US20070116928A1 - Sheet slitting forming belt for nonwoven products - Google Patents

Sheet slitting forming belt for nonwoven products Download PDF

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Publication number
US20070116928A1
US20070116928A1 US11/285,454 US28545405A US2007116928A1 US 20070116928 A1 US20070116928 A1 US 20070116928A1 US 28545405 A US28545405 A US 28545405A US 2007116928 A1 US2007116928 A1 US 2007116928A1
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US
United States
Prior art keywords
forming fabric
fabric
protuberances
forming
nonwoven
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
US11/285,454
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English (en)
Inventor
Jean-Louis Monnerie
Remy Trubacz
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.)
Albany International Corp
Original Assignee
Albany International 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
Application filed by Albany International Corp filed Critical Albany International Corp
Priority to US11/285,454 priority Critical patent/US20070116928A1/en
Assigned to ALBANY INTERNATIONAL CORP. reassignment ALBANY INTERNATIONAL CORP. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MONNERIE, JEAN-LOUIS
Assigned to ALBANY INTERNATIONAL CORP. reassignment ALBANY INTERNATIONAL CORP. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: TRUBACZ, REMY
Priority to AU2006316842A priority patent/AU2006316842A1/en
Priority to PCT/US2006/043577 priority patent/WO2007061635A1/en
Priority to JP2008541232A priority patent/JP2009516778A/ja
Priority to EP06837206A priority patent/EP1951944A1/en
Priority to KR1020087015212A priority patent/KR20080073347A/ko
Priority to CA002628147A priority patent/CA2628147A1/en
Priority to CNA2006800432884A priority patent/CN101313099A/zh
Priority to BRPI0619327A priority patent/BRPI0619327A2/pt
Priority to RU2008119913A priority patent/RU2414552C2/ru
Priority to TW095142405A priority patent/TW200730695A/zh
Publication of US20070116928A1 publication Critical patent/US20070116928A1/en
Priority to US12/112,512 priority patent/US20080199655A1/en
Priority to NO20082720A priority patent/NO20082720L/no
Abandoned legal-status Critical Current

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Classifications

    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
    • D21F11/00—Processes for making continuous lengths of paper, or of cardboard, or of wet web for fibre board production, on paper-making machines
    • D21F11/006—Making patterned paper
    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D1/00—Woven fabrics designed to make specified articles
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D25/00—Woven fabrics not otherwise provided for
    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/492—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet
    • D04H1/495—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet for formation of patterns, e.g. drilling or rearrangement
    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/56—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in association with fibre formation, e.g. immediately following extrusion of staple fibres
    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
    • D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
    • D04H1/732—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged by fluid current, e.g. air-lay
    • 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
    • D04H13/00—Other non-woven fabrics
    • 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
    • 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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24058—Structurally defined web or sheet [e.g., overall dimension, etc.] including grain, strips, or filamentary elements in respective layers or components in angular relation
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
    • Y10T428/24281—Struck out portion type
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
    • Y10T428/24372—Particulate matter
    • Y10T428/24405—Polymer or resin [e.g., natural or synthetic rubber, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y10T442/2762—Coated or impregnated natural fiber fabric [e.g., cotton, wool, silk, linen, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y10T442/2861—Coated or impregnated synthetic organic fiber fabric
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y10T442/2926—Coated or impregnated inorganic fiber fabric
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]

Definitions

  • the instant invention relates generally to the production of nonwoven products. More specifically, the instant invention relates to a forming fabric or belt for use in the manufacture of nonwovens.
  • Nonwoven products are used in a wide variety of applications ranging from baby diapers to high performance textiles where the engineered qualities of the products can be advantageously employed.
  • Numerous nonwoven products can be manufactured using the instant invention including, but not limited to: geotextiles; building materials such as MDF (medium density fiberboard), roofing and tile underlayment, acoustic ceiling tiles and thermal and sound insulation; hygienic and healthcare products such as bandages, tapes, sterile packaging, diapers and sanitary napkins; and household goods such as wipes, scouring pads, fabric softener sheets, placemats, napkins, washcloths, tablecloths and vacuum bags.
  • the fibers or filaments of the product are integrated into a coherent web. Entanglement of the fibrous elements of the nonwoven web, coupled with other processes such as chemical or thermal bonding, provides the desired product integrity, functionality and aesthetics.
  • Such products are produced directly from fibers without conventional textile methods such as weaving or knitting operations. Instead, they are produced by nonwoven manufacturing methods and processes such as meltblowing.
  • meltblown process for manufacturing nonwoven products, a thermoplastic forming polymer is placed in an extruder and is then passed through a linear die containing about twenty to forty small orifices per inch of die width. Convergent streams of hot air rapidly attenuate the extruded polymer steams to form solidifying filaments. The solidifying filaments are subsequently blown by high velocity air onto a take-up screen or another layer of woven or nonwoven material thus forming a meltblown web.
  • nonwoven products may be produced by air-laying or carding operations where the web of fibers is consolidated or processed, subsequent to deposition, into a nonwoven product by needling or hydroentanglement.
  • needling high-pressure water jets are directed vertically down onto the nonwoven web to entangle the fibers with each other.
  • entanglement is achieved mechanically through the use of a reciprocating bed of barbed needles which force fibers on the surface of the web further thereinto during the entry stroke of the needles.
  • Nonwoven products are generally made up of fibers locked into place by fiber interaction to provide a strong cohesive structure, with or without the need for chemical binders or filament fusing.
  • the products may have a repeating pattern of entangled fiber regions of higher area density (weight per unit area) than the average area density of the product, and interconnecting fibers which extend between the densely entangled regions that are randomly entangled with each other. Localized entangled regions may be interconnected by fibers extending between adjacent entangled regions to define regions of lower area density than that of the adjacent high-density region.
  • a pattern of apertures substantially free from fibers may be defined within or between the dense entangled regions and interconnecting fibers. Unlike in the instant invention, however, these patterns are not used to separate the nonwoven web into a plurality of individual or separate nonwoven sheets.
  • the densely entangled regions are arranged in a regular pattern and joined by ordered groups of fibers to provide a nonwoven product having an appearance similar to that of a conventional woven fabric, but in which the fibers proceed randomly through the nonwoven product from entangled region to entangled region.
  • the fibers of an ordered group may be either substantially parallel or randomly disposed relative to one another.
  • Embodiments include nonwoven products having complex fiber structures with entangled fiber regions interconnected by ordered fiber groups located in different thickness zones of the nonwoven, which are particularly suitable for apparel and industrial products such as wipes.
  • the nonwoven web may be processed and the fibers locked into place in the product by fiber interaction.
  • locked into place it is meant that individual fibers of the structure not only have no tendency to move from their respective positions in the patterned structure, but they are actually also physically restrained from such movement by interaction with themselves and/or with other fibers of the product. Fibers are locked into place in the entangled fiber regions of higher area density than the average area density of the product, and such fiber interaction may also occur elsewhere.
  • interaction it is meant that the fibers turn, wind, twist back-and-forth and pass about one another in all directions of the structure in such an intricate entanglement that they interlock with one another.
  • Mechanical entanglement processes such as needling, bind or secure a layer or layers of fibers to themselves or to a substrate by impaling the fibrous webs with a large number of barbed needles in a device called a needle loom or fiber locker. This action pushes fibers from the fiber layer surface into and through the bulk of the web layers. While strength properties are improved by this entangling of fibers within the web, the process can be slow, the needles can damage the fibers, and the needles themselves are worn out rapidly.
  • hydroentangling or “spunlacing” processes which use the energy of small-diameter, highly coherent jets of high-pressure water to mimic the entangling action of the older needle loom.
  • the process involves forming a fiber web as described above, after which the fibers are entangled by means of very fine water jets under high pressure. Several rows of water jets are directed against the fiber web which is supported by a movable wire or fabric. The entangled fiber web is then dried.
  • the fibers that are used in the material can be synthetic or regenerated staple fibers, e.g. polyester, polyamide, polypropylene, rayon or the like, cellulose or other material fibers or mixtures of any combination of these materials.
  • Spunlace materials can be produced in high quality at a reasonable cost and have a high absorption capacity. They can be used as wiping materials for household or industrial use, as disposable materials in medical care and for hygiene purposes, etc.
  • the hydroentangling process can be used to produce a large number of different products by varying the initial material and/or the belt/patterning member used.
  • the initial material may consist of any web, mat, batt or the like of loose fibers disposed in random relationship with one another or in any degree of alignment.
  • the term “fiber” as employed herein, is meant to include all types of fibrous material, whether naturally or synthetically produced, and comprises, for example, fibrids (of a type of synthetic fibrous particles used in bonding), cellulose fibers, and textile staple fibers. Improved properties can be obtained by suitable combinations of different lengths of fibers.
  • Reinforced products are provided by combinations of staple length fibers with fibrous strands, where the term “strands” includes filaments and various forms of conventional textile fibers, which may be straight or crimped, and other desirable products are obtained by using highly crimped and/or elastic fibers in the initial material.
  • Particularly desirable patterned, nonwoven products are prepared by using an initial material comprising fibers having a latent ability to elongate, crimp, shrink, or otherwise change in length, and subsequently treating the patterned, nonwoven structure to develop the latent properties of the fibers so as to alter the free-length of the fibers.
  • the initial material may contain different types of fibers, e.g., shrinkable and nonshrinkable fibers, to obtain special effects upon activation of the latent properties of one type of fiber.
  • binding materials include binding fibers, binding powders and binding webs.
  • Binder fibers are the most widely used in thermal bonding and include single-component and bi-component fibers. When heat is applied, portions of the binder fibers melt, thereby binding with other fibers at the fiber cross-over points.
  • Binding powders in the form of powdered polymers are also used to bind the fibers to each other. The binding powders are applied between layers of fibers during cross-laying, air-laying or as an after treatment.
  • binding powders With binding powders, a short exposure to heat in an oven is usually sufficient to melt and fuse the powder to the nonwoven fibers resulting in a nonwoven web comprised of fibers that are bound to each other.
  • a binding web which is a low-melting point, thermoplastic open-structured fabric, can be placed between the nonwoven webs.
  • heat is applied to completely melt the binding web and calendar rolls are used to press and bind the nonwoven webs together.
  • Methods of thermal binding include, for example, hot calendaring, belt calendaring, oven bonding, ultrasonic bonding and radiant heat bonding.
  • the bonding method used has a significant effect on product properties such as porosity, thickness and absorbency. All bonding methods, however, provide strong bond points that are resistant to hostile environments and to many solvents.
  • an endless forming fabric or belt plays a key role in the formation of the nonwoven web.
  • these belts take the form of mesh screens woven from plastic monofilaments, although metal wire may be used instead of plastic monofilaments when temperature conditions during a nonwoven manufacturing process make it impractical or impossible to use plastic monofilament.
  • Yet another object of the invention is to provide a forming fabric or belt used in the manufacture of nonwoven products having an impermeable material applied as a coating, an extrusion, a deposition, or as individual strips or pieces of material attached to the surface of the web forming side of the fabric or belt that cuts or slits the nonwoven web into individual, separate nonwoven sheets.
  • a still further object of the invention is to provide a method of forming a plurality of individual nonwoven sheets on a forming fabric or belt used in the manufacture of nonwoven products.
  • the instant invention is directed to a forming fabric that is used in the production of nonwoven products.
  • the forming fabric comprises a plurality of protuberances that are included on the web forming side of the forming fabric.
  • the plurality of protuberances are arranged in a pattern or grid and define the size and shape of nonwoven sheets formed thereon.
  • the protuberances are constructed from an air impermeable material that includes polymeric resins and thermoplastic materials, for example.
  • Another aspect of the instant invention is a method of forming individual nonwoven sheets.
  • the method includes providing an air permeable forming fabric.
  • a plurality of areas on the web forming surface of the air permeable forming fabric are selectively closed to air in a desired pattern or grid, wherein the desired pattern or grid defines the shape and size of the individual nonwoven sheets formed thereon.
  • Vacuum boxes are provided adjacent to the non-web forming surface of the air permeable forming fabric in order to provide suction to the forming fabric, thereby urging the fibers deposited onto the forming fabric toward the air permeable areas of the fabric.
  • the plurality of areas on the forming belt are rendered impermeable to air by the addition of an impermeable material to the web forming surface of the forming fabric, such as polymeric resins or thermoplastic materials, for example.
  • FIG. 1 is a forming fabric of the instant invention installed on an apparatus used to manufacture nonwoven products
  • FIG. 2 depicts a shape and configuration of manufactured nonwoven products, according to one embodiment of the instant invention.
  • FIGS. 3A-3E depict various cross-sectional shapes for the impermeable material, according to one embodiment of the instant invention.
  • the instant invention relates to a forming fabric or belt used to manufacture slitted or individual nonwoven sheets.
  • fabric and belt are used interchangeably.
  • web refers to a nonwoven product formed on a forming fabric.
  • sheet as used herein defines any nonwoven product that has dimensions less than the dimensions of the web forming area on the forming fabric upon which it is formed.
  • a nonwoven web is formed on a forming fabric and requires additional processing to cut or slit the nonwoven web into smaller, individual sheets.
  • the instant invention eliminates post processing cutting or slitting of the formed nonwoven web since use of the instant forming fabric results in separate, individual nonwoven sheets being formed directly on the fabric during the web forming stage of the manufacturing process.
  • the instant invention achieves slitted or individualized nonwoven sheets by obtaining a different fiber distribution directly on the forming fabric in, for example, airlaid, meltblown, or spunlace nonwoven manufacturing processes.
  • an air permeable forming fabric 10 used in the manufacturing of nonwoven product, having machine direction (MD) and cross machine direction (CD) yarns, such as disclosed in pending U.S. Application entitled “High-Speed Spun-Bond Production of Nonwoven Fabrics” Ser. No. 10/280,865, (U.S. 2003/0164199) the disclosure of which is incorporated herein by reference.
  • the fabric 10 includes an impermeable material 15 in the form of a pattern or grid 20 on the web forming surface 25 of the forming fabric 10 .
  • the fabric may be woven from yarns, fibers, threads, strands or the like, and that the term “yarns” as used herein is meant to collectively refer to all such elements.
  • the yarns may be of a synthetic or natural material such as metal. Additional structures may be used as the forming fabric substrate, for example, an extruded mesh, a knitted fabric, MD or CD yarn arrays, or other structures suitable for the purpose.
  • the material used to form the pattern or grid 20 on the forming fabric 10 must be impermeable to air.
  • fibers that are deposited on the fabric during one of the previously discussed nonwoven manufacturing processes are drawn by negative airflow or suction created by vacuum boxes located on the non-web forming side of the forming fabric 10 , to the areas of the fabric that are permeable to air.
  • the fibers that are deposited on the fabric accumulate on the air permeable areas of the fabric and not on the areas of the fabric that have been made impermeable with the addition of the impermeable material.
  • gaps 35 are formed between the individual nonwoven sheets in the areas that correspond to the areas of the forming fabric 10 that have been rendered impermeable to form the pattern or grid 20 .
  • the impermeable material can be applied to the fabric surface as a coating using any of the methods well known in the art or the material can be deposited via extrusion or the material can be deposited via a process as described in commonly assigned, copending application, U.S. patent application entitled “Method of Fabricating a Belt and a Belt Used to Make Both Tissue and Towels and Nonwoven Articles and Fabrics”, Ser. No. 10/334,211 (U.S. 2004/016601 A1), the contents of which are incorporated herein by reference.
  • the impermeable material can also be applied in the form of strips or pieces of material having various shapes and sizes and that are attached to the web forming side of the fabric using any mechanical attachment means known to those skilled in the art, including, but not limited to coatings, gluing with an adhesive, stitching, melt bonding or with the use of hook and loop type fasteners, i.e. VELCRO®.
  • the individual nonwoven sheets 34 that are formed using the instant forming fabric are defined by X and Y dimensions. These dimensions define the areas on the fabric between the impermeable material on the surface of the belt. The width of the gaps 35 between the individual nonwoven sheets is dependent on the width of the impermeable material that is attached or applied to the surface of the belt 25 . Therefore, various sizes and shapes of the individual nonwoven sheets, within the dimensions of the forming fabric, can be manufactured by varying the size and/or shape of the pattern or grid formed on the belt surface by the impermeable material.
  • the individual nonwoven sheets do not have to be square or rectangular but can be any shape as defined by a desired pattern formed by the impermeable material. Additionally, a single belt can be designed to produce a plurality of individual nonwoven sheets having varying shapes and sizes.
  • the impermeable material applied to the fabric surface forms a plurality of protuberances (protrusions) on the surface that can have various cross-sectional shapes.
  • the protuberances ensure that the fibers on each side of the protuberances are well separated and are therefore prevented from interacting or becoming entangled with one another.
  • Examples of the various cross-sectional shapes for the protuberances include, but are not limited to: thin, low profile rectangular shapes 40 shown in FIG. 3A ; square shapes 42 having sides 43 of equal lengths as shown in FIG. 3B ; high profile rectangular shapes 45 as depicted in FIG.
  • any shape or material that produces individual nonwoven sheets on the fabric surface can be used to form the protuberances.
  • the protuberances may be constructed of a thermoplastic material similar to that disclosed in commonly assigned, copending application, U.S. patent application entitled “Fabric with V-Guides”, Ser. No. 10/631,937 (U.S. 2005/0025935) albeit for a different purpose, the contents of which are incorporated herein by reference, or they can be formed from a polymeric resin material, such as, but not limited to, polyamide, polyester, polyetherketone, polypropylene, polyolefin, polyurethane, polyketone, or polyethylene terephthalate resins.
  • the protuberances may also be constructed using silicone, rubber or a rubber like material.
  • the protuberances may be in the form of a coating, an extrusion, a material deposition or they can be pre-formed strips or pieces of impermeable material that are mechanically attached to the fabric or formed in a manner as discussed in aforesaid U.S. patent application Ser. No. 10/334,211.
  • the protuberances may be attached to the fabric by melting of a portion of the protuberance in order to encapsulate a portion of the fabric.
  • the impermeable material is applied to the web forming side of the fabric, the corresponding portions on the backside or non-web forming side of the fabric, must not have any surface irregularities due to the addition of the impermeable material as compared to the remainder of the belt. This is because the backside surface of the fabric is in contact with the various rolls and vacuum boxes of the manufacturing apparatus. Therefore, any surface irregularities will adversely affect the fabric's travel through the apparatus and bleed vacuum, which lowers the effectiveness of the airflow system.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)
  • Absorbent Articles And Supports Therefor (AREA)
US11/285,454 2005-11-22 2005-11-22 Sheet slitting forming belt for nonwoven products Abandoned US20070116928A1 (en)

Priority Applications (13)

Application Number Priority Date Filing Date Title
US11/285,454 US20070116928A1 (en) 2005-11-22 2005-11-22 Sheet slitting forming belt for nonwoven products
RU2008119913A RU2414552C2 (ru) 2005-11-22 2006-11-08 Формовочная лента для изготовления нетканых материалов, разделенных на отдельные листы
PCT/US2006/043577 WO2007061635A1 (en) 2005-11-22 2006-11-08 Sheet slitting forming belt for nonwoven products
KR1020087015212A KR20080073347A (ko) 2005-11-22 2006-11-08 부직포 제품을 위한 시이트 분할 성형 벨트
BRPI0619327A BRPI0619327A2 (pt) 2005-11-22 2006-11-08 composição de formação para uso na produção de produtos não tecidos e método para a formação de folhas individuais não tecidas
JP2008541232A JP2009516778A (ja) 2005-11-22 2006-11-08 不織製品用のシートスリット状の形成ベルト
EP06837206A EP1951944A1 (en) 2005-11-22 2006-11-08 Sheet slitting forming belt for nonwoven products
AU2006316842A AU2006316842A1 (en) 2005-11-22 2006-11-08 Sheet slitting forming belt for nonwoven products
CA002628147A CA2628147A1 (en) 2005-11-22 2006-11-08 Sheet slitting forming belt for nonwoven products
CNA2006800432884A CN101313099A (zh) 2005-11-22 2006-11-08 用于非织造产品的切片成形带
TW095142405A TW200730695A (en) 2005-11-22 2006-11-16 Sheet slitting forming belt for nonwoven products
US12/112,512 US20080199655A1 (en) 2005-11-22 2008-04-30 Sheet Slitting Forming Belt for Nonwoven Products
NO20082720A NO20082720L (no) 2005-11-22 2008-06-19 Arkslisseformbelte for fiberstoffprodukter

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US11/285,454 US20070116928A1 (en) 2005-11-22 2005-11-22 Sheet slitting forming belt for nonwoven products

Related Child Applications (1)

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US12/112,512 Division US20080199655A1 (en) 2005-11-22 2008-04-30 Sheet Slitting Forming Belt for Nonwoven Products

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US20070116928A1 true US20070116928A1 (en) 2007-05-24

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US11/285,454 Abandoned US20070116928A1 (en) 2005-11-22 2005-11-22 Sheet slitting forming belt for nonwoven products
US12/112,512 Abandoned US20080199655A1 (en) 2005-11-22 2008-04-30 Sheet Slitting Forming Belt for Nonwoven Products

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US (2) US20070116928A1 (ko)
EP (1) EP1951944A1 (ko)
JP (1) JP2009516778A (ko)
KR (1) KR20080073347A (ko)
CN (1) CN101313099A (ko)
AU (1) AU2006316842A1 (ko)
BR (1) BRPI0619327A2 (ko)
CA (1) CA2628147A1 (ko)
NO (1) NO20082720L (ko)
RU (1) RU2414552C2 (ko)
TW (1) TW200730695A (ko)
WO (1) WO2007061635A1 (ko)

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US10385509B2 (en) 2015-05-01 2019-08-20 The Procter & Gamble Company Unitary deflection member for making fibrous structures having increased surface area and process for making same
US10465340B2 (en) 2015-06-19 2019-11-05 The Procter & Gamble Company Seamless unitary deflection member for making fibrous structures having increased surface area and process for making same
US10676865B2 (en) * 2016-10-27 2020-06-09 The Procter & Gamble Company Deflecting member for making fibrous structures
US10683614B2 (en) * 2016-10-27 2020-06-16 The Procter & Gamble Company Deflecting member for making fibrous structures
US10794004B2 (en) 2016-03-24 2020-10-06 The Procter & Gamble Company Unitary deflection member for making fibrous structures and process for making same
US10933577B2 (en) 2015-05-01 2021-03-02 The Procter & Gamble Company Unitary deflection member for making fibrous structures having increased surface area and process for making same
US11053617B2 (en) * 2013-03-15 2021-07-06 Honeywell International Inc. Ballistic resistant thermoplastic sheet, process of making and its applications
US11396725B2 (en) 2017-10-27 2022-07-26 The Procter & Gamble Company Deflecting member for making fibrous structures

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US11622919B2 (en) 2012-12-13 2023-04-11 Jacob Holm & Sons Ag Hydroentangled airlaid web and products obtained therefrom
US9394637B2 (en) 2012-12-13 2016-07-19 Jacob Holm & Sons Ag Method for production of a hydroentangled airlaid web and products obtained therefrom
US11053617B2 (en) * 2013-03-15 2021-07-06 Honeywell International Inc. Ballistic resistant thermoplastic sheet, process of making and its applications
US10900170B2 (en) 2015-05-01 2021-01-26 The Procter & Gamble Company Unitary deflection member for making fibrous structures having increased surface area and process for making same
US11725342B2 (en) 2015-05-01 2023-08-15 The Procter & Gamble Company Unitary deflection member for making fibrous structures having increased surface area and process for making same
US11427961B2 (en) 2015-05-01 2022-08-30 The Procter & Gamble Company Unitary deflection member for making fibrous structures having increased surface area and process for making same
US10240298B2 (en) 2015-05-01 2019-03-26 The Procter & Gamble Company Unitary deflection member for making fibrous structures having increased surface area and process for making same
US10385509B2 (en) 2015-05-01 2019-08-20 The Procter & Gamble Company Unitary deflection member for making fibrous structures having increased surface area and process for making same
US10933577B2 (en) 2015-05-01 2021-03-02 The Procter & Gamble Company Unitary deflection member for making fibrous structures having increased surface area and process for making same
US10927500B2 (en) 2015-05-01 2021-02-23 The Procter & Gamble Company Unitary deflection member for making fibrous structures having increased surface area and process for making same
US10465340B2 (en) 2015-06-19 2019-11-05 The Procter & Gamble Company Seamless unitary deflection member for making fibrous structures having increased surface area and process for making same
US10900171B2 (en) 2015-06-19 2021-01-26 The Procter & Gamble Company Seamless unitary deflection member for making fibrous structures having increased surface area and process for making same
US11761151B2 (en) 2015-06-19 2023-09-19 The Procter & Gamble Company Seamless unitary deflection member for making fibrous structures having increased surface area and process for making same
US11486093B2 (en) 2015-06-19 2022-11-01 The Procter & Gamble Company Seamless unitary deflection member for making fibrous structures having increased surface area and process for making same
US10794004B2 (en) 2016-03-24 2020-10-06 The Procter & Gamble Company Unitary deflection member for making fibrous structures and process for making same
WO2018081498A1 (en) * 2016-10-27 2018-05-03 The Procter & Gamble Company Deflection member for making fibrous structures
US10844539B2 (en) * 2016-10-27 2020-11-24 The Procter & Gamble Company Deflecting member for making fibrous structures
US10676865B2 (en) * 2016-10-27 2020-06-09 The Procter & Gamble Company Deflecting member for making fibrous structures
EP3656916A1 (en) * 2016-10-27 2020-05-27 The Procter & Gamble Company Deflection member for making fibrous structures
US10865521B2 (en) * 2016-10-27 2020-12-15 The Procter & Gamble Company Deflecting member for making fibrous structures
US10815618B2 (en) * 2016-10-27 2020-10-27 The Procter & Gamble Company Deflecting member for making fibrous structures
US20180119348A1 (en) * 2016-10-27 2018-05-03 The Procter & Gamble Company Deflecting Member for Making Fibrous Structures
US10683614B2 (en) * 2016-10-27 2020-06-16 The Procter & Gamble Company Deflecting member for making fibrous structures
US11486092B2 (en) 2016-10-27 2022-11-01 The Procter & Gamble Company Deflecting member for making fibrous structures
US11585045B2 (en) * 2016-10-27 2023-02-21 The Procter & Gamble Company Deflecting member for making fibrous structures
US20180119350A1 (en) * 2016-10-27 2018-05-03 The Procter & Gamble Company Deflecting Member for Making Fibrous Structures
US20180119351A1 (en) * 2016-10-27 2018-05-03 The Procter & Gamble Company Deflecting Member for Making Fibrous Structures
US11732413B2 (en) 2017-10-27 2023-08-22 The Procter & Gamble Company Deflecting member for making fibrous structures
US11396725B2 (en) 2017-10-27 2022-07-26 The Procter & Gamble Company Deflecting member for making fibrous structures
US12097654B1 (en) 2017-10-27 2024-09-24 The Procter & Gamble Company Deflecting member for making fibrous structures

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WO2007061635A1 (en) 2007-05-31
CN101313099A (zh) 2008-11-26
TW200730695A (en) 2007-08-16
JP2009516778A (ja) 2009-04-23
RU2008119913A (ru) 2009-12-27
EP1951944A1 (en) 2008-08-06
CA2628147A1 (en) 2007-05-31
US20080199655A1 (en) 2008-08-21
KR20080073347A (ko) 2008-08-08
RU2414552C2 (ru) 2011-03-20
NO20082720L (no) 2008-08-15
AU2006316842A1 (en) 2007-05-31
BRPI0619327A2 (pt) 2016-11-29

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