US3409959A - Process for manufacturing nonwoven fabrics - Google Patents

Process for manufacturing nonwoven fabrics Download PDF

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Publication number
US3409959A
US3409959A US555817A US55581766A US3409959A US 3409959 A US3409959 A US 3409959A US 555817 A US555817 A US 555817A US 55581766 A US55581766 A US 55581766A US 3409959 A US3409959 A US 3409959A
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United States
Prior art keywords
lap
fibers
needles
welding
needle
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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US555817A
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English (en)
Inventor
Barboni Franco Papalini
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.)
RESINTEX SA
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RESINTEX SA
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Filing date
Publication date
Priority claimed from ES0314818A external-priority patent/ES314818A1/es
Priority claimed from ES0317787A external-priority patent/ES317787A1/es
Application filed by RESINTEX SA filed Critical RESINTEX SA
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Publication of US3409959A publication Critical patent/US3409959A/en
Anticipated expiration legal-status Critical
Expired - Lifetime 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
    • D04H1/54—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
    • D04H1/542—Adhesive 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
    • D04H1/44—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
    • D04H1/44—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
    • D04H1/48—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 in combination with at least one other method of consolidation

Definitions

  • ABSTRACT OF THE DISCLOSURE An improvement in the manufacture of nonwoven fabrics is comprised of punching a needle having a hooked end in a down and up motion completely through a lap of loose fibers. As the needle emerges from the lap in its upward path it draws a beam of fibers from the lower face of the lap through its upper face. With the needle Withdrawn, the lap of fibers is displaced in the general direction of the fibers and as the movement of the lap is completed the needle again passes downwardly inserting the beam of fibers back into the lap at a different position. The cyclical down and up movement of the needle and the movement of the lap of fibers forms a continuous stitching of the fibers. A small portion of the fibers making up the lap have a welding rate different from the remaining fibers in the lap and the lap of fibers are consolidated by welding the fibers having a different welding rate from the other fibers in the lap.
  • This invention concerns improvements in the procedures for manufacturing nonwoven fabrics, and a method of intertwining their fibers.
  • the object of this invention is to produce a fabric or cloth from one or more layers of fiber laps, having a de gree of quality and a set of properties characteristically very similar to those of woven fabrics as produced through conventional weaving methods.
  • conventional woven fabrics such as those made from warp and weft yarns, knitted fabrics, and others, exhibit specific properties, particularly those of shape retention, resiliency, stretchability, excellent foldability, transpirability, abrasion strength, and other desirable properties. All such characteristics are more or less marked, and they depend on the end-use intended for the fabric, on the type of fiber used in manufacturing the fabric, on its weave, on its finish, and on a number of other factors.
  • An object of this invention is to effect improvements to obtain, from a mass of loose fibers forming one or more successixe layers, homogeneous or otherwise, through a combination of the methods described below, a cloth made of fibers, nonwoven, and provided with characteristics similar to those of woven fabrics, namely foldability into soft, nonrigid folds, a smooth feel and remarkable flexibility, while showing simultaneously a high level of tensile, rub, friction and similar strengths.
  • the combination of the operations which characterize the improvements forming the object of this invention is based on a special handling Off the loose fibers, to achieve their self-linkage within the lap, and on the welding of some such fibers, so that their self-linkage is thus consolidated.
  • a special handling Off the loose fibers to achieve their self-linkage within the lap, and on the welding of some such fibers, so that their self-linkage is thus consolidated.
  • a further object of the invention is a method to achieve this particular intertwining of the fibers in the lap, through a suitable diaplacement of such fibers, thus causing their self-linkage.
  • this lap both as regards quality and quantity of fibers, and the superimposition of layers or webs of either identical or dissimilar nature, will partially influence the properties of the finished product.
  • a necessary and sufficient condition for the success of this method it will sufiice for a given proportion of the fibers forming the lap to exhibit welding rates differing from those of the remaining fibers in the mixture.
  • Such proportion must be small, say from 1 to 10 percent, and may vary according to the characteristics of the fibers used for making such individual lap.
  • a lap may be formed of fibers of different qualities, enriching for instance one face with the best quality fibers, to obtain better results at a lower cost. Similar arrangements may be made in connection with all other characteristics, such as color, finish, and others.
  • the lap required is subject to a special punching operation, which is also an essential part of the method of the invention.
  • punching the natural structure of the lap, i.e., its particular fiber arrangement, goes through a substantial modification which will depend on the strength and such other features as are required in the end product.
  • the lap may be subject to the action of toothed steel needles, the teeth of which point towards the needle tip.
  • toothed needles by repeatedly piercing the mass of the lap, at right angles to its outer faces, modify the arrangement of some fibers, as these are drawn along by the needles in their movement, and are left laying across the general direction of all the remaining fibers in the lap.
  • the operation last described is replaced by a double-purpose punching, whereby some of the fibers are not only laid across the general fiber direction within the mass of the lap, but their self-linkage is achieved in the following manner.
  • the lap is pierced in a systematic way by needles having a hook fitted at the tip, so that, on the withdrawal of the needle, this hook draws along a beam of fibers making it travel upwards across the lap, until it reaches the upper face. On its travel, this beam loses a number of fibers and leaves them laying across the mass of fibers, until the hooked tip of the needle is no longer in touch with the lap.
  • the lap is automatically moved aside so that the needle, on piercing its upper surface again, does so at a different place.
  • This piercing takes place while its hook still holds some of the fibers drawn, and they are thus introduced again into the lap, to form, together with any other fibers freshly drawn, a downwards path in the opposite direction, until the lower face of the lap is reached by the needle tip.
  • the insertion into the lap of fibers that were previously drawn from inside the same lap is helped by the toothed design of the needles, as their teeth serve to insert fibers into the lap as well as to draw along fresh ones to reinforce the former.
  • An endless, systematic punching operation as described results in a series of stitches made up from fibers of the lap itself, such stitches helping to bind the whole mass of fibers and to achieve full linkage between the two outer faces of the lap.
  • a perfect finish can be imparted to the lap, in such a manner that fibers are displaced without any stresses or breakages whatever, and a perfect intertwining of the fibers displaced is achieved, forming a sort of special stitching to make the lap into a fibrous body provided with excellent properties for a large number of end-uses.
  • the essential feature of this method is the lateral displacement of the lap as the needless start their downward travel from their raised position, carrying beams of fibers in their hooks.
  • Such lateral displacement of the lap takes place over a distance not exceeding the length of the fibers drawn from the lap, that is, not exceeding the distance between the upper face of the lap and the lower tip of the needle, which starts coming down as the lap is drawn aside.
  • FIGURE 1 shows schematically an elevation of the device used for carrying out this method of fiber intertwining
  • FIGURE 2 shows, also schematically and in successive stages, the punching process according to the method which is the object of the invention.
  • the method comprises the punching of a lap 1 by a set of needles 2 provided optionally with side teeth 3 pointing downwards, and ending necessarily in a hook 4 bent upwards.
  • These needles are held by their upper ends in a support consisting of two plates 5 and 6, and are guided through a perforated plate 7 as the lap 1 as laterally drawn over a platform 8, also conveniently perforated.
  • a further perforated plate 9 On top of the lap there is placed a further perforated plate 9.
  • the lateral displacement of the lap 1 is effected through the action of two sets of rollers 13 and 14, one before and the other after the passage of the lap through the punching device, whereby a suitable layout of the lap under the action of the needles 2 is achieved, without any harmful stresses being developed in the lap.
  • the needles 2 come down (stage A in FIG. 2), and as the hook 4 pierces the full thickness of the lap while the latter remains still, the needles are arranged in such a manner that on their subsequent withdrawal upwards, they draw along fibers taken from the lower face of the lap, and these fibers come up together with the needles 2 and through the holes in plate 9 (stage B, FIG. 2), forming a beam of fibers drawn from the lap as the latter is held down by the said plate 9.
  • the lateral displacement of the lap stops shortly before the needless pierce again the lap as they come down, and subsequently the beam of fibers F that was previously drawn from the lap is introduced into it again, to be linked downwards (stage D, FIG. 2).
  • the process is then repeated, the hook 4 taking fresh fibers F from the lap and drawing them upwards for their subsequent lateral displacement. In this way, a number of successive stitches are obtained in the lap, which stitches are made up of beams of lap fibers.
  • laps may be used consisting of several webs of different colors, to be punched in sequential order, i.e., first two webs jointly, then the first two plus a third one, then the first three plus a fourth one, and so on, until a predetermined combination of colors has been obtained.
  • the device used for carrying out this method of intertwining fibers comprises means for adjusting the upwards or downwards displacement of the needles, and for synchronizing such displacement with the intermittent lateral displacement of the lap, for the adjustment of which there are also suitable means provided.
  • the purpose of the perforated plate 9 is to prevent that, as the needles come up drawing beams of fibers F from the lower face of the lap, the lap is also raised, and the said plate holds the lap down while the holes in it allow the passage only of the said beams of fibers and, of course, of the needles carrying them.
  • This perforated plate may, however, be replaced by any other means fulfilling the same purpose of lap retention.
  • the tap should contain a proportion of fibers exhibiting welding rates different from those of the other fibers remaining in the lap (for instance, a given proportion of fibers liable to heat welding at a lower temperature than the rest, or of fibers liable to chemical welding only, such as by solvents). According to the nature of these specific properties, heat or chemical welding, as the case may be, is performed, so that these fibers are Welded to one another on establishing contact, irrespective of their particular welding rates.
  • the method described may be supplemented by dyeing or finishing operations, which may be similar to those already applied in the textile trade to woven fabrics, always according, of course, to the nature of the fibers in each case.
  • a fabric is obtained, nonwoven and of fibrous composition, but with characteristics similar to those of woven fabrics, which fabric is much easier to manufacture and at a much lower cost.
  • Such fabric or cloth may be used by the textile trade, or for decoration, furnishing and similar purposes.
  • the remaining fibers in the lap may be of any nature whatever, even including fibers of different origins, either natural or synthetic.
  • Such freedom in the choice of the fiber source influences costs most favourably, particularly as the nobler fibers may be concentrated on one face only of the lap, the rest being made up or poorer quality fibers. A large number of other combinations are likewise possible.
  • Improvements in the manufacture of nonwoven fabrics whereby a lap made up of loose fibers, a small proportion of which exhibit Welding rates different from those of the remaining fibers in the lap, is subject to systematic punching, whereby beams of fibers are drawn into the lap from one of its faces towards the opposite face, such fibers forming, as they are laid along their path across the general direction of the fibers in the lap, a sort of stitch reaching from one such face of the lap to the opposite one; are subsequently laid over the latter face, and enter the lap again at another point slightly displaced laterally, to reach down to their original level inside the lap, thus binding fully the mass of the lap, and consolidating this binding through welding those fibers which exhibit welding rates different from those of the remaining fibers in the lap.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Nonwoven Fabrics (AREA)
US555817A 1965-06-23 1966-06-07 Process for manufacturing nonwoven fabrics Expired - Lifetime US3409959A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ES0314818A ES314818A1 (es) 1965-06-23 1965-06-23 Perfeccionamientos en la fabricaciën de tejidos no texturados
ES0317787A ES317787A1 (es) 1965-09-24 1965-09-24 Sistema para el entrelazado de fibras de napas

Publications (1)

Publication Number Publication Date
US3409959A true US3409959A (en) 1968-11-12

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ID=26155671

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Application Number Title Priority Date Filing Date
US555817A Expired - Lifetime US3409959A (en) 1965-06-23 1966-06-07 Process for manufacturing nonwoven fabrics

Country Status (5)

Country Link
US (1) US3409959A (pl)
BE (1) BE682471A (pl)
DE (1) DE1660781A1 (pl)
FR (1) FR1484911A (pl)
NL (1) NL6608708A (pl)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4937924A (en) * 1988-05-17 1990-07-03 Textilmaschinenfabrik Dr. Ernst Fehrer Aktiengesellschaft Apparatus for needling a felt from one side
US5140722A (en) * 1989-12-08 1992-08-25 Murata Kikai Kabushiki Kaisha Sliver piecing device having fiber entangling needles and air jets
WO1993001442A1 (en) * 1991-07-03 1993-01-21 Kaleniecki James F Bearingless rotary mechanical fluid coupling
EP0924329A1 (de) * 1997-12-17 1999-06-23 Österreichische Heraklith GmbH Vorrichtung und Verfahren zum Nadeln von Faservliesen zur Herstellung einer Dämmatte
US20110035914A1 (en) * 2009-08-14 2011-02-17 Oskar Dilo Maschinenfabrik Kg Drive and Guide Device in a Needle Loom

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2572426B1 (fr) * 1984-10-31 1987-04-30 Nord Sa Union Textile Geotextile.

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1314565A (en) * 1919-09-02 billington
US2297440A (en) * 1938-08-11 1942-09-29 Szucs Ioan Batting reinforced with knitting stitches and a device for preparing same from raw material as it comes from the carding machine
DE900056C (de) * 1952-03-18 1953-12-17 Oskar Dilo Verfahren und Vorrichtung zur Herstellung von Schnellpolster
GB801440A (en) * 1956-07-20 1958-09-17 Thomas Hardman & Sons Ltd Improvements in felts for use in the manufacture of paper, pulp, board, asbestos-cement and analogous products
GB826163A (en) * 1955-10-07 1959-12-31 Celanese Corp Batting
US2978786A (en) * 1958-06-13 1961-04-11 Crompton & Knowles Corp Process for making non-woven fabric

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1314565A (en) * 1919-09-02 billington
US2297440A (en) * 1938-08-11 1942-09-29 Szucs Ioan Batting reinforced with knitting stitches and a device for preparing same from raw material as it comes from the carding machine
DE900056C (de) * 1952-03-18 1953-12-17 Oskar Dilo Verfahren und Vorrichtung zur Herstellung von Schnellpolster
GB826163A (en) * 1955-10-07 1959-12-31 Celanese Corp Batting
GB801440A (en) * 1956-07-20 1958-09-17 Thomas Hardman & Sons Ltd Improvements in felts for use in the manufacture of paper, pulp, board, asbestos-cement and analogous products
US2978786A (en) * 1958-06-13 1961-04-11 Crompton & Knowles Corp Process for making non-woven fabric

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4937924A (en) * 1988-05-17 1990-07-03 Textilmaschinenfabrik Dr. Ernst Fehrer Aktiengesellschaft Apparatus for needling a felt from one side
US5140722A (en) * 1989-12-08 1992-08-25 Murata Kikai Kabushiki Kaisha Sliver piecing device having fiber entangling needles and air jets
WO1993001442A1 (en) * 1991-07-03 1993-01-21 Kaleniecki James F Bearingless rotary mechanical fluid coupling
GB2272034A (en) * 1991-07-03 1994-05-04 James Frank Kaleniecki Bearingless rotary mechanical fluid coupling
GB2272034B (en) * 1991-07-03 1995-08-02 James Frank Kaleniecki Bearingless rotary mechanical fluid coupling
EP0924329A1 (de) * 1997-12-17 1999-06-23 Österreichische Heraklith GmbH Vorrichtung und Verfahren zum Nadeln von Faservliesen zur Herstellung einer Dämmatte
US20110035914A1 (en) * 2009-08-14 2011-02-17 Oskar Dilo Maschinenfabrik Kg Drive and Guide Device in a Needle Loom
US8046884B2 (en) * 2009-08-14 2011-11-01 Oskar Dilo Maschinenfabrik Kg Drive and guide device in a needle loom

Also Published As

Publication number Publication date
BE682471A (pl) 1966-11-14
NL6608708A (pl) 1966-12-27
FR1484911A (fr) 1967-06-16
DE1660781A1 (de) 1971-04-29

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