TWI513870B - Production method of double embossed nonwoven fabric - Google Patents

Description

Method for manufacturing double-sided embossed non-woven fabric

The present invention relates to a method of making a double-sided embossed nonwoven fabric, and more particularly to a method of adsorbing a layer of semi-molten fibers on a mesh body assembly to form a double-sided embossed nonwoven fabric.

U.S. Patent No. 5,555,801 discloses a method of making a double embossed fiber fabric. This manufacturing method is used to overcome the tendency of undue damage or cracking of the fabric during embossing. The method of manufacture of the patent includes conveying a fabric through a nip between an embossing roll and a press roll. The press roll has a hard, smooth surface to create a double sided embossing effect on the fabric. However, this method has a drawback in that when the material of the embossed portion of the fiber fabric is transported into contact with the pressure roller and the embossing roller, the material of the portion is heated and melted and pressed during the embossing process. Due to factors such as cooling, there is a problem of hardening and shrinkage. Further, the thickness of the embossed portion of the fiber fabric becomes thinner than the portion which is not embossed.

Accordingly, it is an object of the present invention to provide a method of manufacturing a double-sided embossed nonwoven fabric that overcomes the disadvantages mentioned in the foregoing prior art.

According to the present invention, there is provided a method of manufacturing a double-sided embossed nonwoven fabric, the method comprising: forming a layer of a plurality of semi-molten fibers on a mesh member disposed on an adsorption device, the mesh assembly comprising a first layer a structure, and a second layered structure disposed on the first layered structure, first The layered structure has a plurality of suction holes arranged in a first pattern, the second layer structure having a plurality of members arranged in a second pattern; and a method of adsorbing the semi-molten fibers of the layer by the adsorption device The semi-molten fiber of the layer located on the net body component is embossed so that the semi-molten fiber of the layer is drawn into the suction holes and coated with the members, thereby making the layer semi-molten fiber Formed as a non-woven fabric having a convex pattern corresponding to the second pattern of the net body assembly and a concave pattern corresponding to the first pattern of the net body assembly.

Before the present invention is described in detail, it is noted that in the following description, similar components are denoted by the same reference numerals.

1 to 3 are views showing an apparatus for carrying out a first preferred embodiment of a method of manufacturing a double-sided embossed nonwoven fabric of the present invention. The double embossed nonwoven fabric can be used as a breathable substrate for an article, such as a diaper, a filter medium, a surgical gown, or a hospital bed sheet.

The method comprises a plurality of steps of directly stacking a plurality of semi-molten fibers 50 on a mesh body assembly 4 on the adsorption device 6 (a semi-melted state in which the liquid phase and the solid phase coexist) for the mesh assembly The semi-molten fibers 50 on the fourth surface form a gas permeable layer 5, the mesh body assembly 4 includes a first layer structure 41 and a second layer structure 42, the first layer structure 41 has a mesh wall 410, and a plurality An air intake hole 411 is formed in the mesh wall 410 and arranged in a first pattern. The second layer structure 42 is disposed on the mesh wall 410 of the first layer structure 41, and the second layer structure 42 has a plurality of arrays. a second patterned member 421; and used to adsorb by the adsorption device 6 The gas permeable layer 5 formed by the semi-molten fibers 50 on the net body assembly 4 is embossed to the gas permeable layer 5 formed by the semi-molten fibers 50 to form a gas permeable layer formed by the semi-molten fibers 50. 5 is pulled into the suction holes 411 and covers a portion of the member 421 and the mesh wall 410 that is not covered by the second layered structure 42, whereby the gas permeable layer 5 formed by the semi-molten fibers 50 is formed. A non-woven fabric 7 is formed having a base portion 70 covering a region of the mesh wall 410, a first layer 71, and a second layer 72 having a plurality of recessed portions 711 extending downward from the base portion 70. And having a concave pattern corresponding to the first pattern, the second layer 72 has a plurality of convex portions 721 extending upward from the base portion 70 and having a convex pattern corresponding to the second pattern. It is worth noting that the combination of fiber and fiber is produced during the embossing process during which the semi-molten fibers 50 form the gas permeable layer 5.

In the present embodiment, the gas permeable layer 5 formed by the semi-molten fibers 50 is formed by melting the raw material 21, for example, resin pellets, wood fibers, and plastic fibers, which are extruded using an extruder 2. The raw material 21 is melted to form a melt, and then the molten material is conveyed through a fiber forming device 22 to form the semi-molten fibers 50, and then the semi-molten fibers 50 are directly discharged by the fiber forming device 22, and then the semi-molten fibers are directly directly discharged. 50 is formed by the fiber forming device 22 onto the mesh body assembly 4.

In the present embodiment, the fiber forming device 22 is a spinneret for forming spunbonded spun fibers. Alternatively, the fiber forming device 22 can be a meltblowing die for forming melt blown fibers.

Preferably, the method of the present invention further comprises a step of: forming a device by a fiber 22, during the discharge of the semi-molten fibers 50 onto the mesh assembly 4, the semi-molten fibers 50 are heated by a heater 23 to control and maintain a predetermined melt viscosity of the semi-molten fibers 50, and to promote non-woven fabrics. 7 Forming during subsequent embossing.

In the present embodiment, the members 421 are in the form of a plurality of extended ribs forming a mesh body 420 (see Fig. 3).

In the present embodiment, the adsorption device 6 is a delivery device type adsorption device comprising a suction cartridge 61 surrounded by a mesh body assembly 4. The mesh wall 410 acts as a conveyor belt that is aligned with a pair of drive wheels 62 and can be driven by drive wheels 62.

The mesh body assembly 4 can be modified to have more layer structures (not shown) or have a structure as shown in FIG. The modified mesh body assembly 4 differs from the mesh body assembly of FIG. 3 in that the member 421 of the second layered structure 42 of the modified mesh body assembly 4 is disposed on the mesh wall 410 in the form of a plurality of separate projections. .

Alternatively, the adsorption device 6 may be a roller type adsorption device (see FIG. 5) including a suction box 61 surrounded by the mesh body assembly 4 and having a cylindrical shape, and a center for mounting the mesh body assembly 4. Axis (not shown).

In a modified embodiment, the gas permeable layer 5 formed of the semi-molten fibers 50 is formed on the mesh body assembly 4 by directly stacking a plurality of unmelted fibers onto the mesh body assembly 4 to form a layer of unmelted fibers. Then, the unmelted fiber of the layer is conveyed through a heater or an oven (not shown) to form unmelted fibers in the semi-molten fiber 50.

Figure 6 is a manufacturing method for carrying out the double-sided embossed nonwoven fabric of the present invention. The device of the second preferred embodiment. The second preferred embodiment differs from the previous embodiment in that the gas permeable layer 5 formed by the semi-molten fibers 50 includes a plurality of first semi-molten fibers 501, and a plurality of second semi-molten fibers 502, the first semi-molten fibers 501 The first extruder 201 is used to melt a plurality of first resin pellets 211 to form a first melt, and then the first melt is conveyed through a spinneret 221, and the second semi-molten fibers 502 are formed. The method is to use a second extruder 202 to melt a plurality of second resin pellets 212 to form a second melt, and then deliver the second melt through a meltblowing die 222.

Figure 7 is an apparatus for carrying out the method of manufacturing the fiber fabric of the present invention. The method comprises forming a double-sided embossed nonwoven fabric 7 as in the first preferred embodiment, extruding a plastic material 80 using an extruder 81 and an extension extrusion die 82 to form a plastic film 8 (which is in a semi-melting state) State), and then the plastic film 8 is conveyed in the direction of the double-sided embossed nonwoven fabric 7 to bond the plastic film 8 to the double-sided embossed nonwoven fabric 7, and has a plurality of patterns respectively conforming to the convex pattern of the double-sided embossed nonwoven fabric And the concave pattern. Alternatively, a heater 83 is used to control the semi-molten state of the plastic film 8, and the double-sided embossed nonwoven fabric 7 is kept soft to promote the bonding of the plastic film 8 to the double-sided embossed nonwoven fabric 7. The plastic film 8 forms a gas impermeable layer.

By stacking the semi-molten fibers 50 on the mesh body assembly 4, followed by adsorption of the gas permeable layer 5 formed by the semi-molten fibers 50 and drawing the semi-molten fibers 50 into the suction holes 411 in accordance with the method of the present invention, the foregoing The shortcomings mentioned in the technology. In addition, the semi-molten fibers 50 are discharged to the net group Heating the semi-molten fibers 50 during the upper portion 4 to control the melt viscous properties of the semi-molten fibers 50 promotes the formation of the double-sided embossed nonwoven fabric 7.

However, the above is only the embodiment of the present invention, and the scope of the invention is not limited thereto, that is, the simple equivalent changes and modifications made by the scope of the invention and the description of the invention are still It is within the scope of the patent of the present invention.

2‧‧‧Extrusion machine

201‧‧‧First extruder

202‧‧‧Second extruder

21‧‧‧ molten raw materials

211‧‧‧First resin pellet

212‧‧‧Second resin pellet

22‧‧‧Fiber forming device

221‧‧‧ Spinning plate

222‧‧‧melt spray mould

23‧‧‧heater

4‧‧‧ network components

41‧‧‧First layered structure

410‧‧‧Net wall

411‧‧‧ suction holes

42‧‧‧Second layered structure

420‧‧‧ mesh body

421‧‧‧ components

5‧‧‧ gas permeable layer

50‧‧‧Semi-fused fiber

501‧‧‧First half of molten fiber

502‧‧‧second half-melted fiber

6‧‧‧Adsorption device

61‧‧‧Adsorption box

62‧‧‧Drive wheel

7‧‧‧Double-sided embossed non-woven fabric

70‧‧‧ base

71‧‧‧ first floor

711‧‧‧Depression

72‧‧‧ second floor

721‧‧‧ convex

8‧‧‧Plastic diaphragm

80‧‧‧Plastic materials

81‧‧‧Extrusion machine

82‧‧‧Extended extrusion die

83‧‧‧heater

1 is a cross-sectional view showing a first preferred embodiment of a method for fabricating a double-sided embossed nonwoven fabric of the present invention; and FIG. 2 is a partial cross-sectional view of the mesh assembly of the first preferred embodiment. Figure 3 is a partial perspective view of the mesh assembly of the first preferred embodiment; Figure 4 is a partial perspective view of the mesh assembly modified by one of the modifications of the first preferred embodiment; Figure 5 is the first BRIEF DESCRIPTION OF THE DRAWINGS FIG. 6 is a cross-sectional view showing a second preferred embodiment of a method for manufacturing a double-sided embossed nonwoven fabric of the present invention; and FIG. BRIEF DESCRIPTION OF THE DRAWINGS A schematic cross-sectional view showing an apparatus for carrying out the method of producing a fiber fabric of the present invention.

2‧‧‧Extrusion machine

21‧‧‧ molten raw materials

22‧‧‧Fiber forming device

23‧‧‧heater

4‧‧‧ network components

41‧‧‧First layered structure

410‧‧‧Net wall

411‧‧‧ suction holes

42‧‧‧Second layered structure

421‧‧‧ components

5‧‧‧ gas permeable layer

50‧‧‧Semi-fused fiber

6‧‧‧Adsorption device

61‧‧‧Adsorption box

62‧‧‧Drive wheel

7‧‧‧Double-sided embossed non-woven fabric

70‧‧‧ base

71‧‧‧ first floor

711‧‧‧Depression

72‧‧‧ second floor

721‧‧‧ convex

Claims (9)

A method for manufacturing a double-sided embossed nonwoven fabric, comprising: forming a layer of a plurality of semi-molten fibers on a mesh assembly disposed on an adsorption device, the mesh assembly comprising a first layered structure, and a a second layered structure on the first layered structure, the first layered structure having a mesh wall and a plurality of suction holes formed in the mesh wall and arranging a first pattern, the second layered structure a plurality of protruding members disposed on the mesh wall and arranged in a second pattern, wherein the layer of semi-molten fibers is formed by melting a plurality of resin particles to form a melt, and then transporting the melt through a fiber Forming means to form the semi-molten fibers, and subsequently discharging the semi-molten fibers onto the mesh assembly by the fiber forming device; and aligning the mesh with the semi-molten fibers adsorbed by the adsorption device The layer of semi-molten fibers on the body assembly is embossed such that the semi-molten fibers of the layer are drawn into the suction holes and cover the protruding members and the mesh walls are not covered by the second layer structure Covered area Thereby, the layer of semi-molten fibers is formed into a non-woven fabric having a base portion, a first layer and a second layer, the base portion covering a region of the mesh wall, the first layer having a plurality of downwardly extending from the base portion a recess having a recess pattern corresponding to the first pattern of the mesh assembly, the second layer having a plurality of protrusions extending upwardly from the base and having the second portion corresponding to the mesh assembly A convex pattern of the pattern. The method for producing a double-sided embossed nonwoven fabric according to the first aspect of the invention, wherein the semi-molten fiber formed on the mesh member is This is carried out by directly stacking the semi-molten fibers onto the mesh assembly. The method of manufacturing a double-sided embossed nonwoven fabric according to the first aspect of the invention, wherein the projecting members are provided on the mesh wall in the form of a plurality of separate projections. The method of manufacturing a double-sided embossed nonwoven fabric according to the first aspect of the invention, wherein the projecting members are in the form of a plurality of extending ribs forming a mesh body. The method for producing a double-sided embossed nonwoven fabric according to the first aspect of the invention, wherein the fiber forming device is a spinneret. The method for producing a double-sided embossed nonwoven fabric according to the first aspect of the invention, wherein the fiber forming device is a melt-blown die. The method for manufacturing a double-sided embossed nonwoven fabric according to claim 1, further comprising heating the semi-molten fibers during discharge of the semi-molten fibers onto the net body assembly by the fiber forming device for controlling And maintaining a predetermined melt viscosity of the semi-molten fibers. The method for producing a double-sided embossed nonwoven fabric according to claim 1, wherein the semi-molten fiber comprises a plurality of first semi-molten fibers and a plurality of second semi-molten fibers, and the first semi-molten fibers are formed. The method comprises: melting a plurality of first resin particles to form a first melt, and then conveying the first melt through a spinneret, wherein the second semi-molten fibers are formed by melting a plurality of second resin particles to form a first The second melt is then conveyed through a meltblowing die. Manufacture of double-sided embossed nonwoven fabric according to item 4 of the patent application scope The method wherein the mesh wall acts as a conveyor belt that is aligned with and driven by the pair of drive wheels.