US20040055124A1 - Method of making spun bond web from multicomponent filaments - Google Patents

Method of making spun bond web from multicomponent filaments Download PDF

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Publication number
US20040055124A1
US20040055124A1 US10/636,484 US63648403A US2004055124A1 US 20040055124 A1 US20040055124 A1 US 20040055124A1 US 63648403 A US63648403 A US 63648403A US 2004055124 A1 US2004055124 A1 US 2004055124A1
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US
United States
Prior art keywords
web
filaments
multicomponent filaments
filament
mat
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
US10/636,484
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English (en)
Inventor
Bernd Kunze
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.)
Reifenhaeuser GmbH and Co KG Maschinenenfabrik
Original Assignee
Reifenhaeuser GmbH and Co KG Maschinenenfabrik
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
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Application filed by Reifenhaeuser GmbH and Co KG Maschinenenfabrik filed Critical Reifenhaeuser GmbH and Co KG Maschinenenfabrik
Assigned to REIFENHAUSER GMBH & CO. MASCHINENFABRIK reassignment REIFENHAUSER GMBH & CO. MASCHINENFABRIK ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KUNZE, BERND
Publication of US20040055124A1 publication Critical patent/US20040055124A1/en
Priority to US11/705,807 priority Critical patent/US7850899B2/en
Abandoned legal-status Critical Current

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Classifications

    • 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
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/10—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically
    • D04H3/11—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically by fluid jet
    • 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
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • 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
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion

Definitions

  • My present invention relates to a method of making a spun bond web of multicomponent filaments and, more particularly, to a method of making a filament web with increased filament bulk.
  • I mean filaments which are composed of a plurality of different thermoplastic synthetic resin components and especially components with different properties like thermal coefficient of expansion, heat-induced shrinkage and like properties. These components can be of the same synthetic resin, for example, poly sters of different composition or polyethylenes or polypropylenes of different properties, or components of different synthetic resins, like, for example, a polypropylene component and a polyethylene component.
  • a reference to a bicomponent filament is intended to mean a filament which has only two different thermoplastic synthetic resins.
  • a cross section through such filaments will show the two components, usually in a side-by-side relationship and the separation b twe n the two synth tic resins gen rally will ext nd over the entire length of the filament.
  • the reference to spun bond here is intended to mean webs which are formed from continuous filaments as well as webs which may be formed from less than continuous filaments, i.e. filam nts which may have various lengths and need not be continuous.
  • the filaments are extruded from a spinn ret, are stretched, generally by entrainment with air, and are collected on a foraminous surface on which the mat is formed and on which the filaments are bonded at their crossing points.
  • Another object of the invention is to provide a method of making a filament web of high bulk, good mechanical properties and a high degree of reproducibility without drawbacks of prior art systems.
  • the spun bond web is made from multicomponent filaments whereby the multicomponent filaments are deposited upon a collecting surface or support and the mat thus formed by collecting the multicomponent filaments is bonded together or consolidated by a water jet system of the mat. Subsequently, a filament crinkling or crimping is introduced in the resulting web by a heat tr atment thereof to produce a high bulk spun bond web.
  • the mat may comprise
  • filament is here us d to refer to endless filaments of thermoplastic synthetic resins as are commonly employed for spun bond although it can encompass, as far as the present invention is concerned, also shorter filaments and fibers which can benefit from being bonded in the w b by the application of the water jets and crimped or crinkled by the heat treatment.
  • the invention is especially effective when bicomponent filaments are used.
  • the bicomponent filaments are comprised of only two different thermoplastic synthetic resins with different characteristics and especially different thermal expansion coefficients, different shrinkage properties and/or different mechanical or chemical properties in addition to th shrinkage and expansion.
  • the most highly preferred filaments are those which have two or more synthetic resin components in a side-by-side structure, i.e. the two components run next to one another to the full length of the filament. This applies especially to bicomponent filaments with a side-by-side structure. Along the length of the filament, a portion of the surface thereof is formed by the first polymer and the remainder by a second polymer in such bicomponent filaments.
  • the use of the bicomponent filam nts in a side-by-side structure has been found to eliminate completely problems with earlier low-bulk webs and to provide surprising advantages with respect to high bulk webs.
  • the bicomponent filaments and, generally, multicomponent filaments ar produced by the individual extrusion nozzle of a spinneret adapted to handle two or more synthetic resin components.
  • the extruded filament can be cooled, e.g. by contact with process air in a process air shaft and can be stretched in their passage downwardly along this shaft.
  • the foraminous surface can be a perforated conveyor belt, i.e. a si ve belt which can be evacuated below he surface.
  • the water jet stabilization of the mat to produce the web can employ a multiplicity of fine very high speed water jets dir cted uniformly over the entire mat surface.
  • the water jets pr ss the overlying filaments against underlying filaments to effect fusion between the filaments at the cross-over points.
  • the web is activated by a heat treatment and especially a heating in hot air at a temperature above 60° C. Because of different shrinkage and/or xpansion characteristics of the polymers in the filaments, a crinkling or crimping is produced which bulks the web. Indeed, the w b which results in accordance with the invention has especially high bulk and optimal mechanical characteristics which app ars to derive from the combination of water jet stabilization and subsequent heat treatment. In fact, without multicomponent and especially bicomponent filaments and both the water jet stabilization and heat treatment activation, an equivalent high bulk mechanically satisfactory web is not obtainable.
  • the inv ntion provides a w b with esp cially long free filament segments, i.e. a high free filament length, in terms of the average length of filaments between two bonding or contact sizes with filaments at cross-overs.
  • the high prefilament length means that the crimp, curling and in general bulking which is formed by the crinkling step, allows the development of a large number of loops, bends and other formations which extend transversely to the web and account for the bulk thereof.
  • the bulking is esp cially reproducible.
  • FIG. 1 is a diagrammatic cross section of a bicomponent filament in accordance with the invention.
  • FIG. 2 is a schematic side view of the filament coll ction portion of the apparatus and the units downstream th reof in accordance with the invention
  • FIG. 3 is a diagram illustrating the water jet stage of th invention.
  • FIG. 4 is a diagram showing the hot air treatment stag.
  • FIG. 1 shows a cross section through a bicomponent filament in accordance with the invention and from this Figure it can be seen that the bicomponent filament comprises a polymer A making up half the cross section of the filament and a polymer B making up the other half of the cross section.
  • the two polymers adjoin at an interface 1 a and thus are in side-by-side relationship over the length of the filament.
  • either one of the components A or B can mak up a greater portion of the cross section than the other and can extend over a greater portion of the surface of the filaments than the other.
  • the polymers A and B are for example two polymers which are compatible with one another and bond int grally to one another but have different heat shrinkage properties or different coefficients of thermal expansion.
  • FIG. 2 shows in highly schematic fashion the formation of the spun bond web in accordance with the invention.
  • the filaments 1 collected from a spinneret from which the bicomponent filaments are extruded and a cooling and stretching shaft (not shown), gather on the endless sieve belt 2 into a mat 5 which is displaced in the direction of the arrow C.
  • the filament mat or fleece is subjected to a multiplicity of high velocity water jets as shown at 3 a in FIG. 3, these water jets serving to bond crossing filaments 1 to one another at bonding points 1 b where these filaments cross one another.
  • a considerabl free length L may be provided between bonding points.
  • the water jets can be extremely fine water jets and preferably are of very high velocity.
  • the water jets can be directed from nozzles having a diameter of from several millimeters to a fraction of a millimeter and at a pressure ranging from 2 bar to 1000 bar.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Multicomponent Fibers (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
  • Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
US10/636,484 2002-08-09 2003-08-07 Method of making spun bond web from multicomponent filaments Abandoned US20040055124A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US11/705,807 US7850899B2 (en) 2002-08-09 2007-02-13 Method of making spun-bond web from multicomponent filaments

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP02017894A EP1396567B2 (fr) 2002-08-09 2002-08-09 Procédé de fabrication d'une nappe non-tissé de filaments bicomposés
EP02017894.3 2002-08-09

Related Child Applications (1)

Application Number Title Priority Date Filing Date
US11/705,807 Continuation-In-Part US7850899B2 (en) 2002-08-09 2007-02-13 Method of making spun-bond web from multicomponent filaments

Publications (1)

Publication Number Publication Date
US20040055124A1 true US20040055124A1 (en) 2004-03-25

Family

ID=31197796

Family Applications (2)

Application Number Title Priority Date Filing Date
US10/636,484 Abandoned US20040055124A1 (en) 2002-08-09 2003-08-07 Method of making spun bond web from multicomponent filaments
US11/705,807 Active 2026-01-12 US7850899B2 (en) 2002-08-09 2007-02-13 Method of making spun-bond web from multicomponent filaments

Family Applications After (1)

Application Number Title Priority Date Filing Date
US11/705,807 Active 2026-01-12 US7850899B2 (en) 2002-08-09 2007-02-13 Method of making spun-bond web from multicomponent filaments

Country Status (11)

Country Link
US (2) US20040055124A1 (fr)
EP (1) EP1396567B2 (fr)
JP (2) JP2004076249A (fr)
KR (1) KR100566743B1 (fr)
CN (1) CN100507122C (fr)
AT (1) ATE310117T1 (fr)
BR (1) BR0302745B1 (fr)
DE (1) DE50204950D1 (fr)
DK (1) DK1396567T4 (fr)
ES (1) ES2249519T5 (fr)
MX (1) MXPA03007026A (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20050077012A1 (en) * 2001-04-13 2005-04-14 Andre Vuillaume Installation for producing a spunbonded nonwoven web consolidated by fluid projection

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE10338196A1 (de) * 2003-08-20 2005-05-12 Reifenhaeuser Masch Verfahren zur Herstellung eines Vliesstoffes
DE102006045616B3 (de) * 2006-09-25 2008-02-21 Carl Freudenberg Kg Elastischer Vliesstoff und Verfahren zu dessen Herstellung
ES2434019T3 (es) * 2006-12-22 2013-12-13 Reifenhäuser GmbH & Co. KG Maschinenfabrik Procedimiento y dispositivo para la fabricación de una tela hilada por adhesión a partir de filamentos de celulosa
CZ2018647A3 (cs) * 2018-11-23 2020-06-03 Reifenhäuser GmbH & Co. KG Maschinenfabrik Objemná netkaná textilie se zvýšenou stlačitelností a zlepšenou schopností regenerace

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3720212A (en) * 1971-09-09 1973-03-13 Carter W Co Absorbent panty
US5418045A (en) * 1992-08-21 1995-05-23 Kimberly-Clark Corporation Nonwoven multicomponent polymeric fabric

Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3707746A (en) * 1971-06-03 1973-01-02 Du Pont Process of preparing a tufted product
US4025595A (en) * 1975-10-15 1977-05-24 E. I. Du Pont De Nemours And Company Process for preparing mixed filament yarns
FR2749860B1 (fr) † 1996-06-17 1998-08-28 Freudenberg Spunweb Sa Nappe non tissee formee de filaments continus tres fins
EP1149195B1 (fr) * 1998-10-06 2007-01-17 Hills, Inc. Fibres elastomeres composites separables
CZ302192B6 (cs) * 2000-08-03 2010-12-08 Bba Nonwovens Simpsonville, Inc. Zpusob výroby netkané textilie z vícesložkových vláken a zarízení k provádení tohoto zpusobu
US6736916B2 (en) * 2000-12-20 2004-05-18 Kimberly-Clark Worldwide, Inc. Hydraulically arranged nonwoven webs and method of making same
DE10105784A1 (de) * 2001-02-07 2002-08-08 Fleissner Gerold Wasservernadeltes Kompositvlies aus Stapel- und Endlosfasern und Verfahren zur Herstellung

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3720212A (en) * 1971-09-09 1973-03-13 Carter W Co Absorbent panty
US5418045A (en) * 1992-08-21 1995-05-23 Kimberly-Clark Corporation Nonwoven multicomponent polymeric fabric

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20050077012A1 (en) * 2001-04-13 2005-04-14 Andre Vuillaume Installation for producing a spunbonded nonwoven web consolidated by fluid projection

Also Published As

Publication number Publication date
EP1396567B1 (fr) 2005-11-16
ES2249519T5 (es) 2011-06-09
EP1396567A1 (fr) 2004-03-10
KR20040025551A (ko) 2004-03-24
DE50204950D1 (de) 2005-12-22
JP2004076249A (ja) 2004-03-11
DK1396567T4 (da) 2011-08-01
US20070182057A1 (en) 2007-08-09
CN100507122C (zh) 2009-07-01
BR0302745B1 (pt) 2013-02-19
KR100566743B1 (ko) 2006-04-03
EP1396567B2 (fr) 2011-04-20
US7850899B2 (en) 2010-12-14
JP2006152532A (ja) 2006-06-15
ATE310117T1 (de) 2005-12-15
CN1473976A (zh) 2004-02-11
BR0302745A (pt) 2004-08-24
MXPA03007026A (es) 2004-10-15
DK1396567T3 (da) 2006-02-13
ES2249519T3 (es) 2006-04-01

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Legal Events

Date Code Title Description
AS Assignment

Owner name: REIFENHAUSER GMBH & CO. MASCHINENFABRIK, GERMANY

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:KUNZE, BERND;REEL/FRAME:014680/0220

Effective date: 20030911

STCB Information on status: application discontinuation

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