US20090305593A1 - Method for manufacturing a non-woven fabric based on natural wool, plant for applying such method, and product obtained by such method - Google Patents

Method for manufacturing a non-woven fabric based on natural wool, plant for applying such method, and product obtained by such method Download PDF

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Publication number
US20090305593A1
US20090305593A1 US12/375,227 US37522707A US2009305593A1 US 20090305593 A1 US20090305593 A1 US 20090305593A1 US 37522707 A US37522707 A US 37522707A US 2009305593 A1 US2009305593 A1 US 2009305593A1
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United States
Prior art keywords
wool
fibres
flocks
needle
woven fabric
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Abandoned
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US12/375,227
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English (en)
Inventor
Alberto Schiavi
Lorenzo Pernigotti
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ORSA Srl
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ORSA Srl
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Assigned to ORSA S.R.L. reassignment ORSA S.R.L. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: PERNIGOTTI, LORENZO, SCHIAVI, ALBERTO
Publication of US20090305593A1 publication Critical patent/US20090305593A1/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
    • 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
    • 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
    • D04H1/42—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 characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4266—Natural fibres not provided for in group D04H1/425
    • 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
    • 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
    • D04H1/74—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 orientated, e.g. in parallel (anisotropic fleeces)
    • 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.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]

Definitions

  • the present invention concerns a method and a plant for the manufacture of a non-woven fabric, in particular a non-woven fabric based on natural wool, as well as the product obtained by such method.
  • a non-woven fabric is a substantially bi-dimensional, semi-processed product, which is obtained by assembling a plurality of natural or synthetic fibres of a certain length. From this point of view, it is radically different from a classic woven fabric, which is instead put together starting from yarns of indefinite length and using weaving machines which accomplish a classic weft-warp configuration.
  • a needle punching machine is a work station equipped with one or more pairs of arrays of opposite needles (having specific arrangements), which are interpenetrated and alternately moved apart, while a veil of fibres to be processed is made to move between the same; when the two opposite arrays of needles are repeatedly moved closer and further apart, causing the needles to interpenetrate, the interposed fibres are “needle punched”, i.e. they interleave and mechanically connect with one another: this allows to impart a certain cohesion to the veil of fibres.
  • the needle punching process may work—i.e. it may supply a stable non-woven fabric—only in specific conditions, i.e. when the veil of raw material is of an adequate basic weight and when the needles are arranged diagonally and/or characterised by the presence of special hooks.
  • the object of the present invention is hence that of providing a plant and relative treatment method for obtaining non-woven fabrics based on natural wool.
  • a further object of the invention is to provide a product of non-woven fabric based on natural wool which is soft, with a good handle, resistant (also to dying treatments) and suited to a number of applications.
  • FIG. 1 is a schematic view illustrating an exemplifying plant of the invention
  • FIG. 2 is an elevation side view of an exemplifying plant of the invention
  • FIG. 3 is a section view of an exemplifying plate of needles of the needle punching machine employed in the invention
  • FIG. 4 is an elevation view of a needle of the plate of FIG. 3 ;
  • FIG. 5 is a schematic view of an enlarged detail of the water jet station shown in FIG. 2 ;
  • FIGS. 6A and 6B are microscope pictures, with 4 ⁇ lens, 40 ⁇ eyepiece, 128 ⁇ video enlargement and 10 ⁇ lens, 100 ⁇ eyepiece, 320 ⁇ video enlargement, respectively, of the fabric according to the invention after needle punching;
  • FIGS. 7A and 7B are pictures as in FIGS. 6A and 6B of the non-woven fabric after treatments with water jets.
  • FIGS. 8A and 8B are pictures as in FIGS. 6A and 6B of the non-woven fabric after a dying treatment.
  • the manufacturing process provides to start from processed wool, in a manner known per se, so as to have flocks of sufficient volume and uniformity.
  • This first treatment may be performed for example with any known-type mechanical process.
  • the wool flocks are then mixed with variously-sized flocks of synthetic fibres, such as fibres of polyester, polyamide, viscose, acrylic, bamboo, PLA and preferably microfibre, in an amount ranging from 20 to 50% by weight, better about 30%.
  • microfibre flocks are particularly preferred, which impart excellent mechanical and physical qualities to the final woollen fabric;
  • a particularly suited microfibre is the one called “mechanical splittable”, made of polyester/polyamide, for example the one marketed by Far East Textile Ltd. under the name EASTLON SY1250SMS MICRO-SPLIT.
  • fibres are intended with a count below 1 dtex or conjugated fibres, with count above 1 dtex, splittable into ultrafine or super ultrafine segments (with count of 0.09-0.13 dtex) through solvents, alkali or mechanical action (high-pressure water jets).
  • the mixing of the wool flocks with the synthetic fibre flocks must be carried out until a uniform base product is achieved; mixing can be carried out, for example, in a carding willow and mixing box for a time of about 3-4 hours depending on the amount of fibres to be mixed.
  • the mixed mass then undergoes a process by means of a carding machine/veil-forming machine 2 , with subsequent possible pleating machine, to obtain a continuous processable veil, of a thickness from 6 to 8 cm and weight from 120 to 300 g/m 2 , depending on the thickness of the final product which it is intended to achieve.
  • the veil of fibres is preferably stretched by a gill box and then placed on a first needle-punching station 3 , where it is needle-punched with techniques known per se.
  • a needle punching machine manufactured by Fehrer AG may be used.
  • Needle punching may also be carried out through one or more subsequent steps, for example carrying out also a pre-needle-punching.
  • the fabric undergoes an interleaving treatment with water jets 4 (a so-called “spunlace” treatment), which dignifies the non-woven, needle-punched fabric.
  • a so-called “spunlace” treatment a so-called “spunlace” treatment
  • the Applicant has detected that this stage is very advantageous for the good outcome of the process with woollen fibres, because the number and solidity of the bonds between the fibres is increased.
  • the microfibres are divided (split) by the water jets and the ultrathin fibres thereby forming further bind the woollen fibres.
  • Water-jet interleaving hence allows to complete and dignify the non-woven, needle-punched fabric, making it more close-knit, uniform and soft, which result is critical to be able to obtain the desired product based on woollen fibres.
  • Water-jet interleaving is preferably carried out with a jet density of 12-18 per linear cm, preferably 16 per linear cm, at a pressure of 250-400 bar, preferably 150-250 bar, at a low advancement speed.
  • Needle-punching allows to provide a first compaction and intersecting of the mixed woollen/synthetic fibres, also starting from a veil of a significant width (for example above 8 cm). This allows to obtain a substrate suitable to make the subsequent water-jet interleaving effective—which would otherwise be unable to interact with the deeper fibres—which imparts desired characteristics of handle, feel, porosity and cohesion. It is thereby possible to obtain soft and close-knit fabrics, starting from a veil of a thickness even above 8 cm, without nevertheless excessively forcing the needle-punching process which would inevitably lead to a felt-type product.
  • the non-woven fabric based on natural wool has the characteristic pore fineness and hairiness as the “spunlace”, as well as the good edge shear resistance. Due to the high cohesion obtainable through coupling the two treatments, the woollen, non-woven fabric also has a high resistance to tearing and withstands multiple washing cycles. Moreover, precisely in the light of these qualities, the non-woven fabric of the invention can perfectly withstand a dying treatment even at the end of the process, which dying would instead be much more difficult to carry out on the raw material (i.e., upstream of the processing, directly on the fibres). Also this last feature further extends the field of application of the product according to the invention.
  • the Applicant was able to ascertain that the woollen fabric obtained through the process and the plant of the inventions surprisingly has features never obtained so far by using needle-punching processes only or of water-jet interleaving only.
  • the non-woven fabric manufactured according to the invention may find application in the field of blankets or insulating panels, in lining materials and tapestry (including the automotive industry)—also as a replacement of foams, provided it is manufactured with a suitable thickness/volume—in filters, both dry ones and wet ones, in the field of cleaning cloths (wherein it develops a polishing effect, thanks to the wool component), in the clothing industry and other.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Woven Fabrics (AREA)
US12/375,227 2006-07-27 2007-07-24 Method for manufacturing a non-woven fabric based on natural wool, plant for applying such method, and product obtained by such method Abandoned US20090305593A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
ITMI2006A001484 2006-07-27
IT001484A ITMI20061484A1 (it) 2006-07-27 2006-07-27 Metodo di fabbriczione di un tessuto non tessuto a base di lana naturale,impianto per tale processo e prodotto ottenuto con esso
PCT/IB2007/052930 WO2008029307A2 (fr) 2006-07-27 2007-07-24 Procédé de fabrication d'un tissu non tissé à base de laine brute, équipement pour réaliser ce procédé et produit obtenu au moyen d'un tel procédé

Publications (1)

Publication Number Publication Date
US20090305593A1 true US20090305593A1 (en) 2009-12-10

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US12/375,227 Abandoned US20090305593A1 (en) 2006-07-27 2007-07-24 Method for manufacturing a non-woven fabric based on natural wool, plant for applying such method, and product obtained by such method

Country Status (5)

Country Link
US (1) US20090305593A1 (fr)
EP (1) EP2049719A2 (fr)
JP (1) JP2009544862A (fr)
IT (1) ITMI20061484A1 (fr)
WO (1) WO2008029307A2 (fr)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20110177296A1 (en) * 2010-01-21 2011-07-21 Marco Maranghi Process for preparing a non-woven fabric having a surface covered with microfiber and fabric obtainable with said process
US20170057126A1 (en) * 2014-09-22 2017-03-02 Mary Anderle Blended Fiber Pad
CN109537354A (zh) * 2018-11-28 2019-03-29 山东昌诺新材料科技有限公司 一种竹纤维和木浆水刺复合清洁布及其制备方法

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2010109273A1 (fr) * 2009-03-27 2010-09-30 Csir Procédé de fabrication d'un milieu de filtre à air non-tissé
ITBZ20090025A1 (it) * 2009-05-27 2010-11-28 Johannes Winkler Tappeto di protezione per piante, in particolare viti e un processo per la sua realizzazione.
EP3216433B1 (fr) * 2016-03-08 2018-11-21 The Procter and Gamble Company Toile de fibres non tissées cardées et utilisation dans des articles absorbants
CN112831912B (zh) * 2021-02-05 2023-10-03 刘超 超薄椰棕平垫的生产流水线及椰棕平垫的制作方法

Citations (3)

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US6378179B1 (en) * 2001-01-05 2002-04-30 Gary F. Hirsch System and method for reconstituting fibers from recyclable waste material
US20050118918A1 (en) * 2001-12-21 2005-06-02 Werner Schafer Flame-resistant wadding material for clothing protecting against thermal effects
US20100215895A1 (en) * 2005-08-10 2010-08-26 Reliance Industries Ltd. Process of producing ultra fine microdenier filaments and fabrics made thereof

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JP2582994Y2 (ja) * 1992-12-25 1998-10-15 富一 中辻 Ｏａ機器用などのフェルト素材
JPH0719333U (ja) * 1993-09-13 1995-04-07 株式会社フジコー 紫外線カットのフード
JPH0719455U (ja) * 1993-09-20 1995-04-07 株式会社フジコー 紫外線カットのシェード
CN1034879C (zh) * 1994-08-11 1997-05-14 宁波德艺成服装辅料实业公司 领底呢的制备工艺
EP0884413A1 (fr) * 1997-06-13 1998-12-16 Bonded Fibre Fabric Limited Etoffe non tissée
JPH11200213A (ja) * 1998-01-19 1999-07-27 Unitika Ltd 不織布及びその製造方法
NL1010029C1 (nl) * 1998-09-08 2000-03-09 Proeco B V I O Werkwijze voor het vervaardigen van een in hoofdzaak uit katoenvezels bestaand niet geweven textielmateriaal.
JP2006171046A (ja) * 2004-12-13 2006-06-29 Fujikoo:Kk オイル供給装置とクリーニング装置

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6378179B1 (en) * 2001-01-05 2002-04-30 Gary F. Hirsch System and method for reconstituting fibers from recyclable waste material
US20020124366A1 (en) * 2001-01-05 2002-09-12 Hannagan-Tobey Llc System and method for reconstituting fibers from recyclable waste material
US20050118918A1 (en) * 2001-12-21 2005-06-02 Werner Schafer Flame-resistant wadding material for clothing protecting against thermal effects
US20100215895A1 (en) * 2005-08-10 2010-08-26 Reliance Industries Ltd. Process of producing ultra fine microdenier filaments and fabrics made thereof

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20110177296A1 (en) * 2010-01-21 2011-07-21 Marco Maranghi Process for preparing a non-woven fabric having a surface covered with microfiber and fabric obtainable with said process
US8584328B2 (en) * 2010-01-21 2013-11-19 Marco Maranghi Process for preparing a non-woven fabric having a surface covered with microfiber and fabric obtainable with said process
US20170057126A1 (en) * 2014-09-22 2017-03-02 Mary Anderle Blended Fiber Pad
US9731436B2 (en) * 2014-09-22 2017-08-15 Mary Anderle Blended fiber pad
CN109537354A (zh) * 2018-11-28 2019-03-29 山东昌诺新材料科技有限公司 一种竹纤维和木浆水刺复合清洁布及其制备方法

Also Published As

Publication number Publication date
JP2009544862A (ja) 2009-12-17
WO2008029307A2 (fr) 2008-03-13
ITMI20061484A1 (it) 2008-01-28
WO2008029307A3 (fr) 2008-05-15
EP2049719A2 (fr) 2009-04-22

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AS Assignment

Owner name: ORSA S.R.L., FRANCE

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:SCHIAVI, ALBERTO;PERNIGOTTI, LORENZO;REEL/FRAME:022160/0707

Effective date: 20090126

STCB Information on status: application discontinuation

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