JP4546010B2 - Method for producing non-woven fabric and plant for carrying it out and non-woven fabric so obtained - Google Patents

Method for producing non-woven fabric and plant for carrying it out and non-woven fabric so obtained Download PDF

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JP4546010B2
JP4546010B2 JP2001503723A JP2001503723A JP4546010B2 JP 4546010 B2 JP4546010 B2 JP 4546010B2 JP 2001503723 A JP2001503723 A JP 2001503723A JP 2001503723 A JP2001503723 A JP 2001503723A JP 4546010 B2 JP4546010 B2 JP 4546010B2
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Prior art keywords
web
spunbond
fibers
v1
sheet
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JP2003502515A (en
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アンドレ・ヴァルーミ
フレデリック・ノエル
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リエテル・ペルフォジェ
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Priority to FR9907602A priority Critical patent/FR2794776B1/en
Priority to FR99/07602 priority
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Priority to PCT/FR2000/001428 priority patent/WO2000077286A1/en
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    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H3/00Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/16Non-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
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-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
    • D04H1/42Non-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 characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/425Cellulose series
    • D04H1/4258Regenerated cellulose series
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-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
    • D04H1/42Non-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 characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4374Non-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 characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece using different kinds of webs, e.g. by layering webs
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-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
    • D04H1/44Non-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
    • D04H1/46Non-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
    • D04H1/492Non-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 by fluid jet
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-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
    • D04H1/44Non-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
    • D04H1/46Non-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
    • D04H1/498Non-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
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/70Non-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
    • D04H1/74Non-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 orientated, e.g. in parallel (anisotropic fleeces)
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H13/00Other non-woven fabrics
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H18/00Needling machines
    • D04H18/04Needling machines with water jets
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H3/00Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/005Synthetic yarns or filaments
    • D04H3/007Addition polymers
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H3/00Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/10Non-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 yarns or filaments made mechanically
    • D04H3/11Non-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 yarns or filaments made mechanically by fluid jet
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H5/00Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
    • D04H5/02Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by mechanical methods, e.g. needling
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H5/00Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
    • D04H5/02Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by mechanical methods, e.g. needling
    • D04H5/03Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by mechanical methods, e.g. needling by fluid jet
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H5/00Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
    • D04H5/08Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of fibres or yarns

Description

[0001]
BACKGROUND OF THE INVENTION
Over the last few decades, proposals have been made to replace conventional woven webs (woven materials and knits) with a structure called “nonwoven fabric”. Nonwoven fabrics can generally be roughly classified into the following three categories based on the actual manufacturing process.
A category referred to as “wet-formed” non-woven fabrics manufactured using techniques similar to paper manufacturing.
-A category referred to as “dry-formed” non-woven fabric, consisting of discontinuous natural and chemical fibers obtained by paper-making equipment, brushing equipment and other textile production equipment.
-A category called "melt-formed" non-wovens, consisting of continuous chemical fibers usually referred to by the general name "spunbond" (nonwovens made by spinning chemical fibers).
[0002]
The present invention relates to a method for improving the technology for producing a "spunbond" type nonwoven fabric, and more particularly to a production method, a plant, and a new type of product obtained by these means. . Such products have appearance, characteristics such as touch, mechanical characteristics, and flexibility, similar to conventional fabrics, especially woven materials.
[0003]
[Background Art and Problems to be Solved by the Invention]
The production of “spunbond” type non-woven webs is evident by earlier publications disclosing this type of non-woven fabric, for example British Patent Application No. 932 482 and US Pat. No. 3,286,896. As you can see, it goes back decades.
[0004]
In general, in this type of technology,
-Extruding the organic polymer melt, or optionally extruding the organic polymer solution, through a perforated spinneret, thereby forming a fiber bundle or fiber curtain;
-Orienting the extruded fibers by drawing the extruded fibers using one or more devices for forming a fluid jet, in particular for forming a compressed air jet;
-Finally, collecting the fiber bundles in the form of webs on a moving conveyor belt, which is generally suctioned and whose moving speed is set according to the properties to be obtained, in particular according to the density. .
[0005]
After production, the web is generally consolidated, preferably continuously, for example by passing it through a sizing machine or a roll machine at an elevated temperature. Thereby, the individual fibers are bonded to each other.
[0006]
Thus, such “spunbond” nonwovens with very good properties comparable to conventional fabrics are, for example, composite reinforcement members such as coating substrates and members for producing laminates and membranes in particular. In addition, it is widely used in many technical fields as a pollution prevention layer in civil engineering for various applications as a ground laying object.
[0007]
On the other hand, the use of nonwoven fabrics in the field of application of conventional fabrics such as clothing, disposable clothing, wiping materials, finishing materials, interior fabrics, etc. has not progressed. The reason for this is that flexibility, feel and appearance are impaired by the bonding by a roll machine (bonding by calendering) to partially thermally bond the fibers without deteriorating the mechanical properties of the product. is there.
[0008]
In connection with solidifying the “spunbond” web, in addition to the above-described processes such as passing through a sizing machine or a roll machine (calendering), a conventional method using a needle with a barb or a fluid jet is used. It is conceivable that such a web is subjected to a needle punching process according to the method used.
[0009]
Such treatment may be discontinuous, possibly including an internal reinforcement layer, such as a unidirectional or bi-directional fabric or knit or web consisting of a series or more of parallel or non-parallel yarns. When forming a laminate of fibrous webs, it is frequently used.
[0010]
However, according to at least the Applicant's knowledge, the needle punching technique provides “spunbond” webs while imparting to such webs similar properties to conventional fabrics, particularly with respect to properties such as flexibility and feel. It has never been proposed for the purpose of solving the problem of single layer consolidation.
[0011]
That is, when the needle punching process using a barbed needle is applied to a “spunbond” web monolayer, the continuous fibers that make up the web are broken, thereby the main advantage of the nonwoven web This is because the mechanical characteristics that are one of the above are deteriorated.
[0012]
Such techniques are not applicable with respect to the use of conventional coupling processes using fluid jets, particularly using water jets. This is because it is well known that in such a spunbond web made of continuous fibers, it is difficult for the continuous fibers to move relative to each other. As a result, by using such a technique it is virtually impossible to obtain a “spunbond” web equivalent to that obtained by passing through a roll machine without compromising the mechanical properties. is there.
[0013]
[Means for Solving the Problems]
It has the same good mechanical properties (tensile strength, tear strength, etc.) as a “spunbond” web that is fully bonded and thus solidified by high temperature calendering, and moreover that of conventional fabrics such as woven fabrics. An improved method has been devised for producing "spunbond" type non-woven webs having the same appearance, feel and flexibility, which forms the subject of the present invention.
[0014]
Generally speaking, in the process according to the present invention for producing a “spunbond” type non-woven having the same appearance and properties as those of conventional fabrics,
Producing a “spunbond” type web by extruding and drawing continuous fiber bundles and collecting this web on a moving conveyor belt in the form of an unbonded web;
A card against at least one side of the so-formed “spunbond” webIn machineObtained from both natural and / or artificial and / or synthetic discontinuous fibers.10g / m 2 ~ 50g / m 2 Had a density ofTransport the sheet;
The composite formed in this way is compressed by pressing;
Transferring the composite continuously onto a processing unit for binding the composite by using a water jet acting against the surface of the composite made by the discontinuous fibers, thereby Intertwining the fibers in the thickness direction while still positioning the fibers on the surface, thereby forming entanglements with respect to and around the continuous fibers;
-Performing a drying treatment;
-Collecting the final product;
Each operation is performed continuously.
[0015]
In the present invention, before performing a water-based bonding operation, an assembly composed of a laminate of a “spunbond” web and a single discontinuous fiber layer covering the web or a plurality of “spunbond” webs and a plurality of them Note that the compression operation is performed by pressing an assembly consisting of a stack of multiple discontinuous fiber layers.
[0016]
Such compression, which can be performed by any suitable means such as, for example, a press roll, is quite different from the calendering operation when performed cold.
[0017]
In the present invention, a single sheet of discontinuous fibers can be combined with a “spunbond” type web. The sheet of discontinuous fibers is produced upstream of the production area of the “spunbond” web and onto the conveyor belt where the fibers coming from the “spunbond” plant were to be placed after production, The “spunbond” web can be deposited prior to the fibers forming the “spunbond” web being deposited on the surface of the sheet. Alternatively, a single sheet of discontinuous fibers can be transferred downstream from the production area of the “spunbond” web.
[0018]
In one practical embodiment, both sides of a “spunbond” type web are coated with a sheet of discontinuous fibers. In this case, one sheet is produced upstream of the production area of the “spunbond” web, and the other sheet is produced downstream of the production area of the “spunbond” web. Thus, a “spunbond” web consisting of continuous fibers is interposed between two sheets of discontinuous fibers.
[0019]
In that case, the composite consisting of three layers is compressed by pressing, and then to bind the composite by using a water jet that still acts sequentially against the surface of the composite. So that the fibers are entangled with each other in the thickness direction while still on the surface, thereby forming entanglements with respect to and around the continuous fibers .
[0020]
Furthermore, an additional “fabrication” operation can be performed after the water jet joining operation and before the drying operation (for example, as disclosed in EP 059608). be able to). In this weaving operation, the combined composite is transferred onto a coarse woven conveyor and then directly underneath the perforated rotating drum and the conveyor in which the injector for supplying pressurized water is located. A unit comprising a suction unit arranged is used to reorient the fibers by applying a water jet from the injector to the web and to remove water by the suction unit.
[0021]
The invention also relates to a plant in which the above method can be carried out continuously. Generally speaking, this plant is
A unit for forming a “spunbond” type web of continuous fibers on a conveyor belt;
-No discontinuous fiber on at least one side of the manufactured "spunbond" web.10g / m 2 ~ 50g / m 2 Had a density ofAt least one card for producing and conveying sheetsWith the machine;
-Means for pressing the formed complex;
The fluid jet acts on at least one surface covered by the discontinuous fibers, thereby entangled with each other in the thickness direction while the fibers are still located on the surface, whereby continuous fibers Water jet bonding treatment means for forming entanglements against and around continuous fibers;
-A drying means;
-Means for collecting the combined webs;
Are provided in series.
[0022]
In addition, such a plant comprises a weaving unit between the water jet coupling treatment means and the drying means.
[0023]
Compared to the “spunbond” web produced by the conventional method, the product obtained according to the present invention is formed by combining discontinuous fibers with a web formed from continuous fibers, Covers the web based on continuous fibers and penetrates into the web by forming bonds around the fibers.
[0024]
Such a product according to the present invention possesses all the mechanical strength properties of a conventional spunbond web that has been obtained with a calendering process. The product obtained according to the invention also has the same properties as conventional fabrics, for example in terms of properties such as feel, flexibility and appearance.
[0025]
Note that the discontinuous fibers combined to the spunbond web can be any type of fiber, for example natural fiber, chemical fiber, hydrophilic fiber or hydrophobic fiber, depending on the product application. I want to be. The length of such a fiber is 5 mm to 60 mm, and the thickness is 0.8 dtex to 6.6 dtex.
[0026]
The density of the discontinuous fiber sheets combined with the spunbond web can vary depending on the application. However, preferably 10 g / m2 ~ 50g / m2 It is said. Density is 10 g / m2 Smaller sheets cannot be properly bonded to the spunbond web, and conversely the density is 50 g / m.2 Larger sheets reduce the economic benefits of the method.
[0027]
DETAILED DESCRIPTION OF THE INVENTION
The present invention and the advantages obtained by the present invention will be understood more clearly from the following description with reference to the accompanying drawings.
[0028]
As shown in the accompanying drawings, the present invention relates to a method and plant capable of continuously producing a new type of “spunbond” web of continuous synthetic fibers. Such webs not only have the same mechanical strength properties (stretch, tensile strength, tear strength, etc.) as conventional “spunbond” webs consolidated by high temperature calendering, but also for example woven fabrics Thus, the appearance, feel and flexibility equivalent to those of conventional fabrics can be exhibited.
[0029]
In the present invention, a “spunbond” type non-woven web is extruded through a perforated spinneret (2) in a plant as indicated generally at (1), thereby producing an organic polymer melt, Manufactured using conventional techniques of forming fiber bundles or fiber curtains (3).
[0030]
After cooling, at least the surface of the extruded fibers (3) will be hardened, the extruded fibers are stretched and oriented by using one or more fluid jet devices (4). Upon exiting the fluid jet device, the extruded fibers are deposited in the form of a web (S) on the collecting surface.
[0031]
In the present invention, the “spunbond” web (S) thus formed is solidified to give the web cohesive strength and, in particular, strong mechanical properties such as tensile strength and tear strength. In addition, in order to provide the same look and feel and flexibility as conventional fabrics, the “spunbond” web (S) is directly on the surface of the conveyor belt (5) where suction is taking place. Rather, they can be natural fibers, artificial fibers or synthetic fibers and are collected on a sheet (V1) of discontinuous fibers that is manufactured just before the “spunbond” plant (1).
[0032]
This sheet (V1) is manufactured using, for example, a conventional unit (6) that is formed by additionally combining a card web spreading unit with a card machine. The manufactured sheet (V1) is conveyed by a feeding unit consisting of a conveyor belt (7) onto a conveyor belt (5) of a “spunbond” plant.
[0033]
The two fabric layers (V1, S) superposed on each other are then held on the conveyor belt (5) while the first unit (8) consisting of, for example, two rollers, capable of compressing both layers. pass.
[0034]
A second sheet (V2) of discontinuous fibers is produced by a second unit (9), for example a card machine or similar machine, and fed onto the surface of the spunbond web (S). The three individual fabric layers (V1, S, V2) superimposed on each other are compressed again by being pressed between the two rollers (8).
[0035]
The compressed assembly is then processed, still continuously, by a processing unit shown in detail in FIG. 2 and indicated generally by the reference numeral (10). The processing unit (10) performs a binding process on the composite by using a plurality of water jets that act sequentially on both sides of the previous composite (ie, the compressed assembly). Is for.
[0036]
In this embodiment, the processing unit (10) is a water-based coupling unit of the type “Jetlace 2000” sold by the applicant. Regarding this, French Patent Application Publication No. 2 730 246 (U.S. Pat. No. 5,718,022) and French Patent Application Publication No. 2 734 285 (U.S. Pat. No. 5,768,756).
[0037]
Such a coupling unit essentially comprises a conveyor (11). Along this conveyor, a fiber structure consisting of three layers (V1, S, V2) superimposed on each other is conveyed.
[0038]
Then, as clearly shown in FIG. 2, the structure is compressed between the conveyor (11) and the first suction roll (12). The first suction roll (12) is preferably covered by a micro-perforated jacket in which a plurality of holes are randomly arranged as disclosed in French patent application publication 2 734 285. .
[0039]
In other embodiments, the roll (12) is covered by a metal wire mesh.
[0040]
In addition, in the compression region between the surface formed by the conveyor (11) and the surface formed by the roll (12), the composite web (V1 / S / V2) represented by the symbol (N) in the following description. On the other hand, the first wetting process can be performed by using the spray rail (13) shown by the broken line in FIG. In this case, the spray rail (13) supplies a water curtain that passes through the conveyor belt (11) and further through the composite web.
[0041]
However, such a wetting operation is not essential.
[0042]
The compressed composite is then subjected to the action of a water jet from the injector (14) while being supported by the suction drum (12). This water jet acts on the surface made of the fiber sheet (V1) and entangles the constituent fibers of the fiber sheet (V1).
[0043]
A spray rail or injector (14) arranged parallel to the normal of the roll (12) is a conventional spray rail used to produce water jets or water needles with a diameter of 100-170 μm. The water jets are arranged apart from each other by a distance of 0.5 to 2.2 mm, and the supply pressure is 50 to 150 bar depending on the density of the composite.
[0044]
Additionally, further jet processing can be performed on this first roll (12) using additional injectors.
[0045]
After leaving this roll (12), the treated composite contacts the surface of the second roll (15). The second roll (15) is of the same type as the first suction roll (11), and the second roll is provided with one set or two sets of injectors (16, 17). . These injectors emit a water jet that acts on the surface of the web (N) formed by the sheet (V2).
[0046]
In this second solidification process, the rails (16, 17) generate water jets or water needles with a diameter of 100-170 μm. The water jets are arranged apart from each other by a distance of 0.5 to 2.4 mm, and the supply pressure is 50 to 400 bar.
[0047]
In this case, the fibers forming the sheet (V2) are entangled with each other within the thickness of the web (N) by the action of the injectors (16, 17). These fibers surround the continuous fibers and are bonded to the continuous fibers.
[0048]
After leaving this unit, the spunbond web, indicated by reference numeral (18), can be transferred directly to the drying unit (19), in which the conventional heated drum (26) ) And then collected.
[0049]
Additionally, as shown in FIGS. 1 and 2, the third suction drum (20) can be used to perform a third water-based coupling process. The third suction drum (20) is provided with a pair of injectors (21), and a jet from the injector acts on the surface formed by the sheet (V1).
[0050]
After the third processing, complementary processing can be additionally performed. In such a process, as illustrated in detail in FIG. 2, the “spunbond” web (18) is placed on a unit manufactured, for example, as disclosed in EP 059 608. And transfer.
[0051]
In general, such a unit is provided with a “mesh paper machine” type wire mesh (22) used in the paper industry. The spunbond (18) is retained on this wire mesh while the action of a series of water jets obtained by using rails (23) that inject a water curtain towards the inner surface of the perforated rotating drum (24). Receive. These water jets reorient the fibers.
[0052]
The suction unit (25) for removing the water is naturally installed directly under the conveyor (22).
[0053]
By using all the means described above, a composite comprising two sheets of discontinuous fibers can be produced for a “spunbond” type non-woven fabric by the above-mentioned plant. Alternatively, by supplying a sheet of discontinuous fibers to one of the upstream and downstream sides of the formation area of the “spunbond” web, only one discontinuous fiber is provided for the “spunbond” type web. A composite comprising a combination of sheets can be produced.
[0054]
[Experiment 1]
This experimental example demonstrates the production of a composite in which a “spunbond” web is interposed between two sheets of discontinuous fibers.
[0055]
Such a product was manufactured according to the present invention as follows.
[0056]
30 g / m2 A fiber sheet (V1) made of 100% viscous fiber having a density of 1.7 dtex × 38 mm in length was manufactured using a normal card machine (6).
[0057]
This sheet was produced at a speed of 100 m / min.
[0058]
After being discharged from the card machine (6), the sheet (V1) was transferred onto the receiving belt (5) of the plant (1) for producing a “spunbond” type web (S).
[0059]
A “spunbond” web was made from polypropylene and the produced “spunbond” web was spread on a sheet (V1). Thereby, the density is 40 g / m.2 Webs having fibers of 1.7 dtex are formed.
[0060]
The two layers (V1, S) superimposed on each other are then compressed using the pressure roller unit (8). And 30g / m2 A second fiber sheet (V2) produced in the same manner as the sheet (V1) with the density is fed onto the surface of the “spunbond” web (S). The three individual layers (V1, S, V2) superimposed on each other are then subjected to further compression treatment by further pressing roller units.
[0061]
The composite so formed was then processed continuously in a processing unit (10) with a water-based coupling unit of the type “Jetlace 2000” sold by the applicant. .
[0062]
Such a unit basically comprises a conveyor belt (11) and three jet processing units each having a suction roll (12, 15, 20). Here, each roll has a diameter of 516 mm and is covered with a micro-perforated jacket in which a plurality of holes are randomly arranged as disclosed in French Patent Application Publication No. 2 734 285. ing. The suction drums (12, 15, 20) are provided with injector rails (14, 16, 17, 21), and the injector rails include a seat (V1), a spunbond (S), and a seat (V2). It acts on the surface of the composite (N) consisting of
[0063]
These injectors are arranged so that they can act sequentially on both sides of the composite (N).
[0064]
The rails (14, 16, 17, 21) formed 1666 jets per meter and were controlled as shown in the table below.
[Table 1]
[0065]
Arranged downstream of the last water-based unit (20) is a weaving unit consisting of a conveyor belt (22) formed in the form of a polyester wire mesh installed in the actual weaving unit. This unit is equipped with a perforated rotating drum (24). In this drum, an injector (23) which forms a water jet with 150 bar is arranged.
[0066]
The injector (23) formed a water jet having a diameter of 130 μm, thereby reorienting the fibers. Water from the injector (23) was collected by a suction system (25) installed directly below the conveyor (22).
[0067]
The web according to the present invention was obtained from the plant by carrying out the above method under the above conditions. This web has a density of 95 g / m after drying on a heated drum.2 Met.
[0068]
This web is fully and well bonded, flexible, feels good, has a good appearance, and compared to a conventional fabric of the same density obtained using the same type of fiber. , Which had equivalent mechanical properties.
[0069]
[Experiment 2]
This experimental example demonstrates the implementation of the method according to the invention in the production of a structure in which a “spunbond” web is combined with a single fiber sheet formed upstream of the formation area of the “spunbond” web. This is just an example.
[0070]
In accordance with the invention, the method according to the invention was carried out as follows.
[0071]
20 g / m2 A fiber sheet (V1) made of 100% viscous fiber having a density of 1.7 dtex × 38 mm in length was manufactured using a normal card machine (6).
[0072]
This sheet was produced at a speed of 150 m / min.
[0073]
After being discharged from the card machine (6), the sheet (V1) was transferred onto the receiving belt (5) of the spunbond unit.
[0074]
A spunbond web (S) consisting of polypropylene fibers was deposited on the sheet (V1).
[0075]
25g / m2 The density spunbond web has 2 dtex fibers.
[0076]
The two layers (V1, S) superposed on each other are then compressed using a pressure roller (8), whereby 45 g / m2 A composite of the density was formed. This composite was then continuously transferred onto a water-based coupling unit (10) of the type “Jetlace 2000” sold by the applicant.
[0077]
This unit comprises a conveyor belt (11), two water jet processing units each having a suction roll (12, 15), and a final conveyor (22). On the conveyor (22), a patterning / texturing device is arranged.
[0078]
The two rolls (12, 15) are covered by a micro-perforated jacket in which a plurality of holes are randomly arranged as disclosed in French patent application 2 734 285.
[0079]
These rolls are provided with injector rails (14, 16, 17).
[0080]
These injectors are arranged so that they can act sequentially on both sides of the composite.
[0081]
The injector formed 1666 water jets with a diameter of 120 μm per meter. The water pressure of these injectors was 60, 80, and 110 bar, respectively.
[0082]
Fabrication of the composite bonded on the previous roll was performed by a perforated rotating drum (24) as described in the first experimental example. The injector in this drum supplies the water jet with a water pressure of 80 bar.
[0083]
The final product after drying is 45 g / m2 And a mechanical property superior to that of a spunlace web made of the same type of fiber.
[0084]
The appearance and flexibility of the web is important. The appearance and flexibility of the resulting web was significantly better than the same density polypropylene and polyester bonded by calendering.
[Brief description of the drawings]
FIG. 1 is a side view showing an entire production line for carrying out a method according to the present invention.
FIG. 2 is a side view showing in more detail how the bonding operation is performed using a water jet and an additional additional weaving process.
[Explanation of symbols]
1 Spunbond forming plant
5 Conveyor belt
6 Card machine
9 Card machine
10 processing unit (water jet coupling processing means)
11 Conveyor belt
19 Drying unit (drying means)
22 mesh, conveyor (coarse fabric)
23 Injector
24 perforated rotating drum
25 Suction unit
S “Spunbond” type web
V1 Sheet of discontinuous fiber
Sheet of V2 discontinuous fiber

Claims (6)

  1. To produce “spunbond” type non-woven fabrics with the same mechanical properties as spunbond webs solidified by high temperature calendering, but with the same look, feel and flexibility as conventional fabrics A method,
    Producing a “spunbond” type web (S) by extruding and drawing continuous fiber bundles and collecting this web on a moving conveyor belt in the form of an unbonded web;
    A further 10 g / m 2 of at least one side of the so-formed “spunbond” web consisting of discontinuous fibers, both natural and / or artificial and / or synthetic, obtained by a card machine Conveying sheets (V1 and / or V2) having a density of ˜50 g / m 2 ;
    The composite formed in this way is compressed by cold pressing;
    -The composite continuously onto a processing unit (10) for bonding the composite by using a water jet acting on the surface of the composite made by discontinuous fibers; Transport and thereby entangle each other in the thickness direction while still positioning the fibers on the surface, thereby forming an entanglement with respect to and around the continuous fibers;
    -Performing a drying treatment;
    -Collecting the final product;
    A method characterized by continuously performing each operation.
  2. The method of claim 1, wherein
    The both sides of the web (5) of the “spunbond” type are coated with sheets (V1 / V2) made of discontinuous fibers,
    In this case, one sheet (V1) was produced upstream of the production area of the “spunbond” web, and after production, fibers coming from the “spunbond” plant were to be placed. Deposited on a conveyor belt (11) prior to the "spunbond" web, whereby the fibers forming the "spunbond" web are deposited on the surface of this sheet (V1) age,
    In addition, the other sheet (V2) is transferred to the downstream side of the manufacturing region of the “spunbond” web, whereby the “spunbond” web is transferred to the two fiber layers (V1, V2). A method characterized by interposing between.
  3. The method according to claim 1 or 2, wherein
    Performing an additional “weaving” operation after the water jet and before the drying operation,
    In this weaving operation, a perforated rotating drum (in which an injector (23) for transferring pressurized water and supplying pressurized water is disposed on a coarse fabric (22) is disposed. 24) and a unit comprising a suction unit (25) arranged directly under the fabric (22), the fibers are redirected by applying a water jet from the injector to the web. And removing the water by the suction unit.
  4. A plant for producing "spunbond" type non-woven fabrics,
    A unit (1) for forming a "spunbond" type web (S) of continuous fibers on a conveyor belt (5);
    - for at least one surface of the produced "spunbond" web, sheet (V1 and / or V2) further having a density of 10g / m 2 ~50g / m 2 made discontinuous fiber manufactures At least one card machine (6 and / or 9) for transport;
    -Means for cold pressing the formed composite;
    -Exerting a fluid jet against at least one surface covered by the discontinuous fibers, thereby entangled with each other in the thickness direction while still positioning the fibers on the surface, thereby Water jet bonding treatment means (10) for forming entanglements with respect to and around the continuous fibers;
    -A drying means;
    -Means for collecting the combined webs;
    In series,
    A woven unit is provided between the water jet coupling treatment means (10) and the drying means,
    The fabricizing unit includes a coarse fabric (22) for supporting the combined composite, a perforated rotary drum in which an injector (23) for supplying pressurized water is disposed, and the fabric ( 22) and a suction unit (25) arranged immediately below
    A plant characterized in that a water jet from the injector acts on the web to reorient the fibers, and water is removed by the suction unit.
  5. The plant according to claim 4,
    Means (6, 9) for producing fiber sheets upstream and downstream of the production area of the “spunbond” web;
    The sheet (V1) produced upstream is deposited on the conveyor belt (5) of the "spunbond" plant prior to the "spunbond" web, thereby being extruded and further stretched. The fiber bundle forming the “spunbond” web formed in this way is used for direct deposition on the surface of the sheet (V1),
    In addition, the other sheet (V2) is manufactured on the downstream side of the manufacturing region of the “spunbond” web, and is thereby deposited on the surface of the “spunbond” web. A plant characterized by
  6. A nonwoven fabric obtained by the method according to any one of claims 1 to 3,
    It is formed by combining discontinuous fibers against a web formed from continuous fibers,
    The non-woven fabric characterized in that the fiber covers at least one surface of the web based on the continuous fibers and penetrates into the inside of the web by forming a bond around the fibers.
JP2001503723A 1999-06-10 2000-05-26 Method for producing non-woven fabric and plant for carrying it out and non-woven fabric so obtained Expired - Fee Related JP4546010B2 (en)

Priority Applications (3)

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FR9907602A FR2794776B1 (en) 1999-06-10 1999-06-10 Method for producing a nonwoven material, installation for its implementation and resulting nonwoven
FR99/07602 1999-06-10
PCT/FR2000/001428 WO2000077286A1 (en) 1999-06-10 2000-05-26 Method for producing a nonwoven material, installation therefor and resulting nonwoven

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EP1192306A1 (en) 2002-04-03
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FR2794776A1 (en) 2000-12-15
WO2000077286A1 (en) 2000-12-21
DK1192306T3 (en) 2006-12-11
AU4932000A (en) 2001-01-02
FR2794776B1 (en) 2001-10-05
CN1355864A (en) 2002-06-26
TR200103471T2 (en) 2002-07-22
EP1192306B1 (en) 2006-08-16
PL352192A1 (en) 2003-08-11
JP2003502515A (en) 2003-01-21
AT336611T (en) 2006-09-15
DE60030120T2 (en) 2007-02-15
IL146867D0 (en) 2002-08-14

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