MXPA99006202A - Nonwoven process and apparatus - Google Patents

Abstract

Improved equipment and method for spinning filaments for nonwovens using an integral spinbank including one or more spinplates producing filament bundles separated by one or more central conduits for quench air. Embodiments include high velocity quench air driven into the central conduit or quench air blown or drawn in from outside the filaments into the central conduit. Means may also be provided for removal of undesired waxes and/or other condensates through a central exhaust removal using the central conduit. As quench air velocity is increased through the central conduit, the streams tend to improve total quench flow by deflecting opposing flows into a uniform stream. Other variations include division of quench air into flow zones that may be independently controlled and varying the angle of quench air flow and/or the spinplates to maintain separation distance between quench air and filament bundles.

Description

PROCESS AND APPARATUS FOR NON-TISSUE This invention claims priority of the provisional application of the United States of America No. 60 / 034,932 filed on December 30, 1996.

BACKGROUND OF THE INVENTION The non-woven fabrics and their manufacture have been the object of an extensive development that results in a wide variety of materials for numerous applications. For example, lightweight, open-weighted nonwovens are used in personal care articles such as disposable diapers such as lining fabrics that provide contact with dry skin, but which readily transmit fluids to skin. more absorbent materials which may also be non-woven of a different composition and / or structure. Heavier-weight nonwovens can be designed with pore structures that make them suitable for filtration, absorbent and barrier applications such as wrappers for articles to be sterilized, cleaners or protective garments for medical uses veterinary or industrial. Non-woven weights of even heavier weight have been developed for recreational, agricultural construction uses. These are but a few of the practically limited examples of the types of non-wovens and their uses that will be known to those experts in the art who will also recognize that the new nonwovens and their use are constantly being identified. Different ways and equipment have also been developed to manufacture fabrics having desired structures and compositions suitable for these uses. Examples of such processes include spin bonding, melt blowing, carding and others which will be described in greater detail below. The present invention has a general applicability to the equipment and processes generally of the spun bonding type as would be apparent to one skilled in the art.

Spunbond processes generally require large amounts of a fluid such as air that is used to cool the melted filaments and to pull down the filaments for increased strength. This fluid not only represents a cost, but must also be carefully controlled to avoid deleterious effects on the filaments and the resulting non-woven fabric. Even though many advances have been made in the co-bonding processes and in the equipment, the objects sought still are fabric uniformity, strength, touch properties and appearance with greater efficiency and improved.

SYNTHESIS OF THE INVENTION The present invention is directed to an improved process and apparatus for forming spunbonded nonwovens. The process and the apparatus combine multiple spunbonded plates into a single bank or divide a multiple component spun plate with a central fluid conduit. The capacity of multiple banks is obtained with a more efficient and effective use of the fluid (usually air) for cooling and pulling and better control of the fluid resulting in improved properties of the fabric. In several embodiments the center duct can be used to blow the cooling fluid or it can expel fluid that is applied from opposite sides of the curtain bundle of filaments. In all cases, the combined spinning plates operate with greater efficiency and better control of fiber and fabric properties. In the advantageous embodiments, the spinning plates can be placed at an angle with respect to the vertical and each other and increase the natural convex flow. Also, the fluid velocity in the central conduit can be selected to provide improved performance. The results include the acceleration and cooling and the reduction of the turbulence effect which extend the range of operating conditions and allow increased productivity as well as the ability to operate very high numbers of spinner organ holes producing finer fibers at production rates high Another advantage is more uniform cooling through the bundle.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a schematic illustration of an embodiment of a multi-spinning plate arrangement and process of the present invention showing a central duct used for ejection and means for removing waxes and the like from the spinning process.

Figure 2 is a schematic illustration of a different embodiment of a multiple spinning plate arrangement and of a process of the present invention showing a central duct used for air supply cooling to two zones.

Figure 3 is a schematic side view of an additional embodiment of the type shown in Figure 2 illustrating the operation in the suction mode.

Figure 4 is a perspective view of the type of embodiment shown in Figure 3.

Figure 5 is a view of an arrangement like that of Figure 4 except that there are cooling air supply zones and the cooling air is provided at a small angle to the line orthogonal to the central duct.

Figure 6 is a schematic illustration of a divided package configuration with the air flow in opposite directions along the center line of the central duct.

Figure 7 is a view like that of Figure 5 showing yet another embodiment providing additional flexibility to form woven structures compositions.

Figure 8 is a view like that of Figure 7 with the modified fiber outlet to provide fiber folding and the inherent advantages.

DETAILED DESCRIPTION OF THE INVENTION DEFINITIONS As used herein, the term "non-woven or nonwoven fabric" means a fabric having a fiber structure are individual threads which are interlocked, but not in a regular or densifiable manner as in a woven fabric. Fabrics or non-woven fabrics have been formed from many processes such as, for example, meltblowing processes, spinning processes and bonded carded fabric processes: The basis weight of non-woven fabrics is usually expressed in ounces of material per square yard (osy) oe grams per square meter (gsm) and the diameters of useful fibers are usually expressed in microns (note that to convert ounces per square yard to grams per square meter, multiply ounces per yard square by 33.91). As used herein, the term "microfibers" means fibers of small diameter having an average diameter of no more than about 75 microns, for example, having an average diameter of about 5 microns to about 50 microns, more particularly, The microfibers can have an average diameter of from about 10 microns to about 2 microns. Another frequently used expression of fiber diameter is denier, which is defined as grams per 9000 meter of a fiber and can be calculated as fiber diameter in square meters, multiplied by the density in grams / cc, multiplied by 0.00707. A lower denier indicates a finer fibr and a higher denier indicates a heavier or thicker fiber. For example, the diameter of a polypropylene fiber given as 15 microns can be converted to denier by placing the square, multiplying the result by 0.89 g / cc multiplying by .00707. Therefore, a polypropylene fiber of 15 microns has a denier of about 1.42 (152 x 0.89 .00707 = 1.415). Outside the United States of America, the unit of measurement is most commonly the "tex" which is defined as the grams per kilometer of fiber. The tex can be calculated as denier / 9.

As used herein the term "spunbonded fibers" refers to fibers of small diameter which are formed by extruding the thermoplastic material with filaments from a plurality of capillaries of a spinner organ usually circular and thin with the diameter of the filaments. extruded filaments then being rapidly reduced as indicated, for example, in US Pat. Nos. 4,340,563 issued to Appel et al., 3,692,618 issued to Dorschner et al.; 3,802,817 granted Matsuki et al., US Pat. Nos. 3,338,992 and 3,341,394 issued to Kinney, US Pat. No. 3,502,763 issued to Hartman, United States Patent No. 3,502,358 issued to the United States of America, to Levy and U.S. Patent No. 3,542,615 to Dobo and others, each of which is hereby incorporated by reference in its entirety. Spunbonded fibers are generally non-sticky when they are deposited on a collecting surface. The spunbonded fibers are cooled and are generally continuous and have larger average diameters of about 7 microns, more particularly between about 10 and 20 microns.

As used herein, the term "polymer generally includes but is not limited to homopolymers, copolymers such as block, graft, random, and alternating, terpolymers, etc., and mixtures thereof modifications. Furthermore, unless specifically limited otherwise, the term "polymer" includes any possible geometric configuration of the material.This configurations include but are not limited to isotactic, syndiotactic and random symmetry.

As used herein the term "monocomponent fiber" refers to a fiber formed from one or more extruders using only one polymer. This is not to exclude fibers formed from a polymer to which small amounts of color additives have been added, antistatic properties, lubrication, hydrophilicity, etc. These additives, for example, titanium dioxide for color are generally present in an amount of less than 5 percent by weight and more typically of about 2 percent by weight.

As used herein, the term "conjugated fibers" refers to fibers which have been formed from at least extruded polymers of separate extruders but which have been spun together to form a fiber. Conjugated fibers are also sometimes referred to as multicomponent or bicomponent fibers. The polymers are usually different from one another even though the conjugated fibers can be monocomponent fibers. The polymers are arranged in different zones placed essentially constant across the cross section of the conjugate fibers and which extend continuously along the length of the conjugate fibers. The configuration of such conjugated fiber can be, for example, a sheath / core arrangement where one polymer is surrounded by another or can be a side-by-side arrangement or arrangement of "islands in the sea". Conjugated fibers are taught in U.S. Patent No. 5,108.82 issued to Kaneko et al., U.S. Patent No. 5,336,552 to Strack et al., And United States Patent No. 5,336,552. America No. 5,382,400 granted to Pike others, each of which is incorporated here in its total by reference. For the two component fibers, the polymers may be present in proportions of 75/25, 50/50, 25/75 or any other desired proportions.

As used herein, the term "biconstituent fibers" refers to fibers which have been formed from at least two extruded polymers from the same extruder as a mixture. The term "mixture" is as defined below. The biconstituent fibers do not have the various polymer components arranged in different zones placed relatively constant across the cross-sectional area of the fiber. The various polymers are usually not continuous along the entire length of the fiber, instead of this, it usually forms fibrils or protofibrils which start and end at random. Biconstituent fibers are sometimes also referred to as multi-constituent fibers. Fibers of this general type are discussed in, for example, U.S. Patent No. 5,108,827 to Gessner. Bicomponent and biconstituent fibers are also discussed in the text Polymer and Compound Mixtures by Joh A. Manson and Leslie H. Sperling, copyright 1976 by Plenum Press, a division of Plenum Publishing Corporation of New York, IBSN 0-306-30831-2, at pages 273 to 277.

As used herein, the term "mixture" as applied to the polymers means a mixture of two or more polymers while the term "alloy" means a subclass of mixtures wherein the components are immiscible but have been compatibilized. "Miscibility" and "immiscibility" are defined as mixtures that have positive negative values, respectively, for the free energy of mixing.In addition, "compatibilization" is defined as the process to modify the interfacial properties of a mixed polymer in order to to make an alloy.

As used herein, the term "thermal dot attachment" involves passing a fabric or fabric of fibers that are to be joined between a heated calender roll and an anvil roll. The calendering roll is usually, even if not always, patterned in some way so that the entire tel is not attached across its entire surface. As a result of this, several patterns have been developed for the calendering rolls for aesthetic as well as functional reasons. An example of a pattern has points and is the Hansen Pennings or "H &P" pattern with around a 30% co-area around 200 pounds / square inch as taught in the United States Patent No. 3,855,046 awarded to Hansen and Pennings, which is incorporated here in its total by reference. The H &P pattern has a square point or bolt union area where each bolt has a side dimension of 0.038 inches (0.965 mm), a spacing of 0.070 inch (1,778 mm) between the bolts, and a joint depth of 0.02 inches (0.584 mm). The resulting pattern has a bound area of about 29.5%. Another typical point union pattern is the Hansen and expanded Pennings junction pattern or "EHP" which produces a 15% joint area with a square bolt having a side dimension of 0.037 inches (0.94 mm), a bolt spacing of 0.097 inches (2.464 mm) and a depth of 0.03 inches (0.991 mm). Another typical point union pattern designated "714" has square bolt-joint areas where each bolt has a side dimension of 0.023 inches, a gap of 0.062 inches (1.575 mm) between the bolts and a 0.033-inch joint depth. (0.838 mm). The resulting pattern has a bound area of about 15%. Yet another common pattern is the star-C pattern which has a united area of about 16.9%. The star-C pattern has a bar in the transverse direction or a "corduroy" pattern interrupted by shooting stars.Other common patterns include a diamond pattern with slightly off-centered and repetitive diamonds and an embroidery pattern of fabric looking like the name Suggests, like a window grid Typically, the percent bond area varies from about 10% to about 30% of the area of the web-laminated fabric.As is known in art, point bonding holds The layers of the laminate together thus impart the integrity of each individual layer by joining the filaments and / or the fibers within each layer.

As used herein, the term "personal care product" means diapers, training pants, absorbent pants, adult incontinence products, and women's hygiene products.

As used herein, the term "bunch" used co with respect to the fibers or filaments refers to a collection of fibers or filaments in a group or arrangement which may take the form of a generally linear curtain or a rectangular grouping or other configuration such as tow or similar.

TEST METHODS Fiber Tenacity Test: fiber tenacity is determined by dividing the break load in grams per denier and is a measure of the strength of a fiber per area in cross section. Tenacity is an important measure of the adequacy of a fiber for many applications subjected to stress and / or resistance requirements. Burst loading is determined in accordance with ASTM D3822 (Modified) using a Syntech Voltage Tester available from Syntech, Inc., of Stoughton, Massachusetts, and the maximum strength of the fiber is measured when subjected to a rate of constant extension. A fiber specimen inches inches long is tied inside the tester leaving a one inch gap between the lugs. The handles are separated at a rate of 12 inches per minute and the load or maximum force expressed in grams at the breaking point was measured as the breaking load.

DESCRIPTION It is also possible to have other materials mixed with the polymer used to produce a non-woven according to this invention as fluorocarbon chemicals to improve chemical repellency which may be, for example, any of those taught in the U.S. patent. of America No. 5,178,931, the fire retardants for an increased resistance to fire and / or pigments to give each layer the same or different colors. The retarders d were and the pigments for the thermoplastic polymers bonded with spinning and meltblowing are known in the art and are internal additives. A pigment, if used, is generally present in an amount of less than 5 percent by weight of the layer while the other materials may be present in a cumulative amount of less than 25 percent by weight.

The fabric of this invention can be used in multilayer lamination. An example of a multi-layer laminate is an embodiment wherein some of the layers are spun bonded and some are meltblown such as laminate - spunbonded / meltblown / spunbonded (SMS) as described in US Pat. United States patents Nos. 4,041,203 granted to Brock et al., 5,169.70 granted to Collier et al., and 4,374,888 granted to Bornslaeger. Such lamination can be done by sequentially depositing on a forming band first a layer of spunbonded fabric, then a layer of melt blown fabric and finally another spun bonded layer and then joining the laminate in a manner as described below. . Alternatively, the fabric layers can be made individually, collected in rolls, combined in a separate bonding step. Such fabrics usually have a basis weight of from about 0.1 to 12 ounces per square yard (6 to 400 grams per square meter) or more particularly from about 0.75 to about 3 ounces per square yard. * Non-woven fabrics bonded with yarn are generally joined in some way as they are produced in order to give them sufficient structural integrity to withstand the rigors of further processing to a finished product. Bonding can be achieved in a number of ways such as hydroentanglement, perforation, ultrasonic bonding, adhesive bonding, seaming, bonding through air, and thermal bonding.

Referring to Figure 1, an embodiment of the invention will be described. As shown, the spinning packs 10 can be but are not necessarily identical, they are separated by a duct 12. As those skilled in the art will appreciate, the spin packs 10 can be fed to the same or different polymer compositions. In the latter case, a layered structure can be obtained with the properties of the respective layers varying depending on the polymer and / or the additives used in each. The bundles of fibers 14 and 16 leave the spinning packages in the cooling zone 18. Advantageously, the lower surface 20 of the spinning packages 10 forms an angle, OI, with the horizontal or otherwise with respect to a line drawn orthogonally to the central line of the central conduit to help direct the hot ejection fluid (air) which has passed through the bunches of fibers 14 and 16 to the duct 12. This angle may be, for example, within range from a slight angle of around Io to about 25 ° and especially within the range of from about Io to about 10 °. Similarly, the sides 22 and 24 of the cooling zone are advantageously formed at a slight angle of about Io to about 20 °, advantageously from about Io to about 10 °, inwards to help direct the air and to maintain a constant relative distance between the cooling air and the bundle of fiber for more uniform cooling. The cooling air is admitted from both sides of the ducts 26 and 28 in a direction parallel to or almost parallel to the spin plate even when the flow pattern is shown only on one side for clarity. As shown, a part of the cooling air is expelled upwards through the duct 12 while the rest is pulled to the fiber pulling unit together with the bunches of fibers. The temperature of the cooling air is controlled to obtain the desired fiber properties. For example, for the formation of cloth bound with polypropylene yarn, the cooling air is advantageously in the range of from about 5 ° C to about 25 ° C. As shown, the arrangement of the invention provides the advantages of producing multiple banks in a single configuration and allows the use of a single central fluid flow for both bunches. If desired, a fan aid can be provided to assist in the removal of smoke-laden air through the top. Also depending on the need to increase the flow stability, it may be desirable to provide an equalization groove between the spinning plate surface and the cooling duct, for example, from a width of about 1 inch to about 3 inches. .

Figure 1 also illustrates in schematic form advantageous means for ensuring that residues such as condensed oil or wax flow out of the spinning system which is of particular use in some applications of higher and moderate hole densities. As shown, the spin packs 10 are separated by the duct 12 which is connected to the duct 30 which is angled downwardly to pull any condensates. Any or both ducts 12 and 30 can be insulated as to minimize the heat loss in the yarn packages. The duct can be rectangular coming out of the co-jointed machine and reformed to a circle or the like in the ring 32. Euct 30 leads to the condenser 34 which can be cooled by cooling water or the like through the pipes 36 and 38 The air without wax is then removed as by means of a fan through conduit 39. If required, means conventionally used for such purposes can be used to pull the condensates (waxes) out of the bonding system with yarn and through of the capacitor. For very high orifice densities, other means for the expulsion of fumes may be required.

Figure 2 is a similar representation of a second embodiment where the cooling area is placed in the middle and the exhaust flows out through the sides. As shown, the spinning packs 100 are arranged on opposite sides of the duct or duct 112. The cooling area can be supplied down between the rotation plate 100 in a single stream (or zone), pressurizing the air gap between the filament bundles 120 and 122 to allow the air to be pulled out through a bunch of filament. In this embodiment the duct 112 can advantageously be divided by the divider 114 in the supply zones 116 and 118 which direct the cooling fluid through the bundles 120 and 122 respectively. At densities of very high orifices and upper central airflow any interaction of flow from the sides is minimized. The perforated plates or grids 124 and 126 may be provided to control fluid flow and increase uniformity. If used, these plates can advantageously have a graduated open area to further control the fluid flow. In this embodiment the discharge ducts of hum 128 and 130 are placed on opposite sides of the bundles 120 and 122 to receive a portion of cooling fluid. The remainder of the cooling fluid is pulled into the filament bundles and carried or carried by them to the fiber jaw area 148 in much the same manner as in Fig. 1. This arrangement provides the advantages of the arrangement of Fig. 1. and in addition it can allow the control of the cooling fluid applied to the separated bunches. An added advantage is that any smoke can be kept warm until it reaches a desired place to deposit the oils.

Figure 3 illustrates an embodiment operating in a suction mode in which the vertical air stream pulled through the conduit 212 draws the cooling air from the surroundings through the fiber bundles 220, 22 from the spin pack 200 the entrance of the pulled unit 230. In this arrangement the holes increased by inch of matrix width have been demonstrated as well as the superior production and the best stability of the spinning line. For example, the spinning of at least 320 holes by in. is possible with reduced cooling air requirements and reduced process control equipment requirements other variations will be evident such as using a split pull unit to maintain the separation of the curtains to place them down in a layered construction of the same or different fibers. Figure 4 is an arrangement perspective view of Figure 3. Figure 5 shows an embodiment with cooling air zones 441-444., 446-449 plus escape 440, 445 in the orientation to an angle "ß" to the horizonta or otherwise with respect to a line drawn orthogonally to the central line of the central conduit. This angle can be within the range of from a slight angle of around Io about 25 °, advantageously from about Io to about 15 °, for example, and especially between about Io about 5o and can be obtained by, for example, the spinning plate pivots or by shaping the surface of the spinning plac. Although the spacing between the hilad packs can be varied, it is contemplated that most of the operations will be spaced in the range of from a light spacing of about less than 1 inch to about 20 inches and especially within the range of about less than 1 inch to about 4. inches, advantageously up to about 1.5 inches. Other parameters of the array will generally be within conventional ranges depending on the configuration of the equipment in general and the desired operating conditions. For example, the vertical cooling flow air from about 100 feet / minute to about 1000 feet / minute, for example, provides sufficient suction for a desirable level of heat transfer.

Figure 6 illustrates in schematic form or arrangement which can be used with multiple spinning plates with a single spinning plate having a part blocked or left open for the passage of the fluid where the fibers are not formed. The spinning plate areas 710, 712 send the filament bundles 714 and 716 separated by a central duct 718. The nozzle 720 connected to the cooling fluid source directs the cooling upwards and / or downwards of the openings 722 and 724. The cooling air can be sucked and / or blown from the sides 726 and 728 through the bundles 714 and 716 as indicated. In this way, an economic system can particularly be achieved by modifying an existing spinning plate. Also, the relative flow in any direction can be easily controlled by selecting the design parameters of the nozzle 720 and the openings 722 and 724.

Figure 7 illustrates an embodiment like that of Figure 5 except that the central cooling means and the fiber pulling means are modified to add flexibility in the formation of different composition structures. In this case, the smoke ejector boxes 810 and 812 receive a separate fluid from the central cooling box 814 as well as from the lateral cooling boxes 816, 818, 820, 822, 824 and 826. The divided split pack 828 includes the packages 830 and 832 which can receive the same or different polymers from the same different separate sources and form separate filament bundles 834 and 836. These bundles 834 and 836 are directed to the divided pulling unit 838 having a java groove. 840 and 842 for each bunch. From the separate jalad grooves the filaments can be sequentially directed on the forming surface 844 either as a woven fabric 850 d an accumulation of layers of the same type of filaments or, alternatively, different types of filaments can be deposited in sequence by choosing different Yarn compositions for spinning packs 830 and 832 differing spinning conditions which can produce different fiber properties such as crimping or toughness, for example. As shown in Figure 8, a mixed filament fabric can be formed by directing the jalad unit 846 outputs 852 and 854 so that the exiting filaments s mix before the deposit on the forming surface 860. All the options described with with respect to the layers d filaments can be used to form mixtures of filaments. As will also be apparent to those skilled in the art, different treatments, additives and filament forms can also be used in separate bunches. As will be evident, more than two bunches can be formed which can each be the same or a different one in any of the ways described.

Conventional construction materials may be used, and other conventional spinning plates may be employed in the arrangement of the invention. Also, the invention is applicable to multi-component spinning and biconstituent bonding systems and includes any of the processable polymers to form spunbonded fabrics. Any of the known bonding steps for spin-bonded fabrics such as thermal bonding adhesive, hydroentanglement perforation and the like can be used in conjunction with the improvement of the present invention. In each case, the invention results in superior efficiency and better control of the fibers and tissue properties.

EXAMPLES This invention will be described with reference to the specific embodiments thereof. However, as will be recognized by those skilled in the art, these examples are merely illustrative and the invention is not limited thereto. The invention is defined by the appended claims herein and any equivalents as fall within the scope of the subject matter herein claimed.

Ei emplo 1 The equipment was assembled as shown generally in Figure 4. In this case the spinning plates were designed with rows of holes of 0.4 mm in diameter, 320 holes per inch in width of the spinning plate and two rows were blocked for each three. open rows for an operating condition of 192 holes per inch. The polymer used was polypropylene (Shell E5D47 of Union Carbide with a melt flow rate of 34 and including 2% by weight of Ti02 filler.) The extruder was operated with seven temperature zones ranging from about 350 ° F to about 460 ° F at the outlet The production was a rate of around 0.5 grams per hole per minute (ghm) and the pull unit operated at around a multiple pressure of 5 pounds per square inch. at a line speed of about 510 feet per minute (fpm) providing a basis weight of about 0.72 ounces per square yard (osy with a fiber denier of about 1.5.This was woven together with a woven pattern of wire using co-steel rollers at temperatures of about 305 ° F for the patterned roller and around 300 ° F for the anvil roller For this example the cooling zones 1-4 vary in air velocity from about d e 170 feet per minute (fpm), 155 feet per minute, 145 feet per minute, at 140 feet per minute, and cooling zones 5-8 varied in air velocity from about 180 feet per minute, 160 feet per minute, 145 feet per minute , at 140 feet per minute using the cooling air at a fixed point temperature of about 55 ° F. This fixed point was used through the examples. Com will be recognized by those skilled in the art, due to the high melting temperature, the exact temperature of the cooling air is not critical and involves factors such as cost and cooling capacity. The air flow through the central duct was at a rate of 30 feet per minute of air at a temperature around the same temperature. The ejection was at a flow rate of 10 feet per minute.

Example 2 Example 1 was repeated with the spinning plates having only one row locked by 3 open rows providing for 240 holes per inch of width of the machine. In this case, the cooling boxes were each oriented at an angle of about 4o of the horizontal co shown in Figure 5. The production was around d 0.46 ghm at about 7 pounds per square inch producing fibers from around of 1.68 dpf. In this case, cooling zones 1-4 and 5-8 were operated at air flow rates varying identically from about 180 feet per minute, 18 feet per minute, 160 feet per minute, to 150 feet per minute, and Central air was at a speed of around 400 feet per minute.

Example 3 Example 2 was repeated without blocking the spinneret for a hole density of 320 holes per inch. E union pattern was varied to a Hansen Penning extended pattern of 0.037 inch (0.94 mm) squares per side 0.097 inch (2,464 mm) bolt spacing for a percent united area of about 15. The cooling d zones 1-4 were operated at air speeds d around 420 feet per minute, 195 feet per minute, 155 feet per minute, at 147 per minute and zones 5-8 at around 52 feet per minute, 190 feet per minute, 160 feet per minute, at 14 feet per minute, and the central air flow was around 507 feet per minute. The angle of the cooling boxes was changed from 4o to 3o of the horizontal and no escape was provided. In this case we made a fabric of about 0.8 ounce per square yard of a fiber denier of about 2.1. In this case, it was found that within the ranges tested, the improved results tended to be obtained with upper air flows from the sides with the lowest useful central air flows. Especially for these higher orifice densitiesLateral air flows of at least about 500 feet per minute are believed to be advantageous. As will be appreciated by those skilled in the art, as the air flow is increased, a point will be reached where the filament cut occurs. In all the cases of the invention, it was possible to exceed the conventional maximum orifice densities of about 184 holes per inch making possible finer fibers while maintaining desirable strength properties.The results of fiber tenacity on the fibers made according to the invention are generally in the range of results obtained with conventional processes and equipment. For example, the fibers produced as in the previous examples have toughness results in the range d from about 1.56 grams per denier to about 2.3 grams per denier compared to the conventional similar composition fiber results of about 1.5 grams per denier. at around 4.5 grams per denier. Therefore, the strong fibers were obtained according to the invention even at those high orifice densities.

Therefore, according to the invention, a bonding process with improved spinning and an equip and the resulting treated non-wovens and the products incorporating them providing the above-described benefits have been provided even though the invention has been illustrated by the specific incorporations. This is not limited by these and it tries to cover all the equivalents that fall within the broad scope of the claims.

Claims (25)

R E I V I N D I C A C I O N S

1. An apparatus for forming continuous filaments to form non-woven comprising: to . one or more sources of filament forming material in a spinnable condition; b. one or more spinning plates, each adapted to receive said filament forming material. c. means for directing said filament forming material through the spinning plates forming a plurality of filament bundles; d. a central conduit between said bundles of filament; Y e. means for directing a fluid through the central duct to contact said filaments; the improvement characterized in that said means a-e comprises an integral spinning bank.

2. The apparatus as claimed in clause 1, characterized in that at least one of said spinning plates is oriented at an angle with respect to the central dich.

3. The apparatus as claimed in clause 2, characterized in that said angle is within a range of from about Io to about 25 ° with respect to a line drawn orthogonally to the center line of said central duct.

4. The apparatus as claimed in clause 1, characterized in that the fluid directing means provide fluid at a speed in the range d at least about 500 feet per minute in the direction d said filament forming material and medium to aspirate the fluid through the filaments together with and directed fluid.

5. The apparatus as claimed in clause 2, characterized in that said fluid steering means provide fluid at a speed within the range d of at least about 500 feet per minute in the direction of said filament forming material and Means is provided for sucking the fluid through the filaments together with said directed fluid.

6. The apparatus as claimed in clause 4, characterized in that said directed fluid and dich aspirated fluid comprise air.

7. The apparatus as claimed in clause 5, characterized in that said directed fluid and dich fluid aspirated comprise air.

8. The apparatus as claimed in clause 1, characterized in that said fluid steering means comprises means for directing the fluid through said filaments from the opposite sides inside the central conduit.

9. The apparatus as claimed in clause 8, characterized in that said opposite fluid direction means suck the additional fluid through the central conduct.

10. The apparatus as claimed in clause 9, characterized in that said fluid comprises air.

11. The apparatus as claimed in clause 8, characterized in that said steering means comprise a plurality of zones adapted to provide fluid at different speeds.

12. The apparatus as claimed in clause 9, characterized in that said steering means comprise a plurality of zones adapted to provide fluid at different speeds.

13. The apparatus as claimed in clause 4, characterized in that it includes expulsion means comprising means for removing condensates and residues.

14. The apparatus as claimed in clause 5, characterized in that the means of escape comprises means for the removal of condensates and residues.

15. The apparatus as claimed in clause 11, characterized in that said direction means on the sides of said filaments are off-centered with respect to each other in the direction of said central conduit fluid flow.

16. The apparatus as claimed in clause 12, characterized in that said directioning means on the sides of said filaments are off-centered with respect to each other in the direction of said central conduit fluid flow.

17. The apparatus as claimed in clause 8, characterized in that means are provided for reducing the variation in the distance between said fluid direction means and said bundles of filaments.

18. The apparatus as claimed in clause 2, characterized in that angle is obtained through d the pivoting means associated with said spinning plates.

19. The apparatus as claimed in clause 2, characterized in that angle is obtained by the form of said spinning plate.

- 20. A continuous filament forming process for forming non-woven fabrics comprising the steps of: to. providing a material for filament form in a spinnable condition; b. extruding said filament forming material into filaments through one or more of the spinning plates in an integral spinning bank forming a plurality of filament bundles; c. separating said bundles by means of a central conduct; d. directing the fluid through said central conduct in the direction of said filament extrusion containing said filaments; Y and. join those filaments.

21. The filaments produced by the process of clause 20.

22. The apparatus as claimed in clause 1, further characterized in that it includes two pull zones comprising a plurality of grooves, each of which receives at least one bundle of fiber and pulls such fibers and directs the pulling fibers to one another. forming surface.

23. The apposition as claimed in clause 22, characterized in that several pull slots are placed in an angle to cause the mixing of said bundles of fiber at or before reaching the forming surface.

24. The process as claimed in clause 20, characterized in that it includes the step of pulling said bundles separately prior to joining said filaments.

25. The process as claimed in clause 24, characterized in that it includes the additional step of mixing said previously pulled bundles to join said filaments. SUMMARY The improved equipment and the method for spinning d yarns for non-woven fabrics using an integral yarn bank including one or more spinning plates producing bunches of filaments separated by one or more center conduits for air tuning. Improvements include the tempered air at high speed handled in the central circuit and the tempered air blown or pulled in from the outside of the filaments in the central conduit. The means can also be provided by the removal of the unwanted waxes and / or other condensates through the removal of the central exhaust using the central duct. As the tempered air velocity is increased through the central conduit, the currents tend to improve the total tempering flow by deflecting the opposite flows in a uniform stream. Other variations include the division of the tempered air into flow zones which can be independently controlled and by varying the flow angle of the tempered air and / or spinning plates to maintain the separation distance between the tempered air and the filament bundles.