JPH01298219A - Apparatus for forming pocket in lateral direction - Google Patents

Abstract

PURPOSE: To obtain the subject machine whose shape and composition are widely changeable by transferring a mold receiving fibers from a mixing zone to a condensing zone with a conveyor, communicating a porous surface of the mold to an air permeative part of the conveyor and sucking. CONSTITUTION: In this machine, separated fibrous materials from lickerins 10 and 20 are transferred from a mixing zone to a conditioning zone 44 and sucked by a high vacuum chamber 49 passing through a mold 402 of a pocket and a condensing screen 42, then pads are formed in the pocket. The condensing screen is guided on a conveyor roller.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention provides a method for producing individualized fibers such as randomly oriented 1a fibers and/or granules obtained from separate feeds of spun fibers, papermaking fibers and powders. An improved method and apparatus for forming composite nonwoven web products of various shapes and sizes consisting of a more or less homogeneous intermixture of materials.

Nonwoven fibrous structures often consist of irregular yet homogeneous aggregates of long and short fibers. Long fibers are of both natural and synthetic origin suitable for textiles.
It is m. They are longer than 0.64 cm (0.25 in) and generally 1°27-6, 35 cm (0.5-
2.5 inches). Short molars are suitable for paper making and generally have a length of less than 0.64 cm (2.5 inches), such as wood pulp fibers or cotton linters.

Nonwoven web products can also include particulate materials, such as absorbent powders, in combination with long and short fibers, such as highly absorbent powders or fibers, to provide excellent web transfer properties. The fibers can be held in pockets.

Many methods and apparatus exist for producing nonwoven webs and other fibrous structures. Traditional cursing and guarding methods form non-woven M&M webs, but
These are generally limited to textile length fibers.

The "Rando-Webber" method can be used to produce nonwoven woven fabrics. In this method, the pre-opened spun Ja fiber material is sent to a licker-in which further opens the fibers and introduces them into a stream of high velocity, low pressure air.

The fibers are randomly deposited on the condensing screen to form a monoisotropic formation. Although it is possible to fabricate a uniform web of Ra male (2008), this method is unsuitable for use with short fibers or blends of long and short fibers.

U.S. Patent Section 3.51 to Langdon
No. 2,218 describes two licker-in and rotary feed capacitor assemblies arranged in parallel in sequence. Using this device, m,! ! An isotropic nonwoven web is formed by feeding the material into a licker-in where the fibers are singulated and deposited onto a condensing screen. A single air stream is split into two parts and applied to doff the fibers from the licker-in and deposit them onto a screen where they form a web. This method cannot be used to homogeneously blend two fiber streams.

U.S. Pat. No. 3,535.18 to Woods.
No. 7 was bonded at the interface of adjacent layers by a small zone of mIa of textile length extending across the interface. An apparatus for producing a layered web of randomly oriented fibers is described. The device of this patent provides one individualized fiber that is deposited onto a pair of cylindrical fundensing screens by a pair of respective licker-ins, these licker-ins having an ia, * Doffing works in conjunction with high-velocity air turbulence, moving faster than licker-in. However, the air velocity must also be controlled so that the wL fibers are not forced to impinge on the condenser, the condensing screens are placed closely together, and the layers of fibers on the condenser are Compaction between the condensers forms a composite nonwoven web structure that is somewhat blended at the interface between the layers. However, there is no substantial fiber mixing zone adjacent to the condenser and intermixing of fibers is minimal.

One method of making a nonwoven web consisting of a mixture of irregularly oriented long and short fibers is to use milling equipment to individualize the short mA and licker-ins to individuate the long IA. . The tvm is mixed in a mixing zone and this mixture is deposited on a condenser to form a nonwoven web. mixed M
The fibers are randomly oriented, but rather than homogeneously blended, they become stratified. Furthermore, since milling does not completely individualize the mIa of the short wood pulp, undesirable agglomerates of fibers or "salt" J occur in this web product.

Mixing long and short fibers and other methods of creating randomly oriented webs introduce pre-opened long and short #1 fibers into a single glue-in for individualization. However, the optimum cut-in trajectories for long and short fibers are different. To prevent degradation of the long fibers, the equipment must be operated at slower speeds than are optimal for long ia coarses; eventually, the speed and throughput of this loading are compromised.

A method and apparatus for producing blends of long and short fibers without producing agglomerates or salts is disclosed in U.S. Pat. No. 3,772,73 to Lovgren.
It is disclosed in No. 9. This patent provides for the individualization of each type of fiber separately and simultaneously with separate licker-ins, each of the licker-ins being operated at an optimal speed for opening m sewage, e.g., long ia sewage. ,
For example, rayon is fed into a licker-in operating at around 2400 rpm. Valve board is 6000rpm
Fed into licker-ins operating nearby, this speed would damage the long fibers, doffing the 6m males from their respective licker-ins by a separate air stream, and Take away. These streams are subsequently mixed in a mixing zone to mix the fibers and then create a homogeneous blend in an irregular manner.
It is deposited on a condenser located close to the mixing zone. Although the device of this patent is useful, it cannot be used to manufacture a wide variety of webs.

Other methods of producing homogeneous webs of fibers.

No. 3,740,797 to Farrington.

This patent provides a mix feed to parallel licker-ins rotating in opposite directions, and these licker-ins operating at their respective optimum speeds to individualize long and short fibers. The fibers are doffed from the licker-in by centrifugal force and by a high velocity air flow directed against the fibers which tend not to leave the structure of the licker-in. The individualized M&fibers from each feed are entrained in their respective air streams and propelled toward each other at high velocity along intersecting trajectories in the mixing zone, and in the mixing zone, the At least some of the fibers from each can be blended. A condensing means or screen with a vacuum chamber beneath it is in communication with the mixing zone so that the blended fibers are deposited on the condenser screen within the condensing zone to produce an isotropic web of 1 mm. This screen moves in a direction, the "machine direction", and this direction is perpendicular to the axis of the licker-in. Additionally, baffles can be interposed between the air flows to control the degree of mixing and relative position of long and short fibers in the composite web.

It would also be advantageous to provide composite web structures consisting of different fiber or particulate materials and blends thereof, with non-uniform cross-sections or predetermined topography, e.g. The method and apparatus for producing non-woven structures having absorbent properties, as in the case of sanitary products, e.g. sanitary napkins,
It is particularly desirable to provide a blended composite structure having a predetermined shape with desirable sharply defined edges.

Methods and dressings for producing non-woven fuzzy valve pads and pre-shaped absorbent articles are known, but conventional pocket formations do not provide selective blending and layering of valves, mis materials and particulate materials. The device is
Because of the complex geometries inherent in the use of hammer and disc mills and the use of cylindrical product forming surfaces, only one material, usually the valve, is processed and provides a uniform blended pad. Typical of these conventional devices, which cannot be easily modified to
chenfabrik and Curt G,
Joa, Inc.

and are described, for example, in the following literature: Stemmler.
i) U.S. Pat. No. 4,560,379 and U.S. Pat. No. 4,598,441.

PCT application to Johnson et al. W
No. 035104366 is also of interest.

J o h o n s o n i s selectively supplied with vacuum! Another perforated drum arrangement with a cavity of zero circumference that teaches the use of a fiber-receiving type, placed on a continuously rotating drum, is a facet (
U.S. Pat. No. 4,592,708 to Feist et al. and U.S. Pat. No. 3,518 to BankS.
, 726.

An early method of manufacturing sanitary napkins was winter (
Win ter) F (1') U.S. Patent No. 2.0
No. 73.329. Winter (Wi
nter) teaches that a patch of loose cotton fibers can be blown down onto a gauze-like material at regular intervals in cooperation with suction means.The absorbent material is then blown down onto the cotton patch. With the size S'2L on top, the gauze can be folded and cut at regular intervals to make napkins. The loose cotton fibers can be directed towards the surface of the moving vehicle and
The wheel has a fitted and screened suction inlet capable of receiving and condensing cotton fibers in a uniform patch. Winter's method requires several time-consuming separate steps and subsequent assembly of a composite structure from its constituent structures. It does not provide a shaped and layered composite structure formed by blending one or two position W&fibers and/or particulate materials in a single operation.

To C1ark (7) U.S. Patent No. 2,949
．． No. 646 is also representative of the prior art and describes a method for providing three-dimensional shaped structures with sharply defined edges. Clark (C1a r
k) describes a prior art method in which the fibers are deposited continuously on a continuously moving perforated belt equipped with suction from a stream of entrained air, partially masking the belt;
Deposit and condense tiAm into a web with the desired shape. As described by C1ark, this method is useful for capturing fibers deposited by gravity, which is undesirable because the laminar leaks from masked areas of the belt to unmasked areas, creating an uneven layer. Pan's use of prior art is based on Clark (CI
a r k) cuts the web into the desired shape;
Some also describe a method for separating the web using a caul plate.

An improvement of Clark's invention over the prior art is a fiber deposition head whereby unblended structures with contoured edges are pre-singulated in circular passages within a circular housing. m
entraining dirt and directing a uniform pile of entrained fibers through openings in a perforated separation wall of the housing to a moving collection wall;
and by forming a continuous web from the fibers fed over the collection or masking member of the collection wall. Clear separation of the continuous web into individual mats is achieved by the arrangement of troughs in the collecting wall, which separate adjacent collecting members and prevent leakage of fibers onto the collecting members by trapping excess fibers. To prevent. A means for separating the masked collection member from the final product is also described.

A number of absorbent articles, and methods and apparatus for making them, are disclosed in the following U.S. patents to Kolbach: No. 3,846.871, No. 3,860.
,002, No. 3,973.291 and No. 4,01
No. 6,628, No. 3.973,291 and No. 4.0
No. 16,628 is a franking end (flanki
gend) and a central portion of greater basis weight than the side portions.

These structures are obtained by providing a perforated surface with distinct zones of relatively high and low suction.

Nos. 3,846,871 and 3,973.

No. 291 describes a three-dimensional spaced apart fiber receiving pad-forming assembly separated by air impermeable regions. Each of the composites has the desired final product shape and is provided with a perforated lower surface and moving air-impermeable sidewalls.The individualized fibers are fed into a compartment.

This compartment communicates with the ila fiber entrainment suction means. Selective masking of the suction means can be used to influence the density and weight of the material collected within each area of the compartment, and allows different air-suspending fibers to be placed in different non-overlapping compartments. of time to achieve zones of different weight and density within each of the compartments.

U.S. Patent No. 3,939.2 to Savich
No. 40 and No. 4,005,957 disclose methods and apparatus for forming pads of fibers. Sabichi (S
avich) has a three-dimensional perforated cavity around it. A continuously driven condenser roller is taught. Each of the air conditioners is supplied with a vacuum and in communication with a pad forming area supplied with air suspended fibers are deposited within the cavity and form layers, each of the layers then being It is removed from the cavity as a pad by another vacuum in conjunction with a downstream moving conveyor. Because the opening into the cavity has a smaller surface area than the surface area within the cavity, the resulting pad is consolidated within the cavity and is more compact than a composite web structure that is contoured and has sharply defined edges. Reference weight is increasing.

The prior art consists of layers and/or vertical zones of blends of long fibers, short fibers and/or particulate materials. Methods and devices capable of providing these structures that do not provide well-defined composite nonwoven structures with predetermined shapes are unknown, and in particular, prior art methods have been unable to provide this in a single continuous operation. does not teach the means of manufacturing such a structure.

The present invention produces blends of long and short fibers with or without particulate materials at high speeds resulting in a wide variety of composite nonwoven web structures of different widths, thicknesses, distinct shapes and compositions. Concerning what to do.

In one exemplary embodiment of the present invention, two independent fiber sources propelled by feed rolls are individualized by parallel, oppositely rotating licker-ins. ff1 to the mixing zone.
ll12. The man is mixed irregularly and uniformly or held in separate streams, and the condensers in the condensing zone are located below the parallel lickers and generally defined by the space between them. deposited on the screen.

The screen supports and moves a series of product molds or pockets with open tops and bottoms in a direction generally parallel to the axis of the licker-in, so that the licker-in deposits material into the pockets. The fibers fill the pocket and are thus formed into the shape defined by the shape of the pocket.

A duct plate is used to further define a passageway between the licker-in and the top surface of the pocket, and suction slots below the screen are preferably used to promote fiber deposition in the pocket and on the screen. Since the screen moves parallel to the licker-in axis, l
There is a transverse univer according to the present invention where there is a high velocity lateral formation of a series of shaped structures.
se webber) provides a relatively long web-forming zone, which depends on the actual length of the licker-in, the wide glacial angle of the duct plate, and the actual length of the duct plate from the mixing zone to the condensing zone. limited only by.

Composite and layered structures can be created by varying the material introduced into the licker-in along the length of each of the licker-ins. Webs with different cross-sectional shapes can be generated by changing the shape of the slots in the duct plate or screen, by introducing baffles, or by programming the drive of the feed rolls.

Short fibers and long fibers, e.g., respectively.

Separate sources of pulp and rayon are singulated and formed into a structure by separate licker-ins. Each of the fiber sources is guided by a feed roll and a nose bar to engage its licker-ins, and each licker-in rotates at a high speed appropriate to the fibers acting on it. The two licker-ins are placed parallel to each other and rotated towards each other, ie in opposite directions. The nose bar and licker-in are positioned to provide an optimal opening relationship for the fibers. Each licker-in acts on its feed of fibers and rapidly individualizes the fibers by vigorous contact between the miscellaneous feed and the rapidly rotating teeth of the licker-in.

By directing the flow of the individual fibers downward and towards each other, the fibers meet in the mixing zone; however, the webbing of the fibers entering the mixing zone is sparse and does not generate a substantial number of collisions. Make the two streams cross each other.

After all, the fibers to the left side of the condensing screen that carry the mold from the licker-in tend to reach primarily the right side of the screen, and vice versa. Condensing screen with mold licker-in length,
For example, when moving along 102 cm (40 inches),
! a Male deposition occurs.

Different mixing patterns of fibers can be achieved by inserting baffles into the mixing zone between the licker-ins. This deflector crosses a portion of each fiber stream and redirects it in the opposite direction, so long m
m and short fibers extend across the lateral radius of the web. This results in a proportionally uniform mixing of long and short fibers across the web. If the deflector completely traverses the weep, the material from the left licker-in will be diverted back to the left, and vice versa, so the distribution will be wood-wise opposite to that without the deflector. A product with this occurs.

While the pockets determine the shape of the structure formed, the thickness and density of the web depends primarily on the LA fibers selected, the ratio at which they are mixed, the speed of the feed rolls, and the speed at which the condensing screen moves the pockets. determined by

Pulp and textile fibers of different compositions can be fed simultaneously in parallel relationship to their respective licker-ins. In one embodiment, the pulp and textile fibers are fed into the apparatus from the rear (i.e., towards the entrance of the boquet mold into the frame) to form the bottom of the structure, while the other of the material (i.e.
outlet of the pocket) to form the upper layer. These vertical zones can be varied by applying different materials along the length of the licker-in in conjunction with one or more baffles.

In this way, different zones can be defined and resulting structures with horizontal or vertical layers or zones can be formed. Each zone of the web is integrally associated with one or more zones of its adjacent web by intertwining fibers across the interface.

The mold or pocket according to the invention conforms to the shape of the desired product and is oriented through the condensing zone of the condensing screen. The condensing zone is also provided with a suction means and a cover assembly capable of preventing unwanted weep leakage or loss of suction pressure.

Alternatively, the conveyor screen may be eliminated and the mold may incorporate an integral condensing screen. In such cases, the mold is transferred to a condensing zone located below the mixing zone of the Univer.
It can be fed systematically by means of belts, chains, etc. In each case, within the condensing zone, the molds were provided by one another and, for example, by ducts. As it mates with the sealing assembly, all of the mla is condensed onto the mold screen or conveyor screen, thereby forming individual shaped pads of fibrous material.

However, the pocket-forming condensing means is interchangeable with a continuous web condensing screen consisting of a perforated conveyor belt.

In all cases, the direction of pressing of the condensing screen is parallel to the axis of the licker-in. Although pocket-forming condensing means can be used with conventional dual-licker-in uniforms, such methods and arrangements are limited to two materials and therefore produce horizontal layers and vertical zones within the mold. The production capacity in conventional sea urchins can only be increased by increasing the length of the licker-in and forming the pockets in parallel, which results in a very complex device. By using a lateral unibar, capacity can be increased by increasing the length of the licker-in and the linear speed of the pocket or mold.

The above advantages and numerous other features of the present invention will be readily understood and appreciated in light of the following detailed description and accompanying drawings.

1 and 2 show a perspective view and a cross-sectional view of the main components of the device with the finished IJ, the undeveloped 11 has a horizontal and vertical cross-sectional composition with variable short and long fibers. Adapted for bonding to non-woven fabrics. Primarily, this equipment consists of two licker-ins 10 that operate in parallel.
．． 20, one licker-in 10 can individualize short TA fibers, and the other licker-in 20
individualizes long fibers. Fiber individualization, rather than web formation, is generally described by Farring E.
No. 3,740,797 to On), the details of which are incorporated herein by reference.

Referring first to the short M & F fibers shown on the left side of the drawing, wood pulp in the form 78 of the pulp board 30 is placed on the plate 11 (Fig. 2) and on the wire wound supply roll 12.
Direct between. The play) 11 has a nose bar 12 in its lower part, which provides an anvil for the pulp board 30 during the singulation of short fibers. u & fiber supply roll 1
2 and operatively adjacent the nose bar 13 by a rotating licker-in lO.

The nose bar 13 is connected to the plate 11. It facilitates orienting the pulp board 30 along the path formed by the supply roll 12, the licker in IO, the nose bar 13 r-1 body, and the sloped surface 15 adjacent to the licker in 10. These elements form the fiberization station, where the fiber material is processed.

That is, pulpboard 30 is converted into individual mta. The sloping surface 15 is located at a short distance from the licker-in 10 and the pulp board 30 is exposed to the licker-in 10 acting on the pulp board 30 when it comes into contact with m16 by the nose bar 13. m1
6 into individualized fibers.

Typical short fibers include various types of wood, cotton linters, asbestos fibers, glass fibers, etc. Wood pulp fibers are most frequently used due to their low cost and easy availability. Pulp fibers are commercially available in the form of pulp boards of varying sizes and thicknesses.

For short fibers, the nose bar 13 has a relatively flat sidewall 14 (FIG. 2), the supply roll 12 has, e.g.
By the bracket 19 as shown in FIG.
It is mounted in such a way that it can be adjusted with respect to the side walls 14 and the nose bar. Bracket 19 and supply roll 12 are resiliently biased to direct pulp board 30 to nose bar 13 by known means and propel the pulp board through teeth 16 of licker-in lO.
interlock. This design allows the use of pulp boards of varying thickness.

The feed roll 12 is supported on a shaft and rotated by conventional motor means (not shown) at a speed determined by the speed at which the pulp board 30 is to be fed into the licker-in 10. This speed determines the amount of bulb fibers deposited to form a web within a unit time.

The pulp board 30 is fed by the feed roll 12 in the direction indicated by arrow X in FIG.

The licker-in IO is similarly supported by a shaft and rotated at a predetermined speed by a conventional motor (not shown). Licker-in 10 until individual fibers are kneaded from pulp board 1@16
By interlocking with.

Pulpboard can be rapidly and reliably frayed and combed. Speeds around 6000 rpm were found to be suitable for this purpose. Teeth 16 are selected to have an optimal profile for the selected short fiber material represented by pulpboard 30.

The long fibers are individualized in much the same way as the short fibers, as shown on the right side of FIGS. 1 and 2. Typical long fibers include synthetic fibers such as cellulose acetate, vinyl chloride-vinyl acetate and viscose stable rayon tvtn, and natural fibers such as cotton, wool, etc. Long fibers, such as rayon, are commercially available in varying fiber lengths.

A long fiber source is when using rayon as a fiber source.
It usually comes in the form of a curled bat. The bat 32 includes the plate 21 (FIG. 2) and the nose bar 2.
a second wire-wound supply roll 2 acting in cooperation with 3;
2 into the licker-in 20. However, the nose bar 23 can be used with long fiber sources, and the nose bar 13 used with valves
different from. Because rayon and other long fiber sources lack the physical integrity of pulpboard, the batts 32 must be more aggressively constrained and oriented to engage the licker-in 20, as shown in FIG. In addition, the nose bar 23 is curved and conforms to the adjacent surface of the second supply roll 22 . In this way, the fibers in the rayon mud are fed into the teeth 26 of the licker-in 20.
It is maintained in position with respect to the second supply roll 22 .

The licker-in 20 is rotated at a speed such that the teeth 26 can comb the long fibers from the batt 32 without degrading or damaging the long fibers.

Speeds around 300 Orpm were found to be suitable for this purpose. The teeth 26 of the licker-in 20 are generally shorter than the teeth 16 of the licker-in 10 and have a smaller pitch than the solution.

Support structures or frames and drive means are, of course, provided for the various elements of the undeveloped IJJ, as generally indicated in the figures. Additionally, nose bars, supply rolls, etc. should be sized 3 times with respect to each other to achieve optimal results.
1 can be done.

The long and short fibers can be individualized simultaneously or sequentially and distributed across each licker-in location, as shown in Figure 1, ■ more than 6 types of fibers! 11 (ie pulp boards A, B with short wLm and C, D with long ta!11) can be present. The licker-ins 10.20 rotate toward each other, as indicated by arrows Y in FIGS. 1 and 2. The mm sources, their distribution, and the speed and relative proportions at which they are singulated are selected to produce a web with the desired structure and fiber combination.

Doffing of the individualized fibers from the licker-in and transport of the fibers through the mixing zone 40 to the condensing zone 44 is facilitated by air flow. As shown in FIG.
can be drawn by the suction created by. This vacuum is created by a fan driven by a motor (not shown) and drawn through a duct 50 (FIG. 1), resulting in an air
20 and nose bar 3.23 to the mixing zone 40. It is drawn through the pocket mold 402 and condensing screen 42. The fibers are entrained in their respective air streams and propelled into the licker-in 10.
20 to each other in the mixing zone and go through the mixing zone to the condensing zone where #afIn
A pad 45 is formed in the pocket 402.

According to the invention, condensing zone 44 is below and adjacent mixing zone 40 and directly above condensing screen 42.

and is defined within the space between the duct plates 39. The length of the condensing zone 44 is licker in 1O12
Corresponds to a length of 0. The condensing zone 44 is thus in the form of a long, narrow trough capable of receiving individualized fibers from above according to the undeveloped IJJ.

Vacuum chamber 49 has an endless conveyor or cursing 42 packaging it. The suction from the chamber 49 is applied to the condensing zone 44 through a mesh screen 42, for which purpose suitable openings 47 are provided in the upper part of the chamber 49 (FIG. 2), or alternatively pockets are provided in the individual bottom sections. screen 450, in which case the mesh screen 42 can be replaced with a simple means of transporting the pocket through the condensing zone.
(FIGS. 4 and 5) through the bottom screen 450 and from the second part of the pocket to the condensing zone.

The opening in the vacuum chamber generally corresponds to the cross-section of the space defined by the width of the pocket. A conveyor roller run 42 is positioned below and in communication with the condensing zone 44 in a direction parallel to the axis of rotation of the parallel rift car in 10120.

The condensing screen 42 is conveyor roller 5
2.54, thus allowing it to pass near the high vacuum chamber. One or both of the rollers 52,54 are driven to move the screen 42 at a controlled speed.

Screen 42 communicates with other conveyors, thereby transporting web 45 for further processing, if necessary.
can be supplied. Such processing, for example,
U.S. Patent No. 3.77 to Lovgren
2.739, including bonding; shaping procedures; and final finishing of the web product.

The duct plate 39 is attached to a screen 42 to seal the lower end of the duct 39 and maximize the efficiency of the suction fan.
It extends downward toward the screen 42 and stops directly above the screen 42. Duct plate 39 may further include a floating seal 53 (FIG. 2) biased into contact with screen 42 by a spring located in a groove in plate 39 below. . Licker-in cover 5
5 also extends around the outer periphery of the licker-in and engages plate 39 to provide an additional seal for the vacuum forming the air flow.

Rolling seals 57, 56, respectively, where the screens 42 enter and exit the condensing zone 44.
is provided on the duct plate 59 (Fig. 3),
The sealing rolls 56,57 are located between the parallel edges of the duct plate 39 and rotate freely over the screen and web to accommodate movement of the screen and web. When the web 45 leaves the condensing zone 44 supported by the screen 42, it passes under the sealing roll 56. The duct plate 39 is
In addition to maintaining the vacuum, the fibers are guided to the condensing zone 44 and the duct plate 59. Together with the floating seal 53 and the sealing rolls 56,57 improve the efficiency of the suction air flow.

When the molds 402 are within the condensing zone 44, they are in sealable contact with each other in the machine direction with sealingly adjacent molds and in side contact with the sealing assembly and seal convolution;
The only available (F) passage for the air-entrained la fibers leads them into the mold 402; in this way, a series of individual webs are formed, each of which
It has a clear outline defined by its shape. Exemplary products made by this method and apparatus are shown in FIGS. 8-10.

The molds 402 can be permanently secured to a conveyor screen 42, which is in the form of a continuous belt or chain, so that they are continuously circulated through the condensing zone and the final product is transferred from the mold 402 to the zone 44. collection point.

Alternatively, the mold 402 is a cartridge mold assembly 43
0 (FIGS. 1 and 2), thus a series of unconnected molds 402 pass through condensing zone 44.

As shown, the cartridge assembly 430 is a vertical rectangular structure with an open top to receive the stacks 5402. With the exception of wall 432 adjacent condensing zone 44 , the lower ends of the side walls are in sealing contact with condensing screen 42 . At the base of wall 432 there is an opening 434 that is slightly larger than one cross section of mold 402.

As the condensing screen 42 moves, it comes into frictional contact with the bottom of the stack of molds in the assembly 430 and propels it forward (to the left in FIG. 3) into the condensing zone below the licker in 1O 120. do. A seal 57 is provided at the entrance of the mold to the condensing zone to maintain the vacuum. Using this seal, cartridge assembly 430 need not be immediately adjacent to the condenser; instead, it can be anywhere δ along the -L flow conveyor from the condenser.

To improve the operation of feeding the pocket mold 402,
The screen and the bottom of the mold can be coated with a crystalline abrasive material. Also, small hooks can be placed at intervals along the condensing screen to engage the under-slide mold and pull it into the condenser.

Unreleased [! The device according to 1 is also used as a licker-in 1O12
It is possible to have a retractable single-piece or multi-section baffle plate disposed in a plane that passes vertically between 0 and intersects the mixing zone 40. The deflector is
Although the lower front edge can be arranged to descend to any predetermined point on or above the moving condensing screen 42, three distinct quantitative positions can be defined. When the baffle plate 60 or a portion of the baffle plate is in the up or fully retracted position, the front edge is in contact with the flow of fibers leaving the licker-in and the R
Removed from 7F contact. When the baffle plate 60, or a portion thereof, is fully lowered, its lower front edge resides at or above the screen 42 at a predetermined location within the mixing zone 40, where it fully directs the fiber flow. to be cut off. Finally, deflection plate 6
0 or a portion thereof can be positioned such that its lower front edge corresponds to a predetermined blending point in the mixing zone 40, where it partially blocks the flow of fibers. A wide variety of composite structures, hitherto unknown, can be constructed by the present invention by varying the position of the baffles 60 or portions thereof and by changing the position of the supply rolls 12, 22 adjacent to portions of these baffles. can be generated by supplying one or more materials through the process. 8-10 illustrate exemplary composite structures according to the present invention, as described in accordance with the following examples. Figures 4-6 illustrate the shape of the mold used to make the product.

Pocket mold 44 sent to condensing zone 44
can be of the type shown in FIG. The mold is generally rectangular in outline and can be made from any convenient material, ie, wood, plastic, full-length, etc. Grooves 445 with the desired final or intermediate product shape.

Completely form through the mold. However, the bottom of the mold
It can be closed with a screen mesh 450. Ultimately, the vacuum source can be directed through the mold, but the fibers entrained in the air flow created by the vacuum force are blocked by the screen 450. As the mold moves through the condensing zone, mta collects in depressions 445. These fibers form a shaped structure of intertwined fibers. In particular, the shape of "8" in Figure 4 is u.
& fiber pads, which after further processing are useful as form-conforming feminine sanitary napkins.

Other cavity shapes can be used to create other three-dimensional pad shapes. The upper mold in Figure 5 is a rectangular groove 44
9 and will have a rectangular pad, the fifth
The mold 465 at the bottom of the figure has a circular groove 451 that produces two circular disk pads. If desired, the molds can be stacked on top of each other as long as the cavities in the upper mold overlap and are larger than the cavities in the lower mold. Additionally, when stacking the molds, the screen 450 for the upper mold must be removed so that the fibers in the upper mold interlock with the fibers in the lower mold. In Figure 7, type 4
A product is shown made by stacking 60 and 465, forming a web therein, inverting the resulting pad, and injecting it from a mold.

As those skilled in the art will appreciate, these examples represent only a few of the many novel structures according to the present invention;
As is clear from these examples, due to the lateral ejection and pocketed arrangement of the forming web, a uniformly blended web can be obtained using known equipment, such as the Farrington (previously shown). 7) Can be obtained in a manner identical to the patented method and apparatus. In contrast, lateral pocket Ubers according to the present invention tend to deposit fibers into a three-dimensional web structure according to a unique zoning pattern. These patterns can be manipulated to produce new and useful composite structures.

Example 1 Two different fiber materials 30.32 of short fiber A and long mmc form 18, respectively, are fed to a supply roll 12.22, each of the different fiber sources being fed into one identical fiber material of the licker-in 10.20. -It is expansive. When the baffle plate 60 is in the up position, a composite web is formed having three transverse zones, each extending in the machine direction.

A schematic cross-sectional view of this product is shown in FIG.

The zone-like composite structure is doffed from the licker-in, passed through the mixing zone 40, and then formed into a lateral web within the condensing zone 44.
This is the result of the trajectory of &.

In conventional Univer, such nascent zones are offset by continuous withdrawal of the forming web in the standard longitudinal machine direction, i.e. in the direction in which such zones would form; Or they tend to become one. However, by laterally extracting the forming web, zones form as a result of the volumetric pattern of fibers caused by the fiber trajectories.

When the baffle plate 60 is on, it does not change the trajectory of the lean fiber/air flow as it goes through the mixing zone 40 to the condensing zone 44; the fibers in the air flow are retains a component of the motion that tends to throw away from each licker-in toward the web on the side of the opposite licker-in.

After all, the flow is so dilute that the tendency for fiber collisions is almost non-existent, so the &a fibers are mixed in the mixing zone 40
Thus, the fibers are deposited primarily towards opposite sides of the condensing zone 44, with a tendency to overtake each other within the condensing zone 44. As shown in FIG. 5, the short LA fibers A resulting from the left licker-in tend to form a narrow right zone A. The long mmc originating from the right-hand licker-in tends to form a narrow left-hand zone C containing mainly fibers C. 1 fiber A+ between zones A and C of ms
There are broad lateral zones containing blends of C. At the boundaries of the zones, the fibers intertwine so that the web is formed in one piece.

Example 2 m! of Example 2! A baffle plate 60 is placed at the blend point within the mixing zone 40 to influence the trajectory of the individualized fibers before final deposition as a web on the screen 42. The converted male passes from each licker-in through the mixing zone 40 onto the condensing zone 44 and falls within a certain range or angle of trajectory in the manner of a spray exiting the nozzle. The baffle 60, when placed at a predetermined blend point, traverses at least a portion of the angle of the trajectory, causing a portion of the fibers and entrained air flow within that portion of the angle to bounce around the baffle 60. , toward the side of the condensing zone 44 where it itself occurred.

If the blend points of the deflectors are selected to allow approximately equal volumes of m miscellaneous from each of the licker-ins to pass uninterrupted under the deflector 60 and be redirected to the deflector 60, short A uniformly blended web of fibers and long 1fiA+c is obtained. The blend point is
Of course, a wide variety of mIn deposition patterns and nonwoven web structures can be selected 11).

Example 3 In still other embodiments, the baffle plate 60.

approximately 5.1 cm (2 inches) above screen 42;
Place it in the bottom position. Licker-in 1O with parallel fibers
as supplied over one operating length of 120;
Two different wt fibers A, C of Example 2 are used. In this case, substantially all of the fiber trajectories are interrupted by the baffle, which tends to throw the fibers back towards the side of the condensing zone 44 from which they originated. The result is a web similar to the web of Example 2, but with fiber zones A and C in reverse order and with a narrower transition zone A+C, as shown in FIG.

It should be understood that regardless of the location of the deflection ramp, there will be some distribution of long and short fibers across the web due to air turbulence. Thus, the representation of the zones in FIGS. 5 and 6 indicates the predominant proportion of fibers in each of the four zones. The proportion of fibers in each of the zones also corresponds to the rate at which the fiber source 30. It can be adjusted by Fibers fed at a faster rate will produce a greater concentration of the product in the web, but will be distributed across the web in a manner determined by the position of the baffle.

Example 4 Each of the licker-ins 10.20 is one m! Although it is not necessary to supply the i source completely, all of the fibers fed to each licker-in match the type of fiber (short mIn or long fiber In) that the licker-in is compatible with. Thus, for example, if the four w& fibers [A-D are distributed equally between the two lickers, m! Each of the i sources covers half of its respective licker-in. Moreover, la
The fibers can be fed into the licker-in by feed rolls rotating at different speeds. FIG. 1 also illustrates this embodiment. Two different pulp boards 30.31 for producing short fibers A, B are fed to the licker in IO and two different batts of textile fibers 32.33 for producing long fibers MC, D are fed to the licker. Supply to Inn 20. The fiber combination A towards the inlet end of the device produces the lower layer of the web, while the miscellaneous combinations B, D towards the outlet end of the device produce the upper layer.

The multiple fiber feeds A-D of FIG. 1 are fed into the apparatus with a baffle plate located at the blending point to promote uniform mixing and deposition of the fibers. The two rear fiber sources A and C in the a-reduction direction initially feed their fibers to the mold. When this part of the mold moves towards the exit,
It passes below the transition between sources AC and BD, and all three fibers! A homogeneous mixture of i sources is laid on top of the bottom layer. As the part of the screen moves under the area of the licker-in fed with fibers B, D, these are deposited as a uniformly blended layer on top of B and D, resulting in the product whose cross section is shown in Figure 1θ. Form. Deflecting plate 60
When made in multiple compartments, these compartments can be set individually to vary the blend ratio in different layers of the product.For example, the two layers shown in the f51θ diagram are shown in Figures 8 and 9. It can be in the form shown.

Other Modifications Products in which the central layer is surrounded by other layers can be very useful as absorbents, such as diapers or sanitary napkins. In such products, the internal m! i
The blend is selected to be a highly absorbent product. For example, this layer can be made with a high proportion of pulp or superabsorbent fibers. The outer m#I are selected for their suction properties, ie, their ability to move liquids. For example, rayon fibers have excellent suction properties. In such products, moisture is directed by the suction mIn towards the user's skin and away from the clothing, and is retained by the highly absorbent mTA in the center of the product.

If the supply of bubbles or highly absorbent fibers is intermittent, patches of this material will be embedded in the forming pad.

Various other products are made in segments by starting and stopping the condensing screen and by starting and stopping or sequentially feeding the various fiber materials A, B, C1 and D to the licker-in. be able to. It can also include fibers that impart properties other than moisture handling to the product, such as thick elastic m! ! The material can be used to impart spring-like properties to a product 1, such as a napkin, that makes it feel similar to a napped material.

Although the invention has been particularly shown and described with reference to its preferred embodiments, it will be apparent to those skilled in the art that various changes in form and detail may be made without departing from the spirit and scope of the invention. Dew.

The main aspects and features of the present invention are as follows.

1. Components: A first supply means for supplying the fiber material to the JSli fiberization station at a first position! a second supply means for supplying material to a second w& masculinizing station at a second location, means for defining a mixing zone between said fiberizing stations, mounted for rotation about respective parallel axes towards each other; first and second licker-ins, portions of the outer peripheries of the first and second licker-ins are adjacent to the first and second supply means, respectively, and are adjacent to the first and second i , * Exists in other stations,
The first and second licker-ins engage the fiber material fed to the respective fiberizing station to open the material and
a conveyor means at least partially permeable to air and moving parallel to the axis of the licker-in, producing individualized fibers moving in a flow of air, in a trajectory towards each other and said mixing zone; ,
The conveyor means is located beyond the mixing zone.

A condensing zone between said conveyor means and a mixing zone, said conveyor means entering said condensing zone at its inlet end and leaving at its outlet end.

at least one mold having a predetermined shape corresponding to the desired shape of the pad product, said mold being capable of receiving fibers in the air stream from the mixing zone and introduced into the condensing zone by said conveyor means; a perforated surface in contact with the lower surface of the mold and in at least partial communication with an air permeable portion of the conveyor, and a perforated surface in contact with the lower surface of the mold and in at least partial communication with an air permeable portion of the conveyor while the mold passes through the condensing zone. vacuum means selectively communicating with said condensing zone through a permeable portion and a perforated surface;
A pad product forming apparatus comprising: said suction means drawing air-entrained fibers into said mold for condensation therein on a perforated surface.

2. The pad forming apparatus of claim 1, wherein said conveyor means comprises a continuous perforated belt forming said perforated surface, and said at least one mold is a series of molds immediately adjacent to each other.

3. The pad forming apparatus of item 1 above, wherein the perforated surface is part of the at least one mold.

4. said molds are a plurality of molds stacked vertically on top of each other in a structure, said structure being located along the conveyor at -hx from the condensing zone; A pad forming apparatus according to claim 1, wherein the lower mold is in contact with the conveyor, and the mold is thus extracted along the conveyor through an opening in the side wall of the structure and into the condensing zone through sealing means. Young.

5. The pad-shaped J& device of claim 1, further comprising means for separating the mold from the fibers condensed therein at a separation point downstream of the condensing zone.

6. Step: providing a first source of W&F material to engage the first licker-in; providing a second source of W&m material to engage the second licker-in; the second licker-in being connected to the 197th licker-in; and rotating the first and second licker-ins about their axes toward each other, thus opening the fibrous material and forming the individualized mta. doffing fibers from said first and second licker-ins in the form of two fiber streams directed toward each other and into a mixing zone; and directing said fiber streams from said mixing zone to condensation. condensing the fibers into at least one individually shaped pad in the mold while the mold is passed through the condensing zone in a direction parallel to the axis of the licker-in; , and preparing a mold having said perforated surface with its surface remote from the flow of fibers in contact to accumulate fibers within said mold.

A method of forming a pad of fibers containing.

7. The method of item 6 above, further comprising the step of removing the web product from the mold.

8. The transportation and condensing steps are as follows.

7. The method of claim 6, further comprising entraining the W&M in a vacuum-induced air flow directed through the perforated surface of the mold.

[Brief explanation of the drawing]

FIG. 1 is a schematic representation of a transverse unibar equipped with a pocket mold according to the invention, showing its main components. FIG. 2 is a more detailed sectional view of a device according to the invention. 3 is a side view of the apparatus of FIG. 2; FIG. FIGS. 4 and 5 are exemplary perspective views of single and double bracket types. 6 and 7 are perspective views of a nonwoven web pad made in accordance with the present invention. FIGS. 8-10 are cross-sectional views of exemplary nonwoven fiber pads made with apparatus according to the present invention. lO licker-in 11 plate 12 opening wound supply roll 13 nose bar 14 side wall 15 slope 16 teeth 19 bracket 20 licker-in 21 plate 22 second wire wound supply roll 23 nose bar 26 teeth 30 valve board 32 cursed butt 35 Duct 37 Duct 39 Duct plate 39° Wall 40 Mixing zone 42 Condensing screen 44 Condensing zone 45 Web 46 Suction plate 47 Suitable opening 49 High vacuum chamber 50 Duct 52 Conveyor roller 53 Floating seal 54 Conveyor roller 55 Licker-in cover 56 Rolling seal 57 Rolling seal 59 Duct plate 60 Rotatable tracing plate 62 Shield 65 Wide layer 66 Central layer 67 Upper layer patent applicant Johnson & Johnson FIG
4 FIG7 △-D C

Claims (1)

[Claims] 1. Components: a first supply means for supplying the fiber material to the first fiberization station at a first position; a second supply means for supplying the fiber material to the second fiberization station at a second position , means for defining a mixing zone between said fiberizing stations; first and second licker-ins mounted for rotation about respective parallel axes toward each other; said first and second licker-ins; A portion of the outer periphery is present in a first and second fiberizing station, respectively, adjacent to said first and second supply means, and said first and second licker-ins are present in respective fiberizing stations. air interlocking with the fibrous material fed to the station to open said material and produce individualized fibers moving in trajectories towards each other and towards said mixing zone in first and second streams, respectively; conveyor means at least partially permeable to and moving parallel to the axis of the licker-in;
a condensing zone between the conveyor means and the mixing zone, the conveyor means entering the condensing zone at its inlet end and leaving the condensing zone at its outlet end; pad products; at least one mold having a predetermined shape corresponding to the desired shape of the mold, said mold being capable of receiving fibers in an air stream from a mixing zone and being introduced by said conveyor means into a condensing zone; a perforated surface in contact with a lower surface of the mold and at least partially in communication with an air permeable portion of the conveyor during passage of the mold through the condensing zone; vacuum means selectively communicating with said condensing zone through a portion and a perforated surface;
A device for forming a pad product, characterized in that said suction means draws air-entrained fibers into said mold for condensation therein on a perforated surface. 2. Steps: providing a first source of fibrous material to mate with the first licker-in, providing a second source of fibrous material to mate with the second licker-in, the second licker-in displacing the first licker-in; arranged with their axes parallel to the axis, and rotating said first and second licker-ins toward each other about their axes, thus opening the fibrous material and forming individualized fibers. forming, doffing fibers from the first and second licker-ins in the form of two fiber streams directed toward each other and into a mixing zone; and condensing the fiber streams from the mixing zone. condensing the fibers into at least one individually shaped pad within the mold while the mold is transported through the condensing zone in a direction parallel to the axis of the licker-in; and preparing a mold having said perforated surface with its surface remote from the flow of fibers in contact to accumulate fibers within said mold.