaged that the method shall proceed continuously, the increased path length could lead to an undesirable effect. In order to avoid this, it may be arranged as in this embodiment that the strips which are less displaced laterally in the closing-up stage undergo a compensating displacement out of and back to the plane of the web so that overall the path length of each strip is identical. Whilst in Figure 2 the twisting and closing up of the webs is shown to take place in one stage, the method shown in Figure 4 indicates an out-of-plane displacer 3 following the slitter 11 and followed in turn by twisting of the strips by means of a reed 7B having wide gaps and a lateral closing up of the strips in a compression zone 8 by a reed 7B' having closer gaps. In this zone the slit edges of the strips are confined between the innermost reaches of a pair of endless belts 9 moving in a direction shown by arrow 12.

The belts 9 ensure that the edges of the strips lie in common planes and facilitate the subsequent bonding of the edges to a backing sheet.

Because of the reduction in width of the web strip assembly on turning each individual strip through 90 , the overall width of the assembly is less than that of the original web it will in practice be necessary to assemble strips from a plurality of webs in order that the finished product of the process shall have a commercially acceptable width. This is indicated schematically in Figure 4 which shows four webs 1 being assembled together. In this figure, as opposed to Figure 3 which showed web bemg formed and slit concurrently, the raw material for the carpets pile is in the form of rolls 21 of web. In order that the process shall run continuously, known means may be used to splice the leading edge of a new web to the trailing edge of web that is almost exhausted. It will be appreciated that the spatial arrangement of the supply rolls may be varied as required by their number and the space available.

Backing sheets 14, supplied from rolls 16 are introduced to the planes of the edges of the strips in their closed up assembly and bonded thereto by conventional means and held in contact to facilitate bonding by means of a further pair of endless belts 18.

During the bonding stage the strips are not held m reeds and lateral pressure may alternatively be provided between belts 18 by narrow belts 19 (shown in Figure 6) or the circumference of thin discs (not shown) substantially in the plane of the assembly of strips, that Is to say in a plane perpendicular to that of the Figure On issuing, bonded, from the bonding zone defined by the belts 18, the bonded sandwich of strips between backing sheets is split down the middle of the strips by a blade 20 so as to produce two fabrics 24 each consisting of a backing sheet to which are bonded an assembly of web strips running parallel to the length direction of the fabric and in each of which strips the fibres are predominantly perpendicular to the backing sheet. Because of the predominantly er- pendicular arrangement of the fibres of the web strips, the bonding to the backing sheet and a cut edge of the strips involves the adhesion of a great number of fibre ends and is thus particularly effective. Moreover, relative to the concertina-folded webs of other methods of pile fabric production, a smaller proportion of the web in the present method is involved in the adhesion and larger proportion is effective as 'pile'.

After slitting, the two fabrics are wound up onto rolls 26 in a convention manner.

WHAT WE CLAIM IS: 1. A method of forming a pile-like fabric comprising the steps of forming a plurality of elongate strips of fibrous material by progressively slitting an elongate fibrous web along its length, progressively turning each strip about its longitudinal axis, condensing the strips laterally and assembling the condensed strips in the form of a pile with a slit edge of each strip in a common plane.

2. A method according to Claim 1 wherein the strips are so coherent as not to require support during said turning.

). A method according to Claim 1 or Claim 2 wherein the forming, turning and assembling are continuous.

4. A method as claimed in any preceding claim wherein adjacent strips are turned in the opposite directions.

5. A method as claimed in any one of Claims 1 to 3 wherein adjacent strips are turned in the same direction.

6. A method according to any one of the preceding Claims wherein the edges of the strips arranged in a common plane are secured to a backing sheet.

7. A method according to Claim 6 wherein the strips are secured to a Pair of backing sheets and divided between the said sheets to form two pile-like fabrics simultaneously.

8. A method according to any preceding claim wherein the fibres of the web lie predominantly in the plane of the web and transverse to the direction of slitting.

9. Apparatus for producing pile-like fabrics comprising means for progressively slitting an elongate fibrous web along its length into strips, means for progressively turning the strips about their longitudinal axes, means for condensing the turned stripes laterally, and means for assembling the slit edges of each strip in a common plane.

10. Apparatus according to Claim 9 wherein the turning means comprises guide means spaced apart in the length direction of the strips.

11. Apparatus according to Claim 9 or Claim 10 further comprising path length equalization means.

12. Apparatus according to Claims 9 to 11 further comprising means for securing the edges arranged in a common plane to a backing sheet.

13. Apparatus according to Claim 12 comprising means for securing the strips between parallel backing sheets, and means for dividing the strips between the sheets.

14. A pile-like fabric made according to the method of Claim 1.

15. A method of forming a pile-like fabric substantially as described with reference to the drawings.

16. Apparatus for producing pile-like fabrics substantially as described with reference to the drawings.

17. A pile-like fabric substantially as described with reference to the drawings.

**WARNING** end of DESC field may overlap start of CLMS **.

Claims (17)

**WARNING** start of CLMS field may overlap end of DESC **. predominantly perpendicular to the backing sheet. Because of the predominantly er- pendicular arrangement of the fibres of the web strips, the bonding to the backing sheet and a cut edge of the strips involves the adhesion of a great number of fibre ends and is thus particularly effective. Moreover, relative to the concertina-folded webs of other methods of pile fabric production, a smaller proportion of the web in the present method is involved in the adhesion and larger proportion is effective as 'pile'. After slitting, the two fabrics are wound up onto rolls 26 in a convention manner. WHAT WE CLAIM IS:

1. A method of forming a pile-like fabric comprising the steps of forming a plurality of elongate strips of fibrous material by progressively slitting an elongate fibrous web along its length, progressively turning each strip about its longitudinal axis, condensing the strips laterally and assembling the condensed strips in the form of a pile with a slit edge of each strip in a common plane.

2. A method according to Claim 1 wherein the strips are so coherent as not to require support during said turning.

). A method according to Claim 1 or Claim 2 wherein the forming, turning and assembling are continuous.

4. A method as claimed in any preceding claim wherein adjacent strips are turned in the opposite directions.

5. A method as claimed in any one of Claims 1 to 3 wherein adjacent strips are turned in the same direction.

6. A method according to any one of the preceding Claims wherein the edges of the strips arranged in a common plane are secured to a backing sheet.

7. A method according to Claim 6 wherein the strips are secured to a Pair of backing sheets and divided between the said sheets to form two pile-like fabrics simultaneously.

8. A method according to any preceding claim wherein the fibres of the web lie predominantly in the plane of the web and transverse to the direction of slitting.

9. Apparatus for producing pile-like fabrics comprising means for progressively slitting an elongate fibrous web along its length into strips, means for progressively turning the strips about their longitudinal axes, means for condensing the turned stripes laterally, and means for assembling the slit edges of each strip in a common plane.

10. Apparatus according to Claim 9 wherein the turning means comprises guide means spaced apart in the length direction of the strips.

11. Apparatus according to Claim 9 or Claim 10 further comprising path length equalization means.

12. Apparatus according to Claims 9 to 11 further comprising means for securing the edges arranged in a common plane to a backing sheet.

13. Apparatus according to Claim 12 comprising means for securing the strips between parallel backing sheets, and means for dividing the strips between the sheets.

14. A pile-like fabric made according to the method of Claim 1.

15. A method of forming a pile-like fabric substantially as described with reference to the drawings.

16. Apparatus for producing pile-like fabrics substantially as described with reference to the drawings.

17. A pile-like fabric substantially as described with reference to the drawings.