JPS5833090B2 - Amimekouzobutsuno Seizouhouhou - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a new and improved method of manufacturing a network structure.

In particular, by creating ribs on both sides of a sheet of thermoplastic polymer,
The present invention relates to a network structure by stretching the sheet and splitting or tearing the web between the ribs, and a method for manufacturing the same.

In the manufacture of mesh (e.g., from U.S. Pat. No. 3,488,415 to A.D. Patchel et al.), one side of a sheet of plastic material is made with continuous diagonal grooves in one direction and the other side of the sheet is grooved in the opposite direction. It is known to create diagonal grooves that are continuous in one direction, and when the sheet is stretched biaxially, the thin part of the sheet tears at the intersection of the grooves, creating holes, thereby opening the material into a mesh. There is.

The mesh shown therein is constructed in such a way that thicker areas are created at the points where the ridges intersect, and when the embossed sheet is stretched biaxially, i.e. stretched, the ridges intersect. Since the thicker section is only oriented to a limited extent, it acts as a discontinuous reinforcement section.

The tensile strength and tear properties of such networks are relatively low since the presence of unoriented thick sections weakens the tensile strength and tear resistance of the resulting network.

The appearance of such a mesh is also not uniform.

In yarn manufacturing techniques (e.g. from Charles W. Kim's U.S. Pat. No. 3,500,627), a ribbon of plastic material is made with ribs forming a large number of parallel filaments on one side and an acute angle with the ribs on the other side. Yarns can be manufactured by creating ribs that form a large number of intersecting fibrils.

That is, the ribbon is then uniaxially oriented and mechanically fibrillated by a toothed fibrillating device, breaking the fibril-forming ribs to produce a yarn with fibrils extending laterally therefrom.

According to the invention, the network creates a number of parallel continuous major ribs on one side of the sheet of thermoplastic polymeric material and a number of parallel continuous or continuous ribs on the other side of the sheet at an angle to the major ribs. Create discontinuous connecting ribs, stretch the sheet, orient and separate the main ribs to form main filaments, and separate the connecting ribs to form filaments that connect between the main filaments, and if the connecting ribs are discontinuous, If so,
It is manufactured by making the webs between the main ribs facing and not extending across the portion of the sheet occupied by the main ribs on the opposite side.

Preferably, the main ribs have a cross-sectional area at least 1.5 times the cross-sectional area of the connecting ribs and a height at least three times the thickness of the web between the main ribs.

After making the main ribs and connecting ribs on the plastic sheet,
1 sheet in order to orient the main ribs continuously and uniformly.
Stretch in one direction.

It is also possible to stretch in two different directions, preferably in the vertical direction, to orient both the main ribs and the connecting ribs.

For example, when the main ribs are made in the machine direction and the connecting ribs are made in the transverse direction, the network is made in only one stretch, ie in this example in the machine direction.

Alternatively, the open network structure can be produced by stretching in the machine direction and the cross direction, either separately or simultaneously.

To separately draw seeds with major ribs in the machine direction, it is common to first draw them in the cross-machine direction.

When stretched, the thinnest part of the sheet, i.e. the part where the web between the main ribs intersects the web between the connecting ribs, is oriented;
They usually open up naturally, leaving uniformly shaped holes or spaces in the sheet.

Under certain conditions and certain degrees of stretching, web perforation may not occur during the initial stretching, but only during the subsequent vertical stretching.

In any case, there is no need for mechanical fibrillation as web perforation occurs naturally.

This natural fibrillation or aperture of the web transforms or forms the connecting ribs into connecting filaments and the main ribs into main filaments.

The term rib is used to refer to main ribs or connecting ribs while they are connected by a web, and the term filament is used to refer to rib sections when they are separated by splitting or perforation of the web. used for.

A highly desirable strength property is to have a main filament in one direction and a connecting filament in another direction intersecting it, with the main filament being more sharp than the connecting filament, so that the overlap between the main and connecting filaments is It was found that the orientation at these points was obtained in a network structure in which the main filaments were concentrated.

The interlocking filaments are preferably small and oriented to provide sufficient structural integrity to the network, flattening it and preventing bending, thereby keeping the main filaments parallel and evenly spaced. Those that tend to retain are preferred.

The single-layer plastic network thus produced is dimensionally stable and self-retaining; easy to handle and has high tensile strength in the main filament direction and high tear resistance in other directions. .

Such meshes are particularly useful for reinforcing paper products, nonwovens based on stable fibers, and for covering absorbent batts.

The network structure made in this way can be used to produce a multilayer fabric by joining two or more layers of the network structure with the same or different arrangement so that the main filaments intersect in various directions. It is also possible to provide multilayer products with certain desired strength properties.

For example, the main filaments of one layer can intersect the main filaments of another layer at 90° to create a right-angled structure that mimics the appearance and physical properties of a woven fabric and provides greater strength and tear resistance in two directions. can.

A diagonal construction in which the main filaments of the two layers intersect each other, preferably at about 90°, and the main filaments of both layers are at an angle to the machine direction of the fabric, similar to the machine direction of knitted fabrics. It has tensile and recovery properties.

Cloth fabrics made of three or more layers of mesh, each with main filaments in different directions, have excellent dimensional stability in all directions, great strength and tear resistance, and high tear resistant strength.

The triaxial structure, employing a diagonal structure with one mesh between two layers with the main filaments formed in the machine direction, has high tear resistant strength with minimal weight.

An isometric structure with at least four layers of primary filaments located at an angle of about 45° to each other is
At the same unit weight, it has dimensional stability and strength in all directions not previously available in woven, knitted or other non-woven structures.

The network structure according to the invention with main filaments in the machine direction can be made into monofilaments, tapes or yarns by separating into strips.

The strip can subsequently be fibrillated, twisted, or bulked to entangle the primary filament.

If desired, the strip can be wrinkled or twisted.

FIG. 1 is an illustrative perspective view of an apparatus for embossing ribs on both sides of a sheet of plastic material proceeding in accordance with the principles of the present invention.

FIG. 2 is an enlarged view of a portion of the embossed sheet shown in FIG.

FIG. 3 is an enlarged perspective view of a portion of an embossed sheet having main ribs that are relatively spaced apart and have relatively deep grooves therebetween and connecting ribs that are closely spaced and have relatively shallow grooves therebetween; .

FIG. 4 is an enlarged perspective view of a portion of another embossed sheet having main ribs that are relatively closely spaced and have shallow grooves therebetween and connecting ribs that are relatively widely spaced and have relatively deep grooves therebetween; It is a diagram.

FIG. 5 is an enlarged perspective view of a portion of the upper portion of the network structure obtained by bidirectionally stretching and orienting the embossed sheet shown in FIG. 2;

6 is an enlarged perspective view of the bottom (back surface) of the mesh structure shown in FIG. 5. FIG.

FIG. 7 shows an apparatus similar to that shown in FIG. 1 for embossing ribs on both sides of a advancing sheet, but used in a modified manner to form discontinuous interlocking ribs running in the machine direction. FIG.

FIG. 8 is an enlarged perspective view illustrating the discontinuity of the connecting ribs on the side of the connecting ribs of the seat shown in FIG. 7;

9 is an enlarged perspective view of a portion of the embossed sheet shown in FIG. 8; FIG.

FIG. 10 is an illustrative perspective view of another apparatus for embossing continuous main ribs running in the machine direction on one side of a sheet and discontinuous connecting ribs on the other side of the sheet.

FIG. 11 shows one side of a network structure made by stretching the sheets shown in FIGS. 7, 8 and 9 in two directions.

FIG. 12 shows another side of the network structure of FIG. 11.

FIG. 13 is a plan view illustrating a portion of a network having main filaments in the machine direction and connecting filaments in the cross-machine direction.

FIG. 14 is a plan view of a portion of a network structure having main filaments in the cross-machine direction and connecting filaments in the machine direction.

FIG. 15 is a plan view illustrating a portion of a network having main filaments formed at an angle to the machine direction and connecting filaments formed in the machine direction.

FIG. 16 is a plan view illustrating a portion of a network having main filaments formed at an angle to the machine direction and connecting filaments formed perpendicular to the main filaments.

FIG. 17 is a perspective view illustrating an apparatus for manufacturing multilayer textile fabric structures in accordance with the principles of the subject invention.

FIG. 18 is a perspective view illustrating another apparatus for manufacturing multilayer fabric structures in accordance with the principles of the present invention.

Figure 19 consists of three layers, one layer with the main filament formed perpendicular to the machine, and two other layers with the main filament formed at equal and opposite angles to the main filament. Cloth foil in 3 axial directions 1
FIG. 3 is a plan view showing the portion.

Figure 20 shows a two-layer diagonal structure made by joining two networks with main filaments oriented at equal angles to the machine direction and preferably, but not necessarily, perpendicular to each other. FIG. 2 is a plan view illustrating a portion of the cloth foil.

FIG. 21 shows one of four layers of isotropic fabric foil made by joining together the two layers shown in FIG. 15 and the two layers shown in FIG. 18 in the desired order. FIG. 3 is a plan view showing the portion.

FIG. 22 is a perspective view illustrating an apparatus for reinforcing paper, foil, nonwoven fabric, or film by using a mesh core made in accordance with the principles of the present invention.

FIG. 23 shows an apparatus for forming a network into yarn.

FIG. 24 is an enlarged view of the leash rod of FIG. 23 used to separate or tear the mesh into strips.

FIG. 25 is an enlarged plan view of a portion of the strip before fibrillation.

FIG. 26 is an enlarged plan view of the sl-IJ tube of FIG. 25 after fibrillation illustrating the cut connecting filaments.

FIG. 27 is an illustration of a section of air jet interlaced multifilament yarn with protruding side threads.

FIG. 28 is an illustration of a section of bulked and entangled multifilament yarn.

Referring now to FIGS. 1 and 2, a number of lateral main ribs 2 are disposed on the advancing sheet of thermoplastic polymeric material 24.
An embossing roll 21 is shown with a number of grooves 22o) to form a 3.

The ribs 23 are connected by webs 25 of reduced thickness.

Another embossing roll 26 with a number of annular or spiral grooves 27 is placed opposite the roll 21 to form a number of vertical connecting ribs on the other side of the sheet 24, and the connection The ribs are webs of reduced thickness 30
are connected.

Embossing rolls 21 and 26 rotate in the direction indicated by the arrow.

There are various ways to accomplish the double embossing described herein.

One method is to feed a sheet of molten plastic, such as 24, from an extrusion die into two opposing rotating embossing machines, such as 21 and 26, which are propelled toward each other by equipment not shown here. It is inserted directly into the mesh of the rolls.

The desired spacing between the rolls and, ultimately, the thickness of the embossed sheet is easily controlled by adjusting the thickness of the extruded sheet entering the embossing rolls and the pressure between the two embossing rolls.

The temperature of the roll is typically controlled internally;
It serves to rapidly cool and solidify the molten plastic, forming the desired embossed shape on each side.

Alternatively, a precast flat sheet or film may be reheated to its softening point and then
It can be passed between a pair of embossing rolls such as.

Another method uses a powdered polymer that is introduced into the mesh between two heated rolls (not shown) that melt or soften the polymer and form it into a sheet. then 21 and 26
It is passed between two embossing rolls such as .

Yet another method involves passing a precast flat sheet or film between two embossing rolls so that the embossed features are pressed onto the sheet without the need to melt or soften the sheet. The key is to press with a sufficiently high pressure.

Alternatively, instead of using embossing rolls to form the desired arrangement of ribs on both sides of the sheet, a
Such an arrangement can also be created by using a pair of relatively movable concentric dies.

The most advantageous range of the ratio of the cross-sectional area of the main ribs to the cross-sectional area of the connecting ribs is between 1.5:1 and 100:1, and the ratio of the height of the main ribs to the thickness of the web between the main ribs is at least I have found that 3:1 or higher is better.

In this relationship, the sheet on which the ribs are formed by the subsequent drawing and orientation process has main filaments that are uniformly and continuously oriented at regular intervals along the length, and has a mesh that is completely uniform in cross section. Can build structures.

If the cross-sectional area ratio of continuous connecting ribs is less than 1.5, uniform and continuous orientation of the main filaments cannot be obtained except with special polymers or special embossing conditions or methods as described below.

It creates a thick section where the main filament and the connecting filaments intersect, and that section does not become oriented when stretched.
This is because there is a tendency for the particles to be oriented only slightly.

As shown in FIG. 2, the cross-sectional area A1 of the main rib and the cross-sectional area A2 of the connecting rib both include the web portion that contacts the base of each rib.

In FIG. 2, the height T1 of the main ribs and the thickness T2 of the web connecting the main ribs are also confirmed.

The cross-sectional shape of the formed ribs can vary.

It may be semicircular, rectangular, triangular, truncated or any other desired shape.

Furthermore, the shapes of the main rib and the connecting rib may be the same or different.

Similarly, the shape and size of the grooves separating the main or connecting ribs are not essential.

The grooves can be narrow so that the ribs are close together, or wide so that the ribs are widely spaced apart.

Furthermore, the connecting ribs may be spaced further apart than the main ribs, or vice versa.

The size of the mesh structure can be controlled to some extent by adjusting the spacing between the main ribs and the connecting ribs.

Referring to FIG. 3, an embossment having a number of main ribs 37 formed on one side of the sheet and a number of connecting ribs 38 formed on the other side of the sheet in a direction perpendicular to the direction of the main ribs 37. A section of the sheet is shown designated as 36 in its entirety.

The main ribs 37 are more spaced apart than the connecting ribs, with a relatively wide web 39 of reduced thickness between them.

However, although there is substantially no web between the connecting ribs 38, there are areas or lines of reduced thickness at 40 between adjacent connecting ribs.

Main rib 3 measured from web 39 to the top of main rib 37
Note that the height 41 of 7 is much greater than the height of the connecting rib 38 measured from the bottom of 40 to the top of the connecting rib 38.

On the other hand, referring to FIG. 4, there are a number of closely spaced main ribs 44 formed in one direction on one side of the sheet and a number of spaced apart main ribs 44 formed in another direction on the other side of the sheet. An embossed sheet having connecting ribs 46 is shown generally designated 43.

The webs 47, which are lines or sections of reduced thickness between the main ribs 44, are now very small, while the webs 48 between the connecting ribs 46 are relatively thick.

It is thus understood that the present invention is relatively independent of rib-to-rib spacing and rib height.

Moreover, the direction of the main ribs is not an essential condition.

The main ribs can be formed in the machine direction of the sheet, or perpendicular to the machine direction, i.e. at 90° thereto, or at any angle in between.

For main ribs formed in the machine direction or in the transverse direction, the main ribs are oriented along the longitudinal axis using a conventional linear speed differential stretch roll device.
erential 5peed drawroll
devce) or a normal tenter.

Similarly, if the embossed ribs are oblique to the machine direction, the rib orientation and mesh formation can be done using the same type of equipment.

Orientation where the main ribs are formed at an angle in the machine direction along their longitudinal axis, it may be advantageous to use linear draw unit equipment with long draw intervals, so that when stretched in the machine direction The sheet is tapered and the orientation of the main ribs occurs primarily along the longitudinal axis.

When drawing in such a manner, it is usually desirable to orient the sheet in a direction perpendicular to the machine by passing the sheet through a tenter prior to linear drawing.

The orientation of the connecting ribs on the opposite side of the sheet must be at an angle to the main ribs, which is often preferred at 900, but may be at other angles.

The angle between the main rib and the connecting rib is about 15° to 90°
Any angle in between can be used.

When an embossed sheet having a first type of continuous major ribs on one side and a second type of continuous connecting ribs on the other side is stretched, the thinner portions or webs 25 and 30 of the sheet intersect. The parts split naturally, creating holes.

After the second stretching, a network structure as shown in FIGS. 5 and 6 or similar thereto is obtained.

The main ribs 23 of the embossed sheet shown in FIGS. 1 and 2 are separated into connecting filaments 54 that connect continuous and uniformly oriented main filaments 53 and keep them uniformly spaced apart. Ta.

FIG. 6 shows the back side of the mesh shown in FIG. 5, where it can be seen that the connecting filaments 54 continue uninterruptedly across the main filaments 53.

Alternatively, the interlocking filaments 54 may be formed on the main filaments 5 by a controlled embossing process that creates a "pump" effect or by using a roll to emboss discontinuous interlocking ribs.
It is possible to prevent it from being formed where it intersects above 3.

As shown in FIG. 7, the controlled embossing process can be carried out with fluted embossing rolls 55 and 56 similar to rolls 21 and 26, respectively, of FIG. 1.

The distribution of the polymer between the main rib rolls 55 and the connecting rib rolls 56 depends on the melting temperature, the temperature of the embossing rolls, the pressure between the rolls, the contact time of the embossed sheet with one roll, and the engagement between the embossing rolls. This can be changed by adjusting the thickness of the sheet when it enters the chamber.

Some changes in controlling the polymer distribution can also be made by selecting which roll contacts the molten sheet first.

Shrinkage of the polymer as it cools also contributes to the unique results of this method.

In patterns embossed with interlocking ribs, the development of discontinuities is due to the use of thin polymer sheets, the relatively low temperature of the melted polymer before contacting the embossing rolls, and the development of discontinuities before the sheet enters the interlock between the rolls. contacting the sheet with one of the rolls over a short distance, preferably with the larger groove; and contacting the embossed sheet with one of the rolls over a distance after the embossed sheet exits the mesh between the rolls, preferably with the one having the larger groove. It is strengthened by keeping it in contact with the one with the larger groove pattern.

The degree of penetration of the polymer into the finely patterned grooves of the rolls and the shrinkage of the polymer as it cools after being embossed in the interlock between the rolls are of course factors that contribute to the unique results of this process.

Particularly if the sheet is relatively thin at the point where the grooves 57 of the main rib embossing roll 55 intersect the grooves 58 of the connecting rib embossing roll 56, the polymer can be deposited in both the relatively narrow grooves 58 and the relatively coarse grooves 57. It would be inappropriate to fill the larger groove 57 with the polymer used.

This is because the polymer tends to flow towards the path of least resistance, ie, the large groove.

The same phenomenon occurs with thick sheets at lower pressures.

At lower embossing temperatures, there is a greater tendency to form discontinuous interlocking rib patterns due to the higher flow resistance of the polymer.

Therefore, although the coarse grooves 57 of the embossing roll 55 are uniformly filled with polymer through these adjustments, the narrow grooves 58 of the embossing roll 56 are not completely filled.

The embossed connecting ribs are made discontinuously as shown in FIG.
0, there is not enough polymer flow to form the connecting ribs 59.

After orientation, this becomes a strong and inexpensive network.

This is because, among other reasons, the proportion of polymer occupied by the main ribs is higher than under other operating conditions.

Moreover, the discontinuous connecting ribs 59 are further advantageous in that the main ribs 61 and the connecting ribs 59 are virtually aligned and do not intersect, so that the main ribs 61 are oriented completely uniformly.

The desirable range of the ratio of the cross-sectional area of the main ribs to the cross-sectional area of the connecting ribs is between 1.5:1 and 100:1, and the ratio of the height of the main ribs to the thickness of the web between the main ribs is at least 3:1. I found that 1 or more is better.

Therefore, as shown in FIG. 9, the cross-sectional area A1 of the main rib and the cross-sectional area A2 of the connecting rib both include the web portion in contact with the base of each rib.

As in Fig. 2, the height T1 of the main rib and the thickness T2 of the web connecting the main ribs are determined in Fig. 9.
As shown in the figure, a continuous main rib embossing roll 62
and discontinuous connecting rib embossing rolls 63, with the main ribs being created in the machine direction of the sheet.

The main rib embossing roll 62 is attached to the main rib 6 on the sheet 70.
A number of parallel annular grooves 6 made to form 5
It has 4.

The connecting rib embossing roll has a number of discontinuous grooves or depressions 66 made parallel to the longitudinal axis of the roll to form discontinuous connecting ribs 67.

In each row of grooves or indentations 66 across the embossing roll 63, each groove 66 corresponds to an interrupted portion 6 of the roll 63.
It is interrupted from the adjacent groove by 8.

Preferably, the width of the interruption 68 is equal to or slightly less than the width of the groove 64 of the main rib embossing roll 62.

It should be noted that the connecting ribs are not continuous across the embossed sheet, but are continuous only from one major rib 65 to the next, and are discontinuous at 69.

Due to the arrangement of the rolls 63, little or no polymer remains on the connecting rib side of the sheet directly opposite the main ribs 65.

By embossing the sheet 70 in this manner and subsequently stretching it in two directions, the major ribs are oriented continuously and very uniformly.

When using the modulated embossing method described above to produce the depression effect shown in FIG. 8, or when using the discontinuous connecting rib formation method as shown in FIG. The ratio of the cross-sectional areas of the main ribs to the connecting ribs is not important in view of the fact that there is little or no polymer crossing.

Therefore, a ratio of 1:1 is sufficient.

However, to obtain a lower unit weight or a finer mesh pattern, such as as many square yards (crits) of mesh per ounce (g) of polymer as possible, it is necessary to use more crits than the main ribs shown in FIGS. It is desirable to use a pattern with small connecting ribs.

11 and 12 show the front and back sides of a portion of a network structure formed by stretching the sheet shown in the embossing method shown in FIG. 10 both in the direction perpendicular to the machine and in the machine direction.

Note that the main filaments 71 are somewhat flattened after drawing, and the connecting filaments 72 are spaced evenly apart from the main filaments 71.

The connecting filament 72 has both ends connected to the main filament 71.
and does not extend across the main filament 71 as shown in FIG.

When stretching the embossed sheet, the suitable amount of stretching will depend on factors such as the polymer used, the pattern of embossing used and the degree of spacing of the primary filaments desired in the final network.

Conventionally, an initial stretching or orientation step stretches the embossed sheet in a direction generally perpendicular to the direction of the major ribs in order to orient the thin sections of plastic material between the major ribs.

For example, the embossed sheet shown in FIG. 2, in which the main ribs 23 are formed in the cross-machine direction, is typically (but not necessarily) first stretched in the machine direction.

This stretching can be carried out using ordinary linear differential speed stretching rolls.

This orientation is typically greater than or equal to 1.5X (1,5 times) and generally results in initial holes or actual gaps between the major ribs and small connections spanning the gaps between the not yet oriented major ribs or filaments. A filament is formed.

Stretching more than five times (5x) the original dimension at this stage is generally undesirable because orthogonal orientation of the polymer will occur at the point where the main ribs and Q connecting ribs overlap.

This interferes with the desired uniform orientation of the main filaments in the subsequent drawing step.

Alternatively, it may be desirable to carry out an initial stretch in the direction of the main ribs, for example up to a factor of 2 (2x), and then to stretch at right angles to this direction.

This tends to orient and strengthen the main ribs, preventing them from warping during transverse orientation, and preventing orthogonal orientation of the polymers from occurring in areas of overlap.

A second orientation step is performed in a direction generally parallel to the main ribs.

Thus, referring again to the embossed sheet shown in FIG. 2, the second orientation is in the cross-machine direction.

This lateral stretching step can be carried out using a common tenter.

The lateral stretching orients the main ribs along their longitudinal axes and also separates the small interlocking filaments.

The amount of stretching determines the strength and size of the primary filament produced.

It can vary from 1.5 times (1,5X) to more than 10 times (IOX).

The maximum amount of stretch will depend, among other conditions, on the orientation properties of the polymer used.

The temperature during stretching varies depending on the polymer used, but is generally slightly lower than the temperature used to orient flat sheets of the same polymer.

Although first and second sequential stretching steps have been described, both stretching steps can be performed simultaneously if desired.

The network structure produced by the method described above usually consists of main filaments oriented vertically, horizontally or diagonally as desired, connected by oriented connecting filaments of fine denier, the main filaments being oriented continuously over their entire length. ing.

Examples of different configurations of network structures that can be produced are shown in FIGS. 13 and 14.

FIG. 13 shows a network structure having main filaments 73 extending in the machine direction, ie, in the direction of the arrows, and connecting filaments 74 formed in a direction perpendicular to the machine direction at 90 DEG.

In FIG. 14, the main filament 75 is formed perpendicular to the machine direction indicated by the arrow, and the connecting filament 76 is formed parallel to the machine direction.

In FIG. 15, the main filament 77 is formed at an angle to the machine direction indicated by the arrow, and the connecting filament 7
8 is formed parallel to the machine direction.

Alternatively, the connecting filaments 78 can be formed in a direction perpendicular to the machine direction or perpendicular to the main filaments as shown in FIG.

When the primary filaments 77 are formed at an angle of 75° or less to the machine direction, it is sometimes desirable to draw them in the machine direction while allowing the network to become thinner to orient such filaments. .

To create a conventional arrangement, if desired, first stretch perpendicular to the machine in a tenter and then stretch in the machine direction to narrow.

It is clear that many other arrangements of networks can be produced in accordance with the principles of the present invention having major filaments at the desired angles requiring maximum tensile strength and connecting filaments formed at angles relative to the major filaments. It is.

The networks described herein have good tensile strength in the direction of the main filaments, reflecting the degree and uniformity of orientation along the length of the filaments.

This strength is small in the opposite direction due to the small size of the connecting filaments of the tether.

The tear strength is greater in the direction perpendicular to the main filament due to the strength of the main filament.

The network structure shown in Figures 5, 6, 11 and 12 may be continuous, overlapping and intersecting the main filament, or
or having interlocking filaments that are discontinuous and completely fused to the main filament, in each case without notches at the seams, as is characteristic of many network structures produced by prior art methods. It is noteworthy.

Such notches at seams or overlapping intersections make the mesh susceptible to tearing in either direction.

Although the subject network is useful as a single layer network, very useful multilayer fabrics can also be used to make the structure.

Referring to FIG. 17, one network, labeled 81, has main filaments 82 formed in the machine direction and connecting filaments 82 formed in the cross-machine direction (not shown here). is shown bonded in layers with a second network, labeled 83, having primary filaments 84 formed in the cross-machine direction.

No connecting filaments are shown in any of the network structures shown in FIGS. 17-22 to facilitate illustration and explanation of the fabric structure.

However, there are connecting filaments in each mesh, which can be thought of as shown in FIGS. 13-16 or as previously described.

One method of joining the two mesh structures 81 and 83 is to feed them through rolls 79 and 80 and into a preheater 84, where the mesh structures are bonded under tension so as not to adversely affect the orientation. and then advance them into the mesh of two heated calender rolls 86 and 87 to bond the plastic materials together.

Rolls 79 and 80 rotate very slightly slower than rolls 86 and 87 and continue to exert a long force during heating to keep networks 81 and 83 from losing orientation.

It may also be desirable to use a tenter, a series of closely spaced rolls, or other methods to prevent lateral shrinkage of the mesh in this area.

This bonding or lamination process creates a two-layer fabric foil with a woven-like appearance and physical properties that have high strength and good tear resistance in both the machine and transverse directions.

Such fabric foils do not extend much in the machine direction or perpendicular thereto, but do extend diagonally.

Excellent dimensional stability, high strength in all directions and high tensile strength are achieved by using three layers of boards with main filaments formed in different directions to provide a fabric fabric with excellent dimensional stability, high strength in all directions and high tear resistance. Cloth foil can also be manufactured.

As shown in Figure 18, the first
The layer or first network has major filaments 89 formed at an angle to the machine direction indicated by the arrows.

The second middle layer or network 91 has main filaments 92 formed in the machine direction.

The third layer or network 93 has major filaments 94 formed at an acute angle in the machine direction opposite the angular major filaments of layer 88.

The three layers pass through a mesh of rolls 85 and 90 into a preheater 95 and pass through a mesh of two heated calender rolls 96 and 97 where the three layers are joined at their overlapping points.

The bonded fabric foil then passes through an annealing device 98 and is wound onto a take-up spool 99.

If desired, a conventional tenter or other method can be used to apply tension perpendicular to the machine direction during heating and bonding.

Such cloth foils with three or more layers are woven cloth,
Provides strength and dimensional stability in all directions not available with knitted or other nonwoven fabrics.

Such cloth foils exhibit good extensibility in the direction perpendicular to the machine.

Referring to FIG. 19, a similar three layer fabric is shown except that the middle layer has the main filaments 100 in the cross-machine direction.

Such cloth foils have good extensibility in the machine direction.

If we exclude the middle mesh layer 91 shown in FIG. 18, the layer 88 extends at an angle, such as 45°, in the machine
A two-layer fabric is obtained, as shown in FIG. 20, consisting of main filaments 89 and a second layer 93 having main filaments 94 facing each other at equal angles in the machine direction.

If the main filaments 89 and 94 are 45° in the machine direction
, the main filament 94 is the main filament 8
It will be perpendicular to 9.

Such a network structure excluding the middle layer 91 has stretchability and recovery properties similar to those of a knitted fabric in the machine direction and a direction perpendicular thereto.

That is, the fabric stretches both in the machine direction and in the cross-machine direction.

If desired, the three-layer structure of FIG. 18 can be constructed by bonding or laminating a top layer of a network structure having main filaments 84 extending perpendicular to the machine, such as 83 shown in FIG. It can be a four-layer isotropic fabric fabric construction.

Such a four-layer isotropic fabric foil is shown in FIG.

For the most homogeneous properties in such a fabric, the main filaments 89 and 94 should be aligned at 45° in the machine direction.
It is desirable to have an angle of 1°.

This cloth foil is dimensionally stable and has little stretch in any direction.

Referring to FIG. 22, a single layer plastic network, generally designated 101, with main filaments 102 formed in a direction perpendicular to the machine can be fabricated from paper, film, foil or carded fibers. It is bonded between two layers 103 and 104 of nonwoven webs, such as garnet fiber or air laid fiber webs, or combinations thereof.

The bonding is accomplished by first passing the network 101 and layer 104 through an adhesive applicator 106 and then passing layer 103 along with the other two layers through a heated zone such as calender rolls 107 and 108 to age the adhesive. Adhesion is achieved by

Paper, non-woven textile webs, whose strength is then reinforced,
The film or foil structure is taken up on a take-up spool 10
It is wound up at 9.

Many different multilayers can be fabricated in accordance with the principles of the invention by joining one network structure with primary filaments in one direction to one or more pond networks with primary filaments in another direction. It is clearly recognized that cloth foil can be manufactured.

The layers can then be bonded by applying or spraying an adhesive between the layers and passing them through a heater and calender rolls, or by simply passing the layers through a pair of heated calender rolls, or by ultrasonic bonding. The fabric can be bonded into the fabric in a number of ways, including spot bonding or other conventional bonding techniques known in the art.

Among the many uses of the subject mesh structures as single or multi-layer cloth foils are sanitary napkins, diapers, continence pads, tampons, surgical hawk products,
Surgical sponges, firefighting suits and paper and paper products, films,
There are other reinforcing materials for non-woven and woven fabrics.

For example, mesh can be used to reinforce masking tape or wallpaper, thereby helping to increase tensile strength and tear resistance.

In the case of paper and stable fiber nonwovens, networks of the type with the main filaments in the cross-machine direction, as shown in FIG. 20, are particularly advantageous.

This is because in the manufacture of paper or staple fiber nonwoven fabrics, the fibers therein are usually oriented in the machine direction and are required to increase cross-machine strength and machine direction tear resistance.

Additionally, thermoplastic networks can be used as adhesives to bond other materials together under heat and pressure.

Mesh can also be used in soluble cores placed inside shirts and the like, and can be used in place of cheese cloth for cheese making and processing.

The multilayer fabric foils described above are used in applications similar to those described for single layer networks, and are particularly useful in applications requiring balanced high strength and tear resistance.

Multilayer products are used, for example, in the production of impact-resistant plastic backings, carpet linings with primary and secondary rafters, plastic-coated fabric foils,
It is particularly useful in other industrial foil applications.

Not absorbent, does not stick to scratches or other materials,
Many other uses are apparent for these meshes and fabrics, which have properties such as easy passage of liquids due to the pores in the mesh structure, and relatively light weight and high strength.

Although the high tensile strength and high tear resistance of the subject networks have been emphasized, the primary filaments may not necessarily be made larger for applications where strength or tear resistance properties are not important, resulting in a network structure with less of those properties. It is of course clear that network structures can be manufactured according to the principles of the invention without stretching.

Depending on the application, texture and smoothness are more important than strength.

An example of such an application is the use of mesh structures as coverings for sanitary napkins, where they are highly permeable to prevent irritation and to allow fluids to pass through and be absorbed by the napkin's absorbent core material. It is highly desirable that the mesh has a soft and smooth texture.

The subject network structure is very smooth as it has no reinforced protrusions or thick sections at the points where the main filament and the connecting filament overlap.

This smoothness gives the mesh a soft feel, which is desirable for many applications where user or wearer irritation is an important factor.

Additionally, the network structure can be stretched in such a way that it results in a relatively flat structure, ie, a structure having a relatively uniform thickness when measured in a plane perpendicular to the plane of the network.

This is important when the mesh is used as an adhesive where it is desired to bond two materials into a laminated or bonded fabric sheet of uniform thickness.

It is also possible to produce novel monofilaments or yarns from some of the network structures described above.

Referring to FIG. 23, the entire structure is labeled 110, having a main filament 111 extending vertically, that is, in the machine direction, and a connecting filament 112 that extends perpendicularly to the machine, that is, at 90 degrees to the main filament 111. A mesh structure is shown.

Any network structure having main filaments formed in the machine direction and connecting filaments formed at an angle to the machine direction can be used to produce monofilaments or yarns.

The mesh 110 is made entirely of 114 by interlocking rolls 115.
Individual filaments or relatively narrow tapes or strips 110a, 110b consisting of a number of main filaments running through a number of wreath rods and connected by connecting filaments.

It is divided into 110c, 110d, etc.

The mesh 110 can be easily divided into monofilaments or tapes of any desired width.

This involves first cutting or splitting the starting end of the mesh 110 into strips of the desired width, loading adjacent stops separately onto the wreath rod 114, and splitting or splitting the mesh as desired as it advances through the wreath rod. This is done by dividing.

For example, as shown in FIGS. 23 and 24, strip 110a is placed over lease rod 114a, over lease rod 1
14b and above lease rod 114c.

The adjacent strike IJ knob 110b is the lease rod 114
a, above lease rod 114b, and below lease rod 114c.

In this manner, as the strips 110a and 110b advance, the wreath rod cuts the connecting filament connecting adjacent strips.

Because of the size of the main filament and the connecting filament, the connecting filament is easily cut as it passes through the wreath rod as shown, without the need for cutting or splitting devices.

If desired, the strips can be continued in U.S. Pat.
The connecting ribs can be fibrillated and completely or partially severed, such as by passing over a beater bar 116 similar to that described in US Pat. No. 4,495,752.

FIG. 25 shows the appearance of a portion of strip 110a before fibrillation.

When the network is fully fibrillated, nearly all of the interlocking filaments are severed, leaving the main filaments intact, so that the strip becomes a yarn consisting of a large number of individual main filaments.

Part 1: The solid main filaments are not interconnected,
Then there are connecting filaments projecting vertically or at an angle if the connecting filaments were initially formed at an angle.

FIG. 26 shows a portion of a cut and fibrillated strip 110a of connecting filaments.

The main filament is drawn through another set of mating rolls 117 and then passed over yarn guides 118 for further processing.

When fibrillated using a beater bar 116 or by other methods, the strips 110a, 11
0b etc. completely or partially transform into a series of multi-filaments, each generally with small, laterally protruding filaments.

If desired, bulking can be accomplished by known crimping or crimp techniques.

Bulking can also be accomplished by thermal relaxation if the primary filament is made from a bicomponent composite polymer sheet.

For example, referring again to FIG. 23, fibrillated strip 110a may be passed from yarn guide 118 into heater 119 for bulking.

If desired, the yarn can be twisted using the twisting head 120 and then wound onto the take-up spool 121.

Alternatively, if untwisted yarn is desired,
The non-fibrillated or fibrillated strip 110b is wound up at the Lisbourg 12 as shown in FIG.
2 can be wound directly.

Alternatively, if desired, the fibrillated strip 110c can be applied to an air jet interlacer 123.
can be wound onto the take-up spool 124.

If desired, fibrillated strip 110d
can be passed through a conventional descending type twisting machine 126 and then wound onto a winding Lisbourg.

Conventional air jet entangling techniques can be used to form the yarn into a form that can be easily rolled and unwound from the package.

Figure 27 shows yarn 12 entangled by air jet.
8 is illustrated.

FIG. 28 illustrates yarn 129 that has been bulked and then entangled with an air jet.

Twisting machine winding packaging makes it well-packed and easy to handle.
You can also create a

Of course, many combinations of these steps can be used, such as fibrillation followed by heat relaxation and twisting.

Non-fibrillated strip or tape meshes are also used in untwisted form in weaving or knitting operations where lightweight maximum coverage and strong fabric foil are required.

Such weaving or knitting operations can be carried out in combination with operations for making strips or tapes.

Yarns made according to these techniques are unique in that the main filaments are provided with protruding interlocking filaments which contribute to the bulking, covering and desirable appearance.

These yarns are useful in knitted, woven, tufted products and generally continuous filament nonwoven applications.

The presence of a section of connected filament lying on its side means that
Fabrics made from these yarns provide good adhesion to plastic, rubber or other coatings when subsequently coated.

Furthermore, the yarns and fabric foils have good abrasion and peel resistance due to their laterally protruding connecting filament portions.

Strips 110, or individual filaments of the present invention having spaced apart fibrils, can also be cut into strands of stable fiber length.

Such synthetic fibers are particularly useful in spinning yarns produced, for example, by conventional cotton, wool, or worsted spinning processes, or in nonwoven fabrics, produced, for example, by conventional coating or air-laying processes.

Because of the protruding connections in the aforementioned artificial fibers and yarns made from continuous filaments, nonwoven or woven fabrics, knitted fabrics, and tufted products made from such fibers and yarns have a pleasant appearance; It has high thermal insulation and moisture absorption properties, and exhibits good adhesion to other materials used to bond or coat the fabric.

In the above description of the embossing method, usually 1
One embossing roll drives the other embossing rolls through the melt or sheet, each roll rotating at the same speed.

However, when using polymers that are relatively slow to spontaneously cleave, such as polyesters, polyamides, and vinyl polymers, the initial cleavage of these polymers may be accomplished using differential speed embossing rolls during the embossing process. I can do it.

The speed difference method means that the surface speed of the embossing roll for the main ribs is slightly different from the surface speed of the embossing roll for the connecting ribs by about 5%.
It means to be faster or slower up to a 0% difference.

The speed difference between the main rib and connecting rib embossing rolls can be used to cause tearing of the thin web of the embossed sheet during the embossing process.

This facilitates tearing or opening into a uniform network during subsequent stretching.

Materials capable of forming the web structures, fabrics and yarns mentioned above include any thermoplastic polymers that form fibers.

These include polyethylene, homopolymers of polypropylene, random copolymers of propylene containing up to 10% of other olefins, block copolymers of propylene containing up to 25% of other olefins, nylon-
6, nylon 66, polyethylene terephthalate ester, other high molecular weight thermoplastic polyesters, and vinyl polymers such as polyvinyl chloride.

Bonded or two-layer composite plastic sheets are also possible, in which two or more polymers are extruded together into a sheet containing a single layer of separate polymers.

For example, two layers or networks each having a portion made of a relatively high melting point polymer and a portion made of a relatively low melting point polymer are heated with the lower melting point polymer in each layer together. It can be joined by

Alternatively, a network made of a high melting point polymer can be joined to a network made of a low melting point polymer.

Additionally, one network having portions made of a relatively high melting point polymer and portions made of a low melting point polymer can be joined to another network made solely of a high melting point polymer.

Particularly desirable are composite plastics in which the main fiber is largely constructed using high melting point components such as nylon or polyester.

This allows the two layers to be laminated without the use of adhesives, by bonding networks or yarns made from such structures by heat or pressure, or by self-bulking by heating.

Blends or mixtures of polymers can also be used.

The principles of the invention are illustrated by the following examples.

These are shown to illustrate the invention and should not be considered as limiting.

Example 1 A homopolymer of propylene with a melt flow index of 7.5 and a homopolymer of propylene with the same melt flow index of 2
, a random copolymer of propylene and ethylene containing 5% ethylene were extruded together through a slit die at 465°F (240°C) to produce a composite sheet that was 75% thick of the homopolymer.

The slit die is 12 inches (30.5CrrL)
length, and the opening was 15 mils (0,038 crrL) wide.

The melted sheet has a diameter of 4 inches (10,2 cm) and 3
inches (7,6 crfL) and each length is 13 inches (
It was passed through a mesh of two chrome-plated steel embossing rolls of 33.0 cr IL).

The 4 inch (10,2 crrL) roll had an embossed pattern of grooves spaced along its circumference at 48 grooves per inch (18 grooves per crrL).

The roll was internally cooled to maintain a temperature of 70°C.

Another 3 inch (7.6 CIrL) roll had a pattern of straight grooves extending parallel to the vertical axis at a spacing of 111 grooves per inch (43.7 grooves per crrL).

This 3 inch (7.6 cfrL) roll was not cooled and was assumed to be at a temperature of about 60°C.

The melted sheet is passed between two rolls at 15 feet per minute (
457cffL) and 48(cffL) per inch.
1800 around the roll of grooves (18 pieces per 1crIL)
We made contact and proceeded.

The bonding sheet was in contact with a roll of homopolymer (JJIJLt 48 grooves per inch (18 per lcrft)).

Embossed sheets are coated with 10 mils (0 mils) vertically on one side.
There were 48 main ribs per inch (Icm, 18 per inch) spaced by grooves with a width of 0.025C11L).

The other side of the sheet is 5 mil (0,0125c) by grooves.
111 pieces per inch (IrL) width apart.
Continuous connecting ribs were formed at a rate of 43.7 pieces per ICrfL.

Maximum sheet thickness is 15 mils (0,0038 cIrL)
Met.

The cross-sectional area ratio of the main ribs to the connecting ribs was about 2:1, and the ratio of the height of the main ribs to the thickness of the web between the main ribs was 8:1.

The embossed sheet was fed at 20 feet per minute (6106IrL) into a tenter heated to 110°C by circulating air.
) and stretched to twice its width.

In this operation, it is opened into a uniform network structure,
The grooves between the major ribs provided orthogonal holes or gaps with oriented connecting filaments, with approximately 30 mils (0,0762 crIL) separating the major ribs.

The sheet was then stretched in a linear direction by passing it in frictional contact through a series of 11 steel rolls heated to 120° C. and moving at progressively faster speeds.

The sheet was loaded at a rate of 15 feet per minute (457 crIL) and exited at 105 feet per minute (3200 cm), thus being stretched to seven times its length in the machine direction.

The resulting network weighed 0.32 ounces per square yard (1,08 x to -31/i).

The uniformly oriented main filament size was approximately 45 denier.

This mesh structure is 11 lb/in (19 lb/in) in the machine direction.
It exhibited a tensile strength of 5 og/CrrL) and an elongation of 12%.

The strength perpendicular to the machine is approximately 1.9 lb/in (3
36g/crrL) and the elongation was 12%.

The mesh is highly resistant to tearing perpendicular to the machine and meets the ASTM D-827 twin edge
h edge) 30 pounds (
13.5 kg).

Example 2 A homopolymer of propylene with a melt flow index of 7 was extruded from the slit die described in Example 1 at 400'F (204°C).

The melted sheet was embossed between two rolls.

One of the rolls was the same as that used in Example 1, with 111 rolls per inch extending parallel to the vertical axis of the roll.
One roll had 36 annular grooves per inch extending circumferentially.

The cross-sectional area ratio of the main ribs and connecting ribs formed on both sides of the obtained embossed plastic sheet was about 13:1, and the ratio of the height of the main ribs to the thickness of the web between the main ribs was 5:1. Ta.

The embossed sheet was then stretched to twice its width in a tenter at 80°C.

During this operation, regular gaps or pores were created between the main filaments.

The sheet was then linearly stretched to 9.2 times its length by passing over a series of differential speed rolls heated to 120°C.

The weight of the network thus produced was 0.45 ounces/square yard (1,52 x 10-3 grams/yard).

The uniformly oriented main filament size was about 160 denier.

This mesh structure is 22 lb/in (38 lb/in) in the machine direction.
It exhibited a tensile strength of 90 g/cm 2 ) and an elongation of 12%.

The strength perpendicular to the machine is 0.8 lb/in (14
2, F/α) and the elongation was 22%.

It has excellent tear resistance perpendicular to the machine and 50 lbs. (22,5 lbs.
kg).

Example 3 The network of Example 1 and a similar network with main filaments oriented perpendicular to the machine were joined by compressive pressing between steel platens at a temperature of 270OF (132°C). , one orthogonally assembled cloth foil was manufactured.

A pressure of 15 p,s,i (1,05-/-) was applied for 15 seconds.

The fabric foil thus produced weighs 0.7 oz/yd (2,40x 10-3.9/i) and 10 lbs/in in one direction (+77o, 9/m) and in the opposite direction. 10 lb/in (1770 g/cIf)
L), and the elongation was 12% in all cases.

The fabric has excellent tear resistance in both directions, and when tested using the twin-edge tear method, it can withstand 25 lbs (11,25 kg) in the machine direction and 25 lbs (11,25 kg) perpendicular to the machine
1.2 skg).

The resistance strength of the Mullen tear is 35p,s,i(2,
46 kg/cytt).

Example 4 High-density polyethylene with a tart index of 10 was grown at 450°F (232°C) to an 18-inch length (45.7cm).
m), extruded through a slit die with a width of 15 mils (0,0381 crIL).

The melted sheets are 4 inches (10,2 CrIL) and 6 inches (15,2 cm) in diameter, each with a length of 15
inch (38,1cfrL) and 20 inch (50,8cfrL)
m) through a mesh of two chrome-plated steel embossing rolls.

A 4-inch (10,2 crrL) roll has a number of grooves around it, spaced at 75 grooves per inch (29.5 grooves per crfL), at a 45° angle to the roll's vertical axis. It had an embossed pattern of grooves.

A 6-inch (15,2 cIrL) roll consists of a number of grooves around it, spaced at 250 grooves per inch (100 per 1 crrL), and also at an angle of 45° to the vertical axis of the roll. It had an embossed pattern.

The temperature of these rolls is controlled internally to approximately 150'F.
(approximately 65°C).

The molten sheet is then passed between two rolls at a rate of 20 feet per minute (610 cIrL) and 5 mils (0.01
The thickness was 27cIfL).

75 pieces per inch (1cIr) diagonally on one side
29.5 pieces per L) and 5 mils (0,
A sheet was embossed with main ribs spaced apart with a width of 0.0127cIrL).

The other side of the sheet is grooved to 1 mil (0,002
25 per inch, with a width of 54cIfL).
Connecting ribs were formed at a rate of 0 (100 per ICrIl).

The ratio of the cross-sectional areas of the main ribs to the connecting ribs was about 13, and the ratio of the height of the main ribs to the thickness of the web between the main ribs was 3.5:1.

The embossed sheet was loaded into linear stretch rolls heated to 120° C. at a speed of 50 feet per minute (15.25 m) and stretched to three times its length.

The sheet was then loaded into a tenter heated to 110 DEG C. with circulating air at a speed of 150 feet per minute (45.7 m) and stretched to 3.0 times its width.

In this operation, it is opened into a uniform network structure,
The groove between the main ribs becomes a hole or gap perpendicular to the oriented connecting filaments, and the main filament is approximately 1
5 mils (0,0381 crfL) apart.

The sheet was then stretched once more in the linear direction by passing it in frictional contact through a series of 11 steel rolls heated to 120° C. and moving at progressively faster speeds.

Sheets are loaded at a speed of 115 feet (35,0 m) per minute and exited at a speed of 150 feet (45,7 m) per minute;
Therefore, it was stretched to 1.3 times its length in the machine direction.

The resulting mesh structure has a density of 0.35 oz/yd (1
, 19 x 10-'' x g/cIj,).

The uniformly oriented main filament size was approximately 90 denier.

Reference example 1 Polypropylene and high-density polyethylene, each with a melt flow index of 10, were heated at 199°C with a length of 12
inches (30,5 cIIL), opening 15 mils (0,38
extrude them together through a slit die (mm),
A molten sheet consisting of 75% polypropylene on one side and polyethylene on the other side was passed between chrome-plated steel embossing rolls.

One roll is 4 inches (10,2 cIIL) in diameter, the other 3 inches (7,66 rIL), each 13 inches (3
The length was 3,0 CrrL).

The 4 inch (10,2 cIrL) roll had an embossed pattern of grooves spaced around its circumference, 48 grooves per inch (2,54 cIrL).

The roll was internally cooled to maintain a temperature of 70°C.

The other 3 inch (7.6 cffL) roll had a pattern of 111 straight grooves per inch spaced evenly apart and running parallel to the axis of the roll.

This 3-inch roll was controlled at 60°C. The molten sheet contacted the 4 inch roll 1 inch before it entered between the meshes of the two rolls.

The polypropylene side of the molten sheet was then in contact with this roll.

The linear velocity of the sheet is 19 feet per second (580CrfL)
The embossed sheet was rotated in 180° contact around a 4 inch roll.

The embossed sheet contains 48 major ribs per inch in height on one side, and the ribs are 10 mil (0,
254mm) width apart.

The other side of the sheet was discontinuous with 111 bonding ribs per inch, and the ribs were spaced 5 mils (0.127 mm) wide apart.

The bonding ribs are discontinuous and are absent on opposite sides of the major ribs on opposite sides of the sheet.

The ratio of the cross-sectional area of the main rib to that of the connecting rib is approximately 2:1
The ratio of the height of the main ribs to the thickness of the web between the main ribs was approximately 5=1.

Maximum main rib thickness for embossed sheets is 11 mils (0
, 279 mm).

The embossed sheet was tentered to twice its width by heating it with circulating air at 100° C. and feeding it into a tenter at a speed of 20 feet per minute (610 cIrL).

This operation opened a uniform network structure.

This network was passed in frictional contact with a series of 11 increasingly speedy steel rolls heated to 120°C.

The sheet was loaded at 15 feet per minute (457 CrrL) and discharged at 105 feet per minute (3200 CIfL) and thus stretched to 7 times its length in the machine direction.

The resulting network weighed 0.27 ounces per square yard (0.91 x 10-3 g/ff1).

The thickness of the uniformly oriented main filament was 45 denier.

This mesh structure is 11 lb/in (1950 g/c
rn), and the elongation in the machine direction was 10%.

The transverse strength is 1.0 lb/in (1779/c
IrL), the elongation was 10%.

The mesh structure is tear resistant in the direction perpendicular to the machine;
Tested using the Finch-Edge method (ASTM D-827) and gave a value of 32 pounds (14.4 kg).

Reference Example 2 Polypropylene and high-density polyethylene each having a tart flow index of about 10 were heated at 207°C in Example 5.
Composite sheets were extruded in an extrusion apparatus as described in 1999 in a two-component ratio of 50:50.

The fused sheet was embossed between two rolls.

One roll is 6 inches in diameter with 1 roll parallel to the axis of the roll.
It had 75 grooves per inch (30 per ICIIL).

The other roll was 4 inches (17.8 CrrL) in diameter and had 75 grooves per inch around the roll.

The 4-inch roll was cooled from the inside and maintained at 60°C.
The inch roll was maintained at 49°C.

The pressure between the two rolls is approximately 40 pounds per linear inch (
7ky/d).

The molten sheet should be 1/2 inch (1/2 inch) into the nip between the rolls.
, 27Cr/L) was first contacted with a 4-inch roll.

The sheet moves between two rolls at 20 feet per minute (610 feet per minute).
CIrL).

Embossed sheets have a maximum thickness of 9 mils (0.23 mm)
) and 1 inch (2,54 cIrL) in the longitudinal direction on the surface.
), including 75 main ribs, and the ribs are 5 mil (0,
They were separated by a groove 13mm wide.

The other side has 75 bonding ribs per inch, with each pair of bonding ribs separated by a 5 mil (0.25 mm) wide groove.

The ratio of the cross-sectional area of the main rib to that of the connecting rib is approximately 1:1
The ratio of the height of the main rib to the thickness of the web is approximately 5:1.
Met.

There were no connecting ribs on the other side of the main rib on the opposite side of the sheet.

The embossed sheets were placed in a tenter heated to 110°C by circulating heated air at 20 feet per minute (
610 cm) and tentered to 6 times its width.

This operation unfolded the sheet into a uniform network structure, and the sheet was then heated to 120° C. and stretched longitudinally by passing it in frictional contact through a series of 11 sets of increasingly speedy steel rolls.

The seat is 1-. 5 feet (457,5 crIL)
It was charged at 90 feet per minute (2745 crrL).

It was thus stretched to six times the length in the mechanical direction.

The resulting network weighed 0.2 ounces per square yard.

The uniformly oriented filaments were approximately 40 denier.

This mesh structure is 9 lb/in (1609 lb/in) in the machine direction.
g/crfL) and an elongation of 14%.

The strength perpendicular to the machine is approximately 7 lb/in (1251
g/crIl) and the elongation was 12%.

The network had high tear resistance in the cross-machine direction, testing to 20 pounds using the Twift Edge method (ASTM D-827).

Reference example 3 High-density polyethylene with a tart index of 6 is slit to a length of 18 inches (45,7 cfrL) to 23
It was extruded at 2°C.

The molten sheet was embossed between two rolls.

One roll has a diameter of 6 inches (15,3 CrfL),
The other rolls have 250 grooves per inch (98 per ICIrL) extending at 45° to the axis of the roll, and the other rolls are 4 inches in diameter (10,2 cffL) with 1 inch grooves extending circumferentially. It had 75 grooves per crrt (30 grooves per crrt).

- Both rolls were maintained at 66°C.

The molten sheet is 1/4 inch (0,
64CrrL) 4-inch roll.

The speed of passage between the embossing rolls is 20 feet per second (610 CrfL) and the embossed sheet is
A 90° contact was made around the inch roll.

The embossed sheet contains 75 ribs per inch in the machine direction with a 5 mil (0,12
7mm) wide groove.

The opposite side of the sheet is formed with discontinuous ribs having 250 ribs per inch, with a spacing of 1 mil (0.254 mm) between the ribs.
mrn) groove.

There are no joining ribs on the opposite side of the sheet opposite the main ribs.

The ratio of the cross-sectional area of the main ribs to that of the discontinuous bonding ribs was about 10=1, and the ratio of the height of the main ribs to the thickness of the web between the main ribs was about 4:1.

The maximum thickness of the embossed sheet is 4 mils (0.1 im
)Met.

The embossed sheet was stretched to 3 times its length with aligned pull rolls at 120°C and 2.5 times its length at 90°C.
It was tentered out by a factor of 5, during which regular openings occurred between the main filaments.

The sheet was further stretched longitudinally by a factor of 1.5 by passing it through a series of rolls heated to 120° C. and at different speeds.

The weight of the mesh structure thus formed is 0.25 ounces per square yard (0.85 x 10-3 g/c11
t).

The uniformly oriented main filaments were about 40 denier.

This mesh structure has a power of 3.9 ps i (0
, has a tensile strength of 27 kg/CI and an elongation of 13%,
It showed high tear resistance in the direction perpendicular to the machine.

Reference example 4 Polypropylene with a tart index of 7 is
°C, opening 20 mils (0,051 crIL), length 12
It was extruded through an inch (30.5 crrL) slit.

The molten sheet was passed between two embossing rolls kept at 70°C.

One roll has a diameter of 4 inches (10,2 crrL),
It had 40 grooves per inch separated by 5 inch wide (12.7 c/rL) ridges in the circumferential direction.

The other roll was 6 inches (15.3 cm) in diameter and had 125 discrete grooves per inch parallel to the axis of the roll.

The discontinuous parallel grooves were 7 mils (0.18 mm) long with an 18 mil (0.46 mm) discontinuity between the grooves.

This discontinuity existed on lines extending circumferentially around the roll.

The two rolls were matched so that the line of discontinuity on the 6 inch roll was exactly opposite the groove on the 4 inch roll.

The linear velocity of the sheet is 25 feet per minute (762,5 crI)
L), the embossed sheet is 6 inch roll and 90
were brought into contact over an angle of °.

The embossed sheet is 5 square meters (0.51mm) on the - side.
) had 40 ribs per inch separated by a web of width.

The opposite side of the sheet had discrete bonding ribs spaced at 125 ribs per inch.

There were no bonding ribs on the other side of the embossed sheet opposite the main ribs.

The ratio of the cross-sectional area of the main rib to the cross-sectional area of the connecting rib is approximately 20
= 1, and the ratio of the height of the main rib to the thickness of the web is approximately 1
The ratio was 0:1.

The maximum thickness of the embossed sheet is I5 mil (0,38
mm).

The embossed sheet was oriented in the machine direction by being passed in frictional contact through a series of 11 sets of steel rolls at 120° C. and increasing speed.

Sheet charging speed is 15 feet per minute (457,5 cr
fL) and was stretched to 10 times its original length.

The sheet is 0.5 ounces per square yard (1,7X
It was separated into a network having a weight of 10-3 g/i).

The filament in the machine direction was approximately 3 mils (approximately 80 denier with 0,076 mJ spacing).

The strength in the machine direction was 20 psi (1.4 kg/i) and an elongation of 15%.

This mesh structure has high tear resistance in the cross-machine direction and approximately 60 lbs. as measured by the Twift Edge method.
27.2 to 9).

A general list of exemplary embodiments of the present invention is as follows: 1. A sheet of plastic material having ribs formed therein and a web of reduced thickness connecting the ribs, with a number of parallel continuous webs on one side of the sheet. The ribs are formed, a number of parallel continuous connecting ribs are formed at an angle to the main ribs on the other side of the sheet, and the sheet is stretched to orient and separate the main ribs so that they are almost uniform. A method for producing a network structure, characterized by forming a network by forming oriented main filaments and separating connecting ribs to form connecting filaments that connect between the main filaments.

2. In claim 1, further characterized in that the main rib and the connecting rib are formed by a first embossing roll and a second embossing roll, respectively, and the sheet of plastic is hot advanced into the mesh of the rolls. The method mentioned.

3. The method of claim 2 further comprising rotating the first and second embossing rolls at different speeds to cause web breakup.

4. The method of paragraph 3, further characterized in that the speed of the first embossing roll is between 5 and 50% of the speed of the second embossing roll.

5 The ratio of the cross-sectional area of the main rib to the connecting rib is at least 1.5:
1, further characterized in that the ratio between the height of the main ribs and the thickness of the web between the ribs is at least 3:1.

6. A method according to any of the preceding clauses, further characterized in that the sheet is stretched in two different directions so that both the main filaments and the connecting filaments are oriented.

7. The method of item 6, further characterized in that the sheet is first stretched in a direction of 15 to 9o0 with respect to the direction of the main ribs, and then stretched in a direction perpendicular to the initial stretching direction.

8. A method according to any of the preceding items, further comprising stretching the sheet in the direction of the main ribs.

9. The method of claim 8, further comprising stretching the sheet in the direction of the connecting ribs to orient the ribs in a uniaxial direction.

A method according to any of the preceding clauses, further characterized in that the 10 stretch is at least about 1.5 times.

11. A method as claimed in any of the preceding clauses, further characterized in that the main ribs are in the machine direction and the connecting ribs are at 900 degrees to the main ribs.

12. A method as claimed in any of the preceding paragraphs, further comprising, after drawing the sheet, laminating another sheet produced in the same manner and whose main filaments are at an angle with respect to the main filaments of the first sheet.

13. Any of clauses 1 to 12 further characterized in that the connecting filament connecting the primary filaments is cut to form a number of individual primary filaments such that portions of the connecting filament protrude from the primary filament. The method described above.

14 The main filaments of the first sheet are stretched in the machine direction;
13. The method of claim 12, further characterized in that the main filaments of the second sheet extend perpendicular to the machine.

15 The laminate of the first and second sheets is joined to a third sheet produced in the same manner, with the main filaments of the first, second and third sheets being aligned at an angle of about 60° to each other. 13. The method according to paragraph 12, further characterized in that:

16 The laminate of the first and second sheets is joined to a third and fourth sheet made in the same manner, with the major filaments of each sheet being approximately 45° from the direction of the major filaments of any other sheet. 13. The method of claim 12, further characterized in that the method is arranged at an angle of .

Items 1-12, further characterized in that the primary ribs are in the machine direction and that the sheet is separated into a number of stops in the machine direction, each having two or more primary filaments connected by a connecting filament. Any of the methods mentioned above.

18. The method of claim 17, further comprising fibrillating the strip, cutting some of the interlocking filaments, and forming the fibrillated strip into a multifilament yarn.

19. The method of claim 17, further comprising cutting the strip into fibers of stable fiber length.

20. A mesh manufactured by the method according to any one of Items 1 to 12.

21 Yarn produced by the method of paragraph 17.

22 Stable fiber produced by the method of item 19.

[Brief explanation of drawings]

FIG. 1 is an illustrative perspective view of an apparatus for embossing ribs on both sides of a sheet of plastic material proceeding in accordance with the principles of the present invention. FIG. 2 is an enlarged view of a portion of the embossed sheet shown in FIG. FIG. 3 is an enlarged perspective view of a portion of an embossed sheet having main ribs that are relatively spaced apart and have relatively deep grooves therebetween and connecting ribs that are closely spaced and have relatively shallow grooves therebetween; . FIG. 4 is an enlarged perspective view of a portion of another embossed sheet having main ribs that are relatively closely spaced and have shallow grooves therebetween and connecting ribs that are relatively widely spaced and have relatively deep grooves therebetween; It is a diagram. FIG. 5 is an enlarged perspective view of a portion of the upper portion of the network structure obtained by bidirectionally stretching and orienting the embossed sheet shown in FIG. 2; 6 is an enlarged perspective view of the bottom (back surface) of the mesh structure shown in FIG. 5. FIG. FIG. 7 shows an apparatus similar to that shown in FIG. 1 for embossing ribs on both sides of a advancing sheet, but used in a modified manner to form discontinuous interlocking ribs running in the machine direction. FIG. FIG. 8 is an enlarged perspective view illustrating the discontinuity of the connecting ribs on the side of the connecting ribs of the seat shown in FIG. 7; 9 is an enlarged perspective view of a portion of the embossed sheet shown in FIG. 8; FIG. FIG. 10 is an illustrative perspective view of another apparatus for embossing continuous main ribs running in the machine direction on one side of a sheet and discontinuous connecting ribs on the other side of the sheet. FIG. 11 shows one side of a network structure made by stretching the sheets shown in FIGS. 7, 8 and 9 in two directions. FIG. 12 shows another side of the network structure of FIG. 11. FIG. 13 is a plan view illustrating a portion of a network having main filaments in the machine direction and connecting filaments in the cross-machine direction. FIG. 14 is a plan view of a portion of a network structure having main filaments in the cross-machine direction and connecting filaments in the machine direction. FIG. 15 is a plan view illustrating a portion of a network having main filaments formed at an angle to the machine direction and connecting filaments formed in the machine direction. FIG. 16 is a plan view illustrating a portion of a network having main filaments formed at an angle to the machine direction and connecting filaments formed perpendicular to the main filaments. FIG. 17 is a perspective view illustrating an apparatus for manufacturing multilayer textile fabric structures in accordance with the principles of the subject invention. FIG. 18 is a perspective view illustrating another apparatus for manufacturing multilayer fabric structures in accordance with the principles of the present invention. Figure 19 consists of three layers, one layer with the main filament formed perpendicular to the machine, and two other layers with the main filament formed at equal and opposite angles to the main filament. Cloth foil in 3 axial directions 1
FIG. 3 is a plan view showing the portion. Figure 20 shows a two-layer diagonal structure made by joining two networks with main filaments oriented at equal angles to the machine direction and preferably, but not necessarily, perpendicular to each other. Cloth bag 1
FIG. 3 is a plan view showing the portion. FIG. 21 shows one of four layers of isotropic fabric foil made by joining together the two layers shown in FIG. 15 and the two layers shown in FIG. 18 in the desired order. FIG. 3 is a plan view showing the portion. FIG. 22 is a perspective view illustrating an apparatus for reinforcing paper, foil, nonwoven fabric, or film by using a mesh core made in accordance with the principles of the present invention. FIG. 23 shows an apparatus for forming a network into yarn. FIG. 24 is an enlarged view of the leash rod of FIG. 23 used to separate or tear the mesh into strips. FIG. 25 is an enlarged plan view of a portion of the strip before fibrillation. FIG. 26 is an enlarged plan view of the I-IJ tube of FIG. 25 after fibrillation illustrating the cut connecting filaments. FIG. 27 is an illustration of a section of air jet interlaced multifilament yarn with protruding side threads. FIG. 28 is an illustration of a section of bulked and entangled multifilament yarn. In these drawings, 23 in FIG. 2 is the main rib,
28 is a connecting rib; in FIG. 5, 53 is a main filament formed from the main rib, and 54 is a connecting rib formed from the connecting rib.

Claims (1)

Claims: 1. Forming a sheet of thermoplastic material with a web of reduced thickness connecting the ribs thereof between the knobs, and opening the sheet into a section of seven webs. A method of manufacturing a network structure in which a number of parallel continuous main ribs are formed on one side of the sheet; and a number of continuous ribs formed at an angle with respect to the main ribs on the other side. forming a series of parallel connecting ribs, the ratio of the cross-sectional area of the main ribs to the cross-sectional area of the connecting ribs being at least 1.5:1; stretching the sheet to orient and separate the main ribs; and converting the connecting ribs into substantially uniformly oriented main filaments, separating the connecting ribs and converting them into connecting filaments to form a network structure.