US20030116878A1 - Method for manufacturing three-dimensional non-woven fabric, mold used for the method, and three-dimensional non-woven fabric manufactured using the method and the mold - Google Patents

Method for manufacturing three-dimensional non-woven fabric, mold used for the method, and three-dimensional non-woven fabric manufactured using the method and the mold Download PDF

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Publication number
US20030116878A1
US20030116878A1 US10/322,682 US32268202A US2003116878A1 US 20030116878 A1 US20030116878 A1 US 20030116878A1 US 32268202 A US32268202 A US 32268202A US 2003116878 A1 US2003116878 A1 US 2003116878A1
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US
United States
Prior art keywords
mold
mold piece
woven fabric
piece
dimensional non
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US10/322,682
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English (en)
Inventor
Takanari Takagaki
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Toyota Boshoku Corp
Original Assignee
Toyota Boshoku Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from JP2001391688A external-priority patent/JP3815320B2/ja
Priority claimed from JP2001394710A external-priority patent/JP2003201663A/ja
Application filed by Toyota Boshoku Corp filed Critical Toyota Boshoku Corp
Assigned to TOYODA BOSHOKU CORPORATION reassignment TOYODA BOSHOKU CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: TAKAGAKI, TAKANARI
Publication of US20030116878A1 publication Critical patent/US20030116878A1/en
Abandoned legal-status Critical Current

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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
    • D04H3/07—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments otherwise than in a plane, e.g. in a tubular way

Definitions

  • the invention relates to a method for manufacturing a three-dimensional non-woven fabric in which semi-molten fibers are spun on a mold to form the three-dimensional non-woven fabric, a mold used for the method, and the three-dimensional non-woven fabric manufactured using the method and the mold.
  • a manufacturing apparatus 90 for the three-dimensional non-woven fabric includes a chain conveyor 91 .
  • a plurality of molds 94 arranged in a moving direction is fitted on the conveyor 91 .
  • Each of the molds 94 is manufactured in accordance with a shape of the three-dimensional non-woven fabric.
  • a spinning nozzle 96 for spinning semi-molten fibers F is provided above the chain conveyor 91 , and a spray gun 97 for spraying a binder or the like for binding each of the fibers F and a heating furnance 98 for drying the fibers are provided downstream of the spinning nozzle 96 .
  • a first aspect of the invention relates to a method for manufacturing a three-dimensional non-woven fabric in which semi-molten fibers are spun on a forming surface of a mold, and are formed into the three-dimensional non-woven fabric.
  • the method includes the steps of preparing at least two mold pieces including a first mold piece, and a second mold piece which can be mutually overlapped with the first mold piece and whose area mutually overlapping with the first mold piece is adjustable, and forming a mold including a forming surface in an desired size by partly mutually overlapping the first mold piece with the second mold piece and adjusting the area in which the two mold pieces are mutually overlapped.
  • the size of the forming surface of the mold can be changed by changing the area in which the first mold piece and the second mold piece, which constitute the mold, are mutually overlapped. That is, plural types of three-dimensional non-woven fabrics whose sizes are different can be formed using only one unit of mold. This results in a cost reduction in the molds when plural types of three-dimensional non-woven fabrics are formed.
  • a second aspect of the invention relates to a mold which is used for a method for manufacturing a three-dimensional non-woven fabric in which semi-molten fibers are spun on a forming surface of a mold to form the three-dimensional non-woven fabric.
  • This mold includes at least a first mold piece, and a second mold piece which can be mutually overlapped with the first mold piece and whose area mutually overlapping with the first mold piece is adjustable.
  • FIG. 1B is an exploded perspective view of the mold shown in FIG. 1A.
  • FIG. 2A is an exploded perspective view showing a first modified example of the mold according to the embodiment.
  • FIG. 3A is an exploded perspective view showing a second modified example of the mold according to the embodiment.
  • FIG. 3B is a general perspective view of the mold shown in FIG. 3A.
  • FIG. 4B is a general perspective view of the mold shown in FIG. 4A.
  • FIG. 5A is a perspective view in schematic form showing manufacturing equipment of a filter.
  • FIG. 5B is a longitudinal sectional view showing the manufacturing equipment shown in FIG. 5A.
  • FIG. 6 is a side view showing a common method for manufacturing the filter.
  • a method for manufacturing a three-dimensional non-woven fabric according to an embodiment of the invention will be explained with reference to FIGS. 1A to 5 B.
  • the embodiment relates to a method for manufacturing a filter as an example of the three-dimensional non-woven fabric.
  • a width direction of the manufacturing equipment is referred to as an X direction
  • a longitudinal direction thereof is referred to as a Y direction
  • an attitudinal direction thereof is referred to as a Z direction.
  • manufacturing equipment 1 for the filter includes a level conveyor 2 , and a plurality of molds 10 (only one unit is shown in FIG. 5A) for forming the filter is arranged on the conveyor 2 in orderly manner.
  • a spinning nozzle 4 is provided at a predetermined position above the conveyor 2 .
  • the spinning nozzle 4 is a nozzle which employs, for example, a melt blow method, and spins fiber type resin F (hereinafter referred to as fibers F) injected from an extruder (not shown) onto the whole mold 10 in which a right mold piece 12 and a left mold piece 17 are mutually overlapped.
  • the fibers F spun out of the spinning nozzle 4 are semi-molten.
  • the fibers F are stacked on the forming surface or the like of the mold 10 , whereby the fibers F are bonded together to form the non-woven fabric.
  • the mold 10 for forming the filter is formed by mutually overlapping the right mold piece 12 and a left mold piece 15 .
  • the right mold piece 12 includes a square frame portion 13 with a constant width.
  • a right mold main portion 14 is formed inside the square frame portion 13 .
  • the right mold main portion 14 includes a bellows portion 14 w having a shape formed by sequentially arranging triangular ridges with substantially triangular side surfaces, and triangular side plate portions 14 s which block right end surfaces of the bellows portion 14 w .
  • left end portions 14 c of the bellows portion 14 w are open.
  • the left mold piece 15 includes an edge portion 16 formed to have a plane U-shape with a constant width.
  • a left mold main portion 17 is formed inside the edge portion 16 .
  • the left mold main portion 17 also includes a bellows portion 17 w having a shape formed by sequentially arranging triangular ridges with substantially triangular side surfaces, and triangular side plate portions 17 s which block left end surfaces of the bellows portion 17 w . Note that right end portions 17 c of the bellows portion 17 w are open.
  • crest portions of the bellows portion 14 w seen from a direction opposite to the Z direction can be regarded as convex portions of the invention, and trough portions of the bellows portion 17 w seen from the Z direction can be regarded as concave portions of the invention.
  • the mold 10 for forming the filter is formed into the same shape as an desired shape of the filter by overlapping the right mold main portion 14 and the square frame portion 13 of the right mold piece 12 with the left mold main portion 17 and the edge portion 16 of the left mold piece 15 , respectively.
  • the left mold main portion 17 of the left mold piece 15 and the right mold main portion 14 of the right mold piece 12 function as forming surfaces for forming a filtration portion of the filter.
  • the edge portion 16 of the left mold piece 15 and the square frame portion 13 of the right mold piece 12 function as the forming surfaces for forming a peripheral portion of the filter.
  • the left mold main portion 17 of the left mold piece 15 and the right mold main portion 14 of the right mold piece 12 are referred to as first forming surfaces 14 , 17
  • the edge portion 16 of the left mold piece 15 and the square frame portion 13 of the right mold piece 12 are referred to as second forming surfaces 13 , 16 .
  • the filtration portion of the filter can be regarded as a main portion of a three-dimensional non-woven fabric of the invention.
  • the peripheral portion of the filter can be regarded as a peripheral portion of a three-dimensional non-woven fabric of the invention.
  • the square frame portion 13 of the right piece 12 is fastened to the edge portion 16 of the left mold piece 15 with a clip or the like (not shown) so that they are retained firmly. As a result, displacement between the right piece 12 and the left mold piece 15 is prevented.
  • the mold 10 is formed from, for example, a wire net, a resin net or the like which has an air permeability. Then, when the mold 10 is formed from a resin net or the like, a mold-releasing agent is applied to the mold 10 in order to prevent the fibers F from adhering to the mold 10 .
  • bellows portions 14 w , 17 w having four triangular ridges are exemplified in FIGS. 1A to 1 C for the purpose of simplification of the figures.
  • the actual number of the triangular ridges can be set at any value.
  • the right mold piece 12 and the left mold piece 15 of the mold 10 are relatively slid in the width direction (X direction), and width dimensions of the forming surfaces 13 , 14 , 16 , 17 of the mold 10 are adjusted to an desired width dimension of the filter. Then, the square frame portion 13 of the right mold piece 12 is fastened to the edge portion 16 of the left mold piece 15 with a clip or the like to be retained firmly to prevent displacement between the right piece 12 and the left mold piece 15 .
  • each of the molds 10 is set on the conveyor 2 . Then, an approximately constant amount per unit of time of the fibers F is spun out of the spinning nozzle 4 , and the conveyor 2 is driven at a constant speed. Thus, the mold 10 moves below the spinning nozzle 4 at a constant speed. Then, as shown in FIG. 5B, semi-molten fibers F are stacked on the first forming surfaces 14 , 17 and the second forming surfaces 13 , 16 of the mold 10 at an approximately constant thickness sequentially starting from an end side (left end in the figure) in the Y direction.
  • the fibers F stacked on the first forming surfaces 14 , 17 of the mold 10 and the fibers F stacked on the second forming surfaces 13 , 16 of the mold 10 are fusion bonded with each other to form the non-woven fabric. Then, the non-woven fabric formed from the fibers F stacked on the first forming surfaces 14 , 17 constitute the filtration portion of the filter. Also, the non-woven fabric formed from the fibers F stacked on the second forming surfaces 13 , 16 constitute the peripheral portion of the filter.
  • the mold 10 including the forming surfaces 13 , 14 , 16 , 17 in a certain size is formed by partly overlapping a pair of the mold pieces 12 , 15 and adjusting the area in which the mold pieces are mutually overlapped. Therefore, the width dimension of the forming surfaces 13 , 14 , 16 , 17 of the mold 10 can be changed by changing the area in which the pair of mold pieces 12 , 15 constituting the mold 10 are mutually overlapped. That is, plural types of filters whose width dimensions are different can be formed using only one unit of mold 10 . This results in a cost reduction in the molds when plural types of filters are formed.
  • a linear dimension of a forming surface of a mold 20 can be changed by changing the number of the triangular ridges of a bellows portion 22 w of a front mold piece 22 fitted to the triangular ridges of a bellows portion 25 w of an end mold piece 25 , as shown in FIG. 2B.
  • the width dimension and the linear dimension of forming surface of a mold 30 can be changed by constructing the mold 30 using four mold pieces 31 , 32 , 33 , 34 , which are arranged in a longitudinal direction and a lateral direction.
  • FIGS. 4A and 4B show modified examples of the mold 10 or the like.
  • a mold 40 shown in FIG. 4B includes a first mold piece 41 and a second mold piece 42 , which are in the same shape.
  • the first mold piece 41 includes a square flat plate portion 41 f and a plurality of convex portions 41 t formed on a surface of the flat plate portion 41 f .
  • the convex portion 41 t is formed in a frustum container shape whose bottom portion is open.
  • An opening of the convex portion 41 t (not shown) is formed on a rear surface of the flat plate portion 41 f .
  • a thickness of the convex portion 41 t is formed to be substantially equal to the thickness of the flat plate portion 41 f .
  • the convex portions 41 t are arranged at certain intervals in a longitudinal direction and a lateral direction in the first mold piece 41 . Note that since the second mold piece 42 is in the same shape as the first mold piece 41 , explanation thereof will be omitted.
  • the first mold piece 41 and the second mold piece 42 are manufactured by pressing a steel plate or the like into shape or injection molding with resin.
  • the first mold piece 41 and the second mold piece 42 may be formed from the non-woven fabric.
  • the mold 40 is formed by fitting a part of the convex portion 41 t of the first mold piece 41 into the inside (concave portion) of the convex portion 42 t of the second mold piece 42 . Therefore, the area in which the first mold piece 41 is overlapped with the second mold piece 42 may be changed by changing the number of the portions where the convex portions 41 t of the first mold piece 41 are fitted in the concave portions of the second mold piece 42 .
  • the filter as an example of the three-dimensional non-woven fabric is shown.
  • a buffer material an acoustic material or the like can be produced.
  • the cross sections of the bellows portions 14 w , 17 w of the mold pieces 12 , 15 into a triangular shape is shown.
  • the cross sections may be formed into a semicircular or polygonal shape.
  • an example of forming the convex portions 41 t , 42 t of the mold piece 41 , 42 into a frustum shape is shown.
  • the convex portions may be formed into a hemispherical shape or a polyangular frustum shape.
  • plural types of three-dimensional non-woven fabrics whose sizes are different can be formed using only one unit of mold. This results in a cost reduction in the molds when plural types of three-dimensional non-woven fabrics are formed.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Filtering Materials (AREA)
US10/322,682 2001-12-25 2002-12-19 Method for manufacturing three-dimensional non-woven fabric, mold used for the method, and three-dimensional non-woven fabric manufactured using the method and the mold Abandoned US20030116878A1 (en)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
JP2001-391688 2001-12-25
JP2001391688A JP3815320B2 (ja) 2001-12-25 2001-12-25 立体不織布の製造方法
JP2001-394710 2001-12-26
JP2001394710A JP2003201663A (ja) 2001-12-26 2001-12-26 立体不織布の製造方法及びその方法に使用される型

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US20030116878A1 true US20030116878A1 (en) 2003-06-26

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US10/322,682 Abandoned US20030116878A1 (en) 2001-12-25 2002-12-19 Method for manufacturing three-dimensional non-woven fabric, mold used for the method, and three-dimensional non-woven fabric manufactured using the method and the mold

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US (1) US20030116878A1 (fr)
EP (1) EP1323857A3 (fr)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20080029685A1 (en) * 2006-07-03 2008-02-07 West Mark W Method of casting a concrete truss
US20110067458A1 (en) * 2009-09-18 2011-03-24 Groz-Beckert Kg Nozzle bar for a textile processing machine
US20110067213A1 (en) * 2009-09-18 2011-03-24 Groz-Beckert Kg Nozzle foil for a nozzle bar with connectable foil segments
US8257626B2 (en) 2009-09-15 2012-09-04 Groz-Beckert Kg Felt body manufacturing method
CN104594135A (zh) * 2015-01-08 2015-05-06 苏州工业园区达菲特过滤技术有限公司 一种滤清器滤芯成型制备方法

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2376693B1 (fr) * 2008-12-23 2014-10-22 3M Innovative Properties Company Toiles fibreuses non tissées à motifs et procédés pour les fabriquer et les utiliser
BR112013000281A2 (pt) 2010-07-07 2016-05-24 3M Innovative Properties Co mantas fibrosas não tecidas produzidas por deposição a ar (airlaid) dotadas de um padrão e métodos de preparo e uso das mesmas
US20130146061A1 (en) * 2011-12-09 2013-06-13 3M Innovative Properties Company Respirator made from in-situ air-laid web(s)
CN109137265B (zh) * 2018-10-23 2020-11-03 厦门大学 一种三维血管电纺制造装置
CN109652920B (zh) * 2019-02-28 2021-10-08 嘉兴学院 一种三维结构熔喷非织造布的制备装置

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20020095920A1 (en) * 2001-01-24 2002-07-25 Toyoda Boshoku Corporation Filter and production method thereof
US20020132544A1 (en) * 2001-03-13 2002-09-19 Toyoda Boshoku Corporation Three-dimensional non-woven fabric, method for manufacturing the same, and mold for manufacturing the same
US20020129587A1 (en) * 2001-03-13 2002-09-19 Toyoda Boshoku Corporation Filter and method for manufacturing the filter
US6454827B2 (en) * 2000-04-28 2002-09-24 Toyoda Boshoku Corporation Filter medium and production method thereof
US20020135106A1 (en) * 2001-03-21 2002-09-26 Toyoda Boshoku Corporation Production method and apparatus for filter, forming die for filter, forming assembly for forming filter, and filter

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2323069A1 (fr) * 1975-09-05 1977-04-01 Nordengren Patenter Procede pour former une bande de filtrage et la monter sur un ensemble de filtrage
DK169084B1 (da) * 1992-02-28 1994-08-08 Hartmann As Brdr Anlæg til fremstilling af et skalformet papmacheemne af pulpmateriale
DK169997B1 (da) * 1993-04-15 1995-04-24 Hartmann As Brdr Modulopbyggede formværktøjer til brug i en maskine til fremstilling af skaller af pulpmateriale
DE19632618C2 (de) * 1996-08-13 1998-06-18 Freudenberg Carl Fa Filtereinsatz

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6454827B2 (en) * 2000-04-28 2002-09-24 Toyoda Boshoku Corporation Filter medium and production method thereof
US20020095920A1 (en) * 2001-01-24 2002-07-25 Toyoda Boshoku Corporation Filter and production method thereof
US20020132544A1 (en) * 2001-03-13 2002-09-19 Toyoda Boshoku Corporation Three-dimensional non-woven fabric, method for manufacturing the same, and mold for manufacturing the same
US20020129587A1 (en) * 2001-03-13 2002-09-19 Toyoda Boshoku Corporation Filter and method for manufacturing the filter
US20020135106A1 (en) * 2001-03-21 2002-09-26 Toyoda Boshoku Corporation Production method and apparatus for filter, forming die for filter, forming assembly for forming filter, and filter

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20080029685A1 (en) * 2006-07-03 2008-02-07 West Mark W Method of casting a concrete truss
US8257626B2 (en) 2009-09-15 2012-09-04 Groz-Beckert Kg Felt body manufacturing method
US20110067458A1 (en) * 2009-09-18 2011-03-24 Groz-Beckert Kg Nozzle bar for a textile processing machine
US20110067213A1 (en) * 2009-09-18 2011-03-24 Groz-Beckert Kg Nozzle foil for a nozzle bar with connectable foil segments
US8882005B2 (en) 2009-09-18 2014-11-11 Groz-Beckert Kg Nozzle bar for a textile processing machine
US9816216B2 (en) 2009-09-18 2017-11-14 Groz-Beckert Kg Nozzle foil for a nozzle bar with connectable foil segments
CN104594135A (zh) * 2015-01-08 2015-05-06 苏州工业园区达菲特过滤技术有限公司 一种滤清器滤芯成型制备方法

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EP1323857A2 (fr) 2003-07-02
EP1323857A3 (fr) 2005-02-02

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AS Assignment

Owner name: TOYODA BOSHOKU CORPORATION, JAPAN

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:TAKAGAKI, TAKANARI;REEL/FRAME:013596/0623

Effective date: 20021122

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION