US3403425A - Method of manufacturing webs - Google Patents

Method of manufacturing webs Download PDF

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Publication number
US3403425A
US3403425A US558121A US55812166A US3403425A US 3403425 A US3403425 A US 3403425A US 558121 A US558121 A US 558121A US 55812166 A US55812166 A US 55812166A US 3403425 A US3403425 A US 3403425A
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US
United States
Prior art keywords
fibers
needles
slivers
separating
webs
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.)
Expired - Lifetime
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US558121A
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English (en)
Inventor
Tajima Eiichi
Yamamoto Kaname
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Individual
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Individual
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Publication date
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Priority to US558121A priority Critical patent/US3403425A/en
Priority to NL6804709A priority patent/NL6804709A/xx
Priority to BE714033D priority patent/BE714033A/xx
Priority to AT392268A priority patent/AT301400B/de
Priority to GB09040/68A priority patent/GB1211894A/en
Priority to LU55949A priority patent/LU55949A1/xx
Priority to CH626268A priority patent/CH490554A/de
Priority to FR149813A priority patent/FR1562546A/fr
Priority to DE19681760299 priority patent/DE1760299A1/de
Application granted granted Critical
Publication of US3403425A publication Critical patent/US3403425A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/10—Fibres of continuous length
    • B32B2305/20—Fibres of continuous length in the form of a non-woven mat

Definitions

  • the present invention relates to an improved method for forming nonwoven webs in the form of a sheet or a mat, and particularly to an improved method for forming synthetic fibers or natural fibers into webs of the aforesaid type for use as waterproof material or filters for industrial purposes.
  • Cloth-like or sheet-form webs formed with textile fibers without processing such fibers through a spinning machine, a weaving machine or a knitting machine are used for a variety of purposes.
  • webs of the aforesaid type which are formed by binding together th fibers by impregnating them with a thermoplastic or rubber-like binder, or webs formed by partially fusing thermoplastic fibers, are known as the so-called nonwoven fabrics.
  • Such processed webs have many uses. For example, there are processed webs which are used as clothing materials, imitation leathers, packing materials, construction materials, and also those for industrial purposes as, for example, filter cloths.
  • webs are produced by the so-called wet methods which includes methods using paper-manufacturing machines and other webs are obtained by means of still further web forming processes which are commonly called dry methods.
  • the latter are exemplified by several types of methods, one of which comprises the steps of forming cotton-form fibers into a thin layer of web through a carding machine or a garnetting machine and laminating such layers into a plurality of layers of a desired thickness.
  • Another method called the Proctor & Schwaltz method, comprises the step of scattering thinly accumulated layers of fibers in a pressurized air current.
  • Still another method, called the Rando Webber method is the combination of such a fiber scattering method and a hopper feeding method.
  • the invention described herein eliminates the aforestated drawbacks of the conventional webs and produces webs with desirable properties by a combination of two features, namely, adequately selected starting fibers and a processing procedure matched with the selected fibers.
  • the invention provides a novel and improved method for manufacturing webs that not only solves all the difficul- 3,403,425 Patented Oct. 1, 1968 ice ties encountered in the webs manufactured by the conventional methods as have been discussed above, but also satisfied all of the desired objects which will be described later herein.
  • An object of the present invention is to provide an improved method for manufacturing nonwoven fiber webs.
  • Another object of the present invention is to provide a method of manufacturing such webs having a property represented by increased strength and rigidity.
  • Still another object of the present invention is to provide a method of manufacturing webs having such an improved property as is represented by increased strength and rigidity and being suited for being used for many purposes.
  • Yet another object of the present invention is to provide a method of manufacturing webs which permits an increased efliciency and economy in the processing of the starting fibers.
  • FIGURE 1 is a schematic illustration of apparatus for performing the steps of the method of the invention.
  • FIGURE 2 is a perspective view of the needle roll of the apparatus.
  • the starting fibers used are limited to either synthetic filament tows of regular type, or stiff and lengthy natural fibers instead of such fibers which have been preliminarily converted into raw cotton wool form as have been used in the conventional methods.
  • the purport of the present invention lies in that the webs are formed by the following procedure which comprises the steps of: preparing slivers of such starting filaments or fibers as have been described above by a known method; feeding the formed slivers between a pair of rotating nip rollers; receiving the outcoming rolled slivers continuously in a substantially uniform amount on a needled roller disposed at the discharge side of the nip rollers; spreading the staple fibers by virtue of the mechanical fiber separation action of said needled roller and also by virtue of the pressurized air current created by the rotation of said needled roller; and accumulating the spread staple fibers on the surface of a travelling net-form air-permeable belt of a conveyor of the next stage by virtue of a suction force applied to said conveyor from
  • the preferred starting fibers used in the present invention are comprised of synthetic filament tows of regular type made of materials such as vinylon, nylon, polyester, polyethylene, polypropylene or polyvinylidene chloride,
  • synthetic filament tows of regular type made of materials such as vinylon, nylon, polyester, polyethylene, polypropylene or polyvinylidene chloride
  • natural fibers such as Manila hemp fibers, Sisal hemp fibers, jute fibers or ramie fibers may also be used, provided that they are lengthy fibers with a considerably coarse degree of fineness.
  • synthetic filament tows there is the particular advantage in that the individual monofilaments constituting the tows may have a fineness of a wide range from 1 denier to 500 denier, more or less.
  • the operation first begins with converting such starting filaments as have been discussed into slivers.
  • synthetic filament tows are used as the starting material, such tows are broken or cut into a desired length by a Perlock type breaker, a tarbo-stapler, a Pacific convertor or like means, whereby to form the tows into slivers.
  • the permissible range of the length of the individual fibers for constituting a sliver is from 50 mm. to 1000 mm., more or less.
  • the starting fibers are used either without cutting them or after the fibers are cut into a desired length; and the cut fibers are successively subjected to a breaker, a spreader and a finisher of a drawing machine to form in a conventional and well known manner the cut fibers into slivers.
  • the fineness of the monofilaments of the synthetic filament tows is so fine as is several scores of denier or less, the tows can be made in slivers through a breaker-type apparatus.
  • Webs are manufactured from the slivers which are obtained in such manner as has been described above. A description will now be made of the steps of manufacturing webs by referring to the drawing.
  • Each run of sliver from these cans is fed in succession to a pair of nip rollers 3 comprising an upper roller and a lower roller.
  • This pair of rollers 3 is rotated at a constant, low speed.
  • the sliver fed to the nip rollers is seized firmly between the circumferences of the pair of rollers and fed further to the next step.
  • a needled roller 4 At the discharge side of the nip rollers is provided a needled roller 4 which has a peripheral speed and a diameter markedly greater than those of the nip rollers.
  • the sliver which is discharged from the nip rollers, is loosened when it is brought into contact with the needles extending radially from the surface of the roller, and the fibers are separated from each other by the needles.
  • said individual fiber which is partially engaged by the needles, is drawn forward in the rotational direction of the roller by virtue of the pulling force of the needles.
  • the fiber which now has been drawn completely out of engagement by the nip rollers and is now located on the needles of the needled roller is driven by the air current which is produced by the rotation of the needled roller to be transferred onto the web-forming, net-form belt of the conveyor 5 of the next stage.
  • the individual staple fibers 7 which have passed the nip point of the nip rollers 3 are fed always in a continuous uniform mass and accordingly a uniform amount of fibers is transferred continuously onto the surface of the belt.
  • the conveyor belt 5 is comprised of an endless belt of wire net and the belt is so designed that the ambient air on the upper surface of the belt is sucked through to the other side of the net by virtue of the suction force created by the exhausting fan 6.
  • the individual staple fibers which have been spread by the blowing action of the needled roller fall on the surface of the constantly moving net of the conveyor one after another, and while being subjected to the suction force produced on the net, the fibers are accumulated on the net in random directions and are thus formed into a web 8 having a substantially uniform thickness all over as a web.
  • the constantly produced web sheet is transferred successively to a transfer conveyor 9' disposed ahead of the belt conveyor 5 to discharge the web as a product.
  • the web thus obtained is now subjected, as desired, to treatment according to the purposes.
  • One thing which requires attention in the web manufacturing procedure of the present invention is the structure of the needled roller.
  • a roller which has sliverloosening and fiber-separating needles merely planted on the periphery of the roller is used, no satisfactory air current is produced by the rotation of such roller, and this leads to the result that a number of staple fibers become entangled with the needles and the entangled staple fibers gradually become accumulated there to cause impairment of the fiber-separating function of the needles.
  • the accumulated mass of staple fibers after reaching a certain volume, becomes separated therefrom one mass after another and contributes to making the thickness of the formed web uneven.
  • the preferred type of needled roller which is used in the present invention is of the structure that the needles 11 are secured to bars 12 which are, in turn, disposed on the periphery of a roller and extend longitudinally thereof at spaced intervals relative to the rotational direction of the roller, or of the structure wherein the roller is provided with a plurality of grooves or narrow recesses 13 of a substantial depth disposed longitudinally on the periphery of the roller and the needles are planted on each ridge 12 between the grooves.
  • the recesses or the grooves formed on the periphery of the roller work as a kind of windmill and creates a strong current of air in the direction of the rotation of the roller.
  • the air current prevents the staple fibers from being tangled about the needles and permits the entire staple fibers to be easily separated from each other and to be scattered.
  • the air which is sucked by virtue of the suction force produced by the exhausting fan may be recycled, without being discharged outside the fan, as an air current to be applied onto the surface of the needled roller to assist the separation and scattering of the staple fibers carried by the needles of the roller.
  • the starting fibers used may have a wide range of fineness and also may have, as a sliver, a long cut strength.
  • the webs manufactured according to the method of the present invention have no particular orientation of fibers and thus they are suited for being used as the material for industrial filters.
  • This entangled staple fiber mat is also useful when used as a pad for making fiber reinforced plastics because of the fact that the mat is made of crimpless fibers.
  • an appropriate type of binder such as rubber latex, synethetic resin emulsion, natural or synthetic glue of high molecular weight
  • the product which is made of the aforestated type of web and impregnated or coated with a material such as blown asphalt and molded into an asphalt roofing form shows remarkable strength and stretchability as compared with similar products manufactured according to the conventional methods.
  • a membrane water-proof laminated product having this latter processed product, which has just been described, as the pad displays a marked breakresistance and good resistance to the cracking tendency of the portions of buildings which are given water-proof treatment, and for this reason this product ensures outstanding reliability when used for such purposes.
  • a product which is made by first molding a web sheet manufactured according to the method of the present invention with a synthetic resin or rubber binder and by subsequently lining one side thereof with a film or sheet made of a material such as synthetic resin, rubber or like substances, and a product which is made by sandwiching such molded sheet between two films or sheets made of the aforesaid materials, are suited as reinforcement materials for flooring materials, tarpaulin cloths or like goods.
  • EXAMPLE 1 Vinylon tows each having a total fineness of 1 million denier and comprising filaments with a fineness of 3 denier were formed, through Parlock type drawing machines, into slivers of staple fibers with an average length of 150 mm. and an average weight of 12.5 grams per meter. 20 runs of such slivers which were disposed at the distance of 50 mm. relative to each other in a row were fed to nip rollers which rotated at the peripheral speed of 20 meters per minute. The rolled sliver being discharged continuously from the nip rollers was received by a needled roller having needles of 50 mm.
  • the mixture was fed to a drawing machine comprising a breaker, a spreader and a finisher, to convert in a conventional and well known manner the mixture of fibers into slivers. runs of such slivers were fed to nip rollers rotating at the peripheral speed of l0 meters per minute.
  • the sliver discharged from the nip rollers was treated in the same way as that in Example 1, and a web of uniform quality of 600 g./m. was obtained.
  • a method of manufacturing nonwoven webs from long, straight fibers comprising the steps of:
  • slivers of crimpless, long, staple fibers having an approximate average length of at least about millimeters with the fibers of said slivers being substantially free of entanglements with each other;

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Laminated Bodies (AREA)
US558121A 1966-06-16 1966-06-16 Method of manufacturing webs Expired - Lifetime US3403425A (en)

Priority Applications (9)

Application Number Priority Date Filing Date Title
US558121A US3403425A (en) 1966-06-16 1966-06-16 Method of manufacturing webs
NL6804709A NL6804709A (de) 1966-06-16 1968-04-03
AT392268A AT301400B (de) 1966-06-16 1968-04-22 Verfahren zur Herstellung eines nichtgewebten Gebildes oder einer Matte aus Fasern sowie Nadelwalze zur Durchführung des Verfahrens
BE714033D BE714033A (de) 1966-06-16 1968-04-22
GB09040/68A GB1211894A (en) 1966-06-16 1968-04-23 A method for manufacturing a non-woven web or layer from fibres and products manufactured according to said method
LU55949A LU55949A1 (de) 1966-06-16 1968-04-23
CH626268A CH490554A (de) 1966-06-16 1968-04-26 Verfahren zur Herstellung von Faservliesware und nach diesem Verfahren hergestelltes Erzeugnis
FR149813A FR1562546A (de) 1966-06-16 1968-04-26
DE19681760299 DE1760299A1 (de) 1966-06-16 1968-04-30 Verfahren und Vorrichtung zur Herstellung einer nicht gewebten Fasermatte oder Bahn

Applications Claiming Priority (9)

Application Number Priority Date Filing Date Title
US558121A US3403425A (en) 1966-06-16 1966-06-16 Method of manufacturing webs
NL6804709A NL6804709A (de) 1966-06-16 1968-04-03
AT392268A AT301400B (de) 1966-06-16 1968-04-22 Verfahren zur Herstellung eines nichtgewebten Gebildes oder einer Matte aus Fasern sowie Nadelwalze zur Durchführung des Verfahrens
BE714033 1968-04-22
GB09040/68A GB1211894A (en) 1966-06-16 1968-04-23 A method for manufacturing a non-woven web or layer from fibres and products manufactured according to said method
LU55949A LU55949A1 (de) 1966-06-16 1968-04-23
CH626268A CH490554A (de) 1966-06-16 1968-04-26 Verfahren zur Herstellung von Faservliesware und nach diesem Verfahren hergestelltes Erzeugnis
FR149813 1968-04-26
DE19681760299 DE1760299A1 (de) 1966-06-16 1968-04-30 Verfahren und Vorrichtung zur Herstellung einer nicht gewebten Fasermatte oder Bahn

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US3403425A true US3403425A (en) 1968-10-01

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US558121A Expired - Lifetime US3403425A (en) 1966-06-16 1966-06-16 Method of manufacturing webs

Country Status (9)

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US (1) US3403425A (de)
AT (1) AT301400B (de)
BE (1) BE714033A (de)
CH (1) CH490554A (de)
DE (1) DE1760299A1 (de)
FR (1) FR1562546A (de)
GB (1) GB1211894A (de)
LU (1) LU55949A1 (de)
NL (1) NL6804709A (de)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2235270A1 (de) * 1971-07-20 1973-02-08 Kendall & Co Verfahren zur erzeugung eines faserflors
US4097965A (en) * 1976-08-17 1978-07-04 Scott Paper Company Apparatus and method for forming fibrous structures comprising predominantly short fibers
US4390336A (en) * 1980-02-15 1983-06-28 Gaf Corporation Apparatus for air laid fiberglass mat
US4514880A (en) * 1983-03-07 1985-05-07 Allied Corporation Formation of nonwoven webs or batts from continuous filament tow or yarn strands

Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US43845A (en) * 1864-08-16 Improvement-in the feed meckanis of batting-machines
US188164A (en) * 1877-03-06 Improvement in cotton cleaning and straightening machines
US2676363A (en) * 1949-02-23 1954-04-27 Chicopee Mfg Corp Method and apparatus for making fabrics
US2702069A (en) * 1951-01-30 1955-02-15 Owens Corning Fiberglass Corp Method for forming fibrous mats
US2789319A (en) * 1952-12-23 1957-04-23 Johns Manville Fiber opener and cleaner
US2878526A (en) * 1956-03-05 1959-03-24 Jr Michael F Kilty Apparatus for making non-woven fibrous webs
US2913365A (en) * 1954-12-01 1959-11-17 C H Dexter & Sons Inc Fibrous webs and method and apparatus for making same
GB898824A (en) * 1957-11-09 1962-06-14 Fehrer Ernst Improvements in or relating to a process of and apparatus for making rope yarns
US3071821A (en) * 1960-06-10 1963-01-08 Crompton & Knowles Corp Method of producing discontinuous fibers from continuous filaments incident to forming a nonwoven web

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US43845A (en) * 1864-08-16 Improvement-in the feed meckanis of batting-machines
US188164A (en) * 1877-03-06 Improvement in cotton cleaning and straightening machines
US2676363A (en) * 1949-02-23 1954-04-27 Chicopee Mfg Corp Method and apparatus for making fabrics
US2702069A (en) * 1951-01-30 1955-02-15 Owens Corning Fiberglass Corp Method for forming fibrous mats
US2789319A (en) * 1952-12-23 1957-04-23 Johns Manville Fiber opener and cleaner
US2913365A (en) * 1954-12-01 1959-11-17 C H Dexter & Sons Inc Fibrous webs and method and apparatus for making same
US2878526A (en) * 1956-03-05 1959-03-24 Jr Michael F Kilty Apparatus for making non-woven fibrous webs
GB898824A (en) * 1957-11-09 1962-06-14 Fehrer Ernst Improvements in or relating to a process of and apparatus for making rope yarns
US3071821A (en) * 1960-06-10 1963-01-08 Crompton & Knowles Corp Method of producing discontinuous fibers from continuous filaments incident to forming a nonwoven web

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2235270A1 (de) * 1971-07-20 1973-02-08 Kendall & Co Verfahren zur erzeugung eines faserflors
US4097965A (en) * 1976-08-17 1978-07-04 Scott Paper Company Apparatus and method for forming fibrous structures comprising predominantly short fibers
US4390336A (en) * 1980-02-15 1983-06-28 Gaf Corporation Apparatus for air laid fiberglass mat
US4514880A (en) * 1983-03-07 1985-05-07 Allied Corporation Formation of nonwoven webs or batts from continuous filament tow or yarn strands

Also Published As

Publication number Publication date
LU55949A1 (de) 1968-07-11
DE1760299A1 (de) 1972-03-23
FR1562546A (de) 1969-04-04
GB1211894A (en) 1970-11-11
BE714033A (de) 1968-09-16
CH490554A (de) 1970-05-15
NL6804709A (de) 1969-10-07
AT301400B (de) 1972-09-11

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