JP2022521613A - ニードルパンチ不織布の製造のための装置 - Google Patents

ニードルパンチ不織布の製造のための装置 Download PDF

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JP2022521613A
JP2022521613A JP2021549750A JP2021549750A JP2022521613A JP 2022521613 A JP2022521613 A JP 2022521613A JP 2021549750 A JP2021549750 A JP 2021549750A JP 2021549750 A JP2021549750 A JP 2021549750A JP 2022521613 A JP2022521613 A JP 2022521613A
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nonwoven fabric
layer
needle
cards
woven fabrics
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JP7453245B2 (ja
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ベルンハルト、ジークフリート
シュルツェ、フォルクマー
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Adler Pelzer Holding GmbH
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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
    • D04H1/44—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
    • D04H1/46—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 by needling or like operations to cause entanglement of fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B19/00—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica
    • B32B19/06—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/06—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
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    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
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    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01G—PRELIMINARY TREATMENT OF FIBRES, e.g. FOR SPINNING
    • D01G15/00—Carding machines or accessories; Card clothing; Burr-crushing or removing arrangements associated with carding or other preliminary-treatment machines
    • D01G15/02—Carding machines
    • D01G15/10—Carding machines with other apparatus, e.g. drafting devices, in integral or closely-associated combination
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01G—PRELIMINARY TREATMENT OF FIBRES, e.g. FOR SPINNING
    • D01G15/00—Carding machines or accessories; Card clothing; Burr-crushing or removing arrangements associated with carding or other preliminary-treatment machines
    • D01G15/02—Carding machines
    • D01G15/12—Details
    • D01G15/46—Doffing or like arrangements for removing fibres from carding elements; Web-dividing apparatus; Condensers
    • 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
    • D04H1/46—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 by needling or like operations to cause entanglement of fibres
    • D04H1/498—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 by needling or like operations to cause entanglement of fibres entanglement of 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
    • D04H1/54—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
    • D04H1/70—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
    • D04H1/736—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 characterised by the apparatus for arranging fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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    • B32B2250/05—5 or more layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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    • B32B2250/20—All layers being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

本発明は、ニードルパンチ不織布を製造するための装置であって、不織布の製造中に、不織布の厚さおよび／または不織布の幅を横切って、個々の層に異なる材料を導入することができるニードルパンチ不織布の製造装置に関する。【選択図】図１

Description

本発明の目的は、ニードルパンチ不織布の製造のための装置であって、製造時にすでに個別にマルチプライ不織布のそれぞれの個々の層へと不織布の厚さ及び／又は不織布の幅を介して同一又は異なる材料を導入することを可能にする装置である。
特には、４００～１８００ｇ／ｍ２の坪量範囲のＰＰ／ＰＥＴ、ＰＰ／ＢｉＣｏ、ＰＰ／ＢｉＣｏ／ＰＥＴ、及びＰＥＴ／ＢｉＣｏ混合繊維不織布がベース不織布として使用され、その用途を、特には自動車の外部領域に見出すことができる。
先行技術において、ベロアカーペットの製造のためのプロセスが知られており、とりわけ独国特許出願公開第４４ ０９ ７７１号明細書、独国特許第２９ ００ ９３５号明細書、及び独国特許出願公開第１０ ２００８ ０２６ ９６８号明細書が参照される。
繊維ウェブの製造のためのカード又はカード機が、例えば、米国特許出願公開第２０１８／００５１４００号明細書、国際公開第２０１７／１７８１４８号パンフレット、米国特許出願公開第２０１６／０３６２８１８号明細書、独国特許出願公開第１０ ２０１５ １１２ ７７７号明細書、及び独国特許出願公開第１０ ２０１４ ００９ ３３９号明細書に記載されている。特には、不織布の積層装置に関して、いくつかの実施形態を、米国特許第３ ９０３ ５６９号明細書、独国特許出願公開第１０ ２０１０ ０５０ ０２７号明細書、及び独国実用新案第２０ ２０１２ １０２ ５９７号明細書に見つけることができる。
さらに、いわゆるリサイクルされたサンドイッチ不織布又は部品の製造のためのプロセスが、先行技術に記載されており、一方ではプレス技術（独国特許出願公開第１０ ２０１６ ２０２ ２９０号明細書）が使用され、他方ではニードル加工（独国特許出願公開第１０ ２０１３ ２２２ ４０３号明細書、独国特許出願公開第１０ ２０１６ ２０３ ３４８号明細書）が使用されている。
国際公開第２０１２／０５２５３５号パンフレットは、連続的なプロセスシーケンスで複合不織布を製造するための方法、及びこの方法を実施するための装置に関する。このプロセスにおいては、繊維ウェブがカーディング装置によって繊維ストリームから形成され、その表面に合成繊維の不織布層が続いて敷設される。この目的のために、繊維ウェブは、デリバリベルト上の吸引ゾーン内でメルトブロー装置へと案内され、メルトブロー装置において、合成繊維が繊維ウェブの表面にメルトブローによって敷設される。次いで、不織布で覆われた繊維ウェブが、不織布積層装置によって数層に敷設され、複合不織布が形成される。
製造時に多層不織布の個々の層に同一又は異なる材料を分散させるプロセス又は装置は、先行技術から知られていない。
したがって、前述の先行技術と比較した本発明の課題は、不織布の製造のための装置であって、不織布の厚さ及び／又は幅を横切って、不織布の製造時にすでに、それぞれの個々の層へと、粉砕された材料及び／又は繊維及び／又はフレーク及び／又は粉末として、同一又は異なる材料及び／又は量を分散させ、不織布の敷設後に得られた複合材をニードル加工することを可能にする装置を提供することである。
第１の実施形態において、本発明の目的は、それぞれの個々の層の不織布厚さ及び／又は不織布幅を横切って同一又は異なる材料を有している多層ニードルパンチ不織布を製造するための装置であって、
少なくとも１つ以上のニードル加工されていない繊維ウェブ層又はニードルパンチされた繊維ウェブ層１、２に材料を適用するための散布装置４、５、６、７を有し、散布装置４、５、６、７のうちの１つ以上が、カード１０のピックアップ搬送ベルト１１、１２の間に位置している、ことを特徴とする装置である。
本発明による装置を用いて、例えば織物ホイールアーチライナの特には音響的及び機械的要件に従って、
散布装置４、５、６、７の可能な接続及び／又は制御を必要とされる材料タイプ及び／又は材料量に従って達成して、繊維ウェブ１、２の間に粉砕された材料及び／又は繊維及び／又はフレーク及び／又は粉末としての同一又は異なる材料及び量を分散させ、
繊維ウェブ１、２を間に材料を位置させつつ敷設して、単一層３を形成し、
個々の層３を複数の層９へと敷設して、材料複合体８を形成し、
材料複合体８をニードル加工する
ことが可能である。
好ましい実施形態に係る装置を示している。 マルチピックアップカードを、対応する散布装置１３、１４及び１５、１６、１７と共に示している。 ２つのカードが互いに前後に配置され、次いで層が積層装置へと移される装置を示している。 互いに隣接して配置された２つのカード及び２つの積層装置の配置を示している。 互いに隣接して配置された２つのカード及び２つの積層装置の配置を示している。
好ましい実施形態において、装置は、二連ピックアップカード機１０（図１）を備え、散布装置４、５、６、７は、２つのピックアップ搬送ベルト１１、１２の間に配置され、ここでは異なるように制御及び／又はスイッチオンされてよい。
図２は、マルチピックアップカードを、対応する散布装置１３、１４及び１５、１６、１７と共に示している。
図３においては、２つのカードが互いに前後に配置され、次いで層が積層装置へと移される。これにより、散布されるべき材料の良好な相互性及び変動性が可能になる。この配置によれば、個々の層を選択的に選択することによって、異なるベース不織布品質を実現することも可能である。
図４は、互いに隣接して配置された２つのカード及び２つの積層装置の配置を示している。この配置の利点は、積層装置ごとの層の数に関して、したがって上部又は下部に、同一又は異なる散布材料を使用できることである。散布材料の分布、したがって重量範囲の変動が与えられる。
したがって、本発明の核心は、不織布から製造すべき部品の音響的及び機械的要件に応じて、カードにおいて繊維ウェブの間に粉砕再生材料及び／又は繊維及び／又はフレーク及び／又は粉末として同一又は異なる材料及び／又は量を散布し、ニードル加工することを可能にする装置の提供である。
したがって、本発明による装置は、カードのピックアップの間に散布装置４、５、６、７を配置して、それらを制御することによって、必要に応じた散布を可能にする。
本発明の利点は、特性に影響を及ぼす層構造をそれぞれの個々の層の厚さ及び／又は幅を介して製造時にすでに生み出すことができる変形に適した／安定な不織布を提供することにある。
これにより、部品の製造時の個々の層の積層及び縫製などが不要になるとともに、時間のかかるロール又はブランクの変更も不要になり、積層システムがもはや必要とされず、これは、特にはサイクル時間の短縮につながる。
織物ホイールアーチライナの製造のための１６００ｇ／ｍ２の総重量を有する８つの個々の層を含む耐変形性／安定性の不織布の製造のために、１５０ｇ／ｍ２のガラス繊維／ｐａｎｏｘ／ＰＥＴ／ＢｉＣｏ粉砕材料が、後にホイールに面する第１の層に取り入れられ、１５０ｇ／ｍ２のＰＰ／ＰＥＴ／ＢｉＣｏ粉砕材料が、第１の層に続く第２の層に取り入れられ、１５０ｇ／ｍ２のＰＰ／ＰＥＴ／ＢｉＣｏ粉砕材料が、第１の層に続く第２の層に取り入れられ、１５０ｇ／ｍ２のガラス繊維／Ｐａｎｏｘ／ＰＥＴ／ＢｉＣｏ粉砕材料が、後に車体に面する外側の第８の層に取り入れられ、１５０ｇ／ｍ２の鉱物及びガラス繊維粉砕材料が、その下方の第７の層に取り入れられる。ベース不織布は、市販の４０重量％のＰＰ繊維及び６０重量％のＰＥＴ繊維からなる。
上述のとおりの散布装置を有する本発明による装置が、この目的のために使用される。
次いで、フリースを、標準的な方法［接触加熱場（Ｔ＝２００℃；ｔ＝５０秒；ギャップ幅＝４ｍｍ）、ツール（Ｔ＝２０℃；ｔ＝５０秒；ギャップ幅＝３．５ｍｍ）］を使用してホイールアーチシェルに形成した。
このホイールアーチライナは、散布されてニードル加工された材料ゆえに、剛性、耐熱性、及び可燃性に関して改善された挙動を有している。

Claims (5)

  1. それぞれの個々の層の不織布厚さ及び／又は不織布幅を横切って同一又は異なる材料及び量を有している多層ニードルパンチ不織布を製造するための装置であって、
    少なくとも１つ以上のニードル加工されていない繊維ウェブ層又はニードル加工された繊維ウェブ層（１、２）に材料を適用するための散布装置（４、５、６、７）を備え、前記散布装置（４、５、６、７）のうちの１つ以上は、カード（１０）のピックアップ搬送ベルト（１１、１２）の間に位置している、ことを特徴とする装置。
  2. ２つ、３つ、又は４つのピックアップを有するカード（１０）を備える請求項１に記載の装置。
  3. 互いに前後に配置された２つのカード（１０）を備えており、前記層を積層装置上に敷設することができる、請求項１又は２に記載の装置。
  4. 横並びに配置された２つのカード（１０）及び２つの積層装置を備える、請求項１又は２に記載の装置。
  5. ２つのピックアップ搬送ベルト（１１、１２）の間の制御可能及び／又はスイッチ可能な散布装置（４、５、６、７）を備える請求項１～４のいずれか一項に記載の装置。
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