US3607567A - Apparatus for nonwoven fabric manufacture - Google Patents

Apparatus for nonwoven fabric manufacture Download PDF

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Publication number
US3607567A
US3607567A US695007A US3607567DA US3607567A US 3607567 A US3607567 A US 3607567A US 695007 A US695007 A US 695007A US 3607567D A US3607567D A US 3607567DA US 3607567 A US3607567 A US 3607567A
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United States
Prior art keywords
streams
projections
extrusion
rollers
roller
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Expired - Lifetime
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US695007A
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English (en)
Inventor
Theodore H Fairbanks
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FMC Corp
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FMC Corp
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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
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion

Definitions

  • the present invention relates to an improved apparatus for making nonwoven fabrics.
  • Nonwoven fabrics have long been made using preformed fibers, for example, by disposing the same into a batt or layer and then bonding the fibers to each other at spaced areas. It has heretofore been recognized that procedures for making nonwoven fabrics which involve manipulation and treatment of preformed fibers are not only costly but often involve some damage to the fibers themselves. Thus, various proposals have been made for making nonwoven fabrics by extrusion, as by depositing extruded streams of strand-forming material along intersecting or crossing paths.
  • a primary object of this invention is to provide an improved and more satisfactory apparatus for making nonwoven fabrics.
  • Another object of this invention is to provide an improved apparatus for making nonwoven fabrics from continuous strands concomitantly with the extrusion thereof.
  • Still another object is the provision of an apparatus for making, at high production rates, a nonwoven fabric having good covering power and stiffness characteristics, yet which is desirably porous.
  • a further object is the provision of an apparatus for making nonwoven fabrics from extruded continuous strands which are strongly bonded to each other at selected areas.
  • a still further object is the provision of an apparatus for making nonwoven fabrics which are free of unattached or loose fibers.
  • an apparatus in which a series of generally parallel streams of flowable strand-forming material is continuously extruded in each of a plurality of overlying planes and, concomitantly with the extrusion, streams in each series are bonded with streams in the other series at longitudinally spaced intervals thereof.
  • each of these areas at which the streams are bonded extends only partially across the planes of extrusion and is in staggered and overlapping relationship with adjacent of such areas.
  • a number of such adjacent, staggered areas when taken together, effect a bonding of the streams entirely across the planes of extrusion.
  • the streams are set to provide a unitary or integral nonwoven fabric.
  • the above planes along which the series of streams are extruded are preferably parallel with each other and the streams in each of the series are staggered or offset from the streams in at least the adjacent and preferably all of the other of such series of streams.
  • the streams in the series of streams are bonded to each other at spaced areas,- as by pressing or squeezing the same together, rather than overlying each other, the streams of each series of streams occupy spaces between streams of the other of such series and, in effect, mesh with each other.
  • the areas of bonding of the different series of streams preferably extend transversely of and either partially or entirely across the planes of extrusion. Bonding of the streams along areas which extend partially, rather than completely, across the planes of extrusion is preferred since the resulting fabric has a greater degree of flexibility in its longitudinal direction. In accordance with this preferred procedure, each of such areas of bonding overlap or extend beyond the ends of ad jacent of such bonded areas with which they are in staggered relationship. During the bonding of the streams, as described above, there is no disruption in the extrusion of the streams of strand-forming material or any weakening of such streams at the areas of bonding.
  • the apparatus of the present invention includes, in general, a means for extruding a series of generally parallel streams of strand-forming material in each of a plurality of overlying planes, means for setting such extruded streams, and means located between the extrusion and setting means for pressing or squeezing streams in each series of extruded streams into contact with streams of the other of such series of streams at longitudinally spaced intervals thereof.
  • the areas at which the streams are pressed together extend only partially across the planes ofextrusion and are in staggered relationship with adjacent of such areas.
  • rollers which extend across the planes of extrusion along opposite sides thereof.
  • Each of such rollers is provided with rows of projections which are generally parallel to the roller axis and are spaced annularly about its periphery.
  • the projections in each row extend only partially across the roller length and are in staggered relationship with at least the projections in the rows which are adjacent thereto.
  • These rollers are both turned at the same rate of speed in the direction of extrusion and the projections are arranged thereon so as to mate with each other as they engage with the streams of strand-forming material travelling therebetween.
  • strand-forming or plastic including materials which are thermoplastic, such as polyamides or superpolyamides, polyesters, polyvinyl chloride, copolymers thereof, polyolefms, cellulose acetates, metals, glasses, etc., natural or synthetic rubbers, therrnosetting materials or wet-spinnable materials, such as viscose, cupro-ammonium cellulose, or carboxymethyl cellulose.
  • materials may include various additives such as stabilizers, dyes, foaming agents, etc., if so desired.
  • FIG. 1 is a side view of an apparatus of the present invention
  • FIG. 2 is a front view of the apparatus shown in FIG. 1;
  • FIG. 3 is a perspective view of a portion ofa nonwoven fabric formed by the apparatus shown in FIGS. 1 and 2.
  • extrusion apparatus 11 having rows of extrusion openings, is provided for continuously extruding a series of generally parallel streams 13 of strand-forming material in each of a plurality of overlying and preferably parallel planes, as indicated at 15, 17, 19, 21, 23 and 25 in FIG. 1.
  • the extruded streams 13 consisting, for example, of thermoplastic polymeric material, are set with a cool gas, such as air, which is delivered by nozzles 27, which are located below the extrusion apparatus 11 and along opposite sides of the planes of extrusion.
  • rollers 29 and 31 each having a shaft 33 which projects beyond the ends of the respective roller and is supported by an appropriate frame.
  • Suitable drive means is provided for rotating the rollers 29 and 31 at substantially the same rate of speed in the direction as indicated by arrows 35 and 37, respectively.
  • the rollers 29 and 31 are of like construction, each having projections 39 which are disposed in rows extending substantially parallel to the roller axis and spaced annularly about the roller periphery.
  • each projection 39 extends only along a portion of the length of the respective rollers.
  • the projections 39 in adjacent rows are in staggered or offset and overlapping relationship. That is, a projection 39 in one row extends beyond the ends of the projections 39 in adjacent rows with which it is in staggered relationship.
  • rollers 29 and 31 are rotated in the direction of arrows 35 and 37 and a series of generally parallel streams 13 of thermoplastic material is extruded from the apparatus 11 in each of the overlying planes l5, l7, 19, 21, 23 and 25.
  • the series of streams are pressed or squeezed together at spaced areas by the cooperating roller projections 39.
  • the extrusion openings in each such row of openings in the apparatus 11 are offset or staggered relative to at least the openings in rows which are adjacent thereto so that the extruded streams 13 of each series of streams are also offset or staggered with relation to streams in the other of such series of streams.
  • streams of thermoplastic material of each series of streams occupy the spaces between the other of such series of streams rather than being bunched and overlying with each other.
  • the spacing of the streams of the different series must be such as to insure that the streams make contact with each other when pressed or squeezed together by the roller projections.
  • the now bonded streams of thermoplastic material are set, as by cool air discharged from nozzles 27, to provide a unitary or integral nonwoven fabric 41, as shown in FIG. 3.
  • the areas at which bonding has occurred are indicated at 43 and it will be noted that the areas 43 are in staggered and overlapping relationship. While the bonded areas 43 are, of course, of reduced thickness, the unbonded portions of the strands impart bulk to the fabric 41 and give it a quiltlike appearance. If desired, the nonwoven fabric 41 may be longitudinally stretched to orient the molecules thereof and thus improve its strength characteristics.
  • Apparatus for making a nonwoven fabric including means having rows of extrusion openings which are arranged to extrude a series of spaced streams of flowable strand-forming material in each of a plurality of overlying, substantially parallel planes with the streams of each series of streams being generally parallel to each other and to the streams in the other of such series, the openings in each such row of openings being in staggered relationship with at least the openings in rows which are adjacent thereto, means spaced from said extrusion means for setting the extruded streams of strand-forming material, and means positioned between said extrusion and setting means and having cooperating projections for pressing streams in each series of streams into contact with streams of other of such series only at longitudinally spaced intervals thereof along areas which extend at least partially across the planes of extrusion.
  • said pressing means includes a pair of rollers which extend across the planes of extrusion and between which the streams are extruded, said rollers each having rows of said projections spaced annularly along the periphery thereof, the projections in each row of projections each being shorter than the roller length and disposed in staggered relationship with at least the projections in adjacent of such rows, and means for together rotating said rollers.
  • each roller projection extends beyond the adjacent end of a roller projection with which it is in staggered relationship whereby such staggered projections overlap each other.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)
  • Nonwoven Fabrics (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)
US695007A 1968-01-02 1968-01-02 Apparatus for nonwoven fabric manufacture Expired - Lifetime US3607567A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US69500768A 1968-01-02 1968-01-02

Publications (1)

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US3607567A true US3607567A (en) 1971-09-21

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US695007A Expired - Lifetime US3607567A (en) 1968-01-02 1968-01-02 Apparatus for nonwoven fabric manufacture

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US (1) US3607567A (en))
BE (1) BE725153A (en))
DE (1) DE1813960A1 (en))
GB (1) GB1215847A (en))
NL (1) NL6818121A (en))

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3819452A (en) * 1970-12-08 1974-06-25 Celanese Corp Apparatus for the production of spray spun nonwoven sheets
US3972760A (en) * 1971-11-02 1976-08-03 Fishair Incorporated Method of making a fishing lure component
US4198735A (en) * 1978-03-29 1980-04-22 Wwg Industries Inc. Method for forming temporary fabrics
US20020036062A1 (en) * 1999-08-13 2002-03-28 Michael Kauschke Nonwoven with non--symmetrical bonding configuration

Citations (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2207279A (en) * 1937-12-07 1940-07-09 Firestone Tire & Rubber Co Cord fabric and method of making the same
US2493968A (en) * 1946-10-17 1950-01-10 Hepner Charles Method and apparatus for making batt-covered sheets
US2621139A (en) * 1947-08-12 1952-12-09 Messing Benjamin Laminated sheet material and methods of making such material
US2760881A (en) * 1953-12-04 1956-08-28 Ohio Commw Eng Co Tile and method of making
US2938821A (en) * 1955-02-18 1960-05-31 Union Carbide Corp Manufacture of flexible metal-coated glass filaments
US3221738A (en) * 1962-04-05 1965-12-07 Gustaf E Ekberg Method for manufacturing diapers and the like, and a diaper manufactured in accordance with this method
US3255064A (en) * 1961-07-17 1966-06-07 Du Pont Process for mechanical crimping of fibers in sheet form
US3308220A (en) * 1964-04-22 1967-03-07 U N I Corp Plastic mesh producing machine
US3311519A (en) * 1964-01-28 1967-03-28 Eastman Kodak Co Additive filter
US3327708A (en) * 1963-06-07 1967-06-27 Kimberly Clark Co Laminated non-woven fabric
US3393110A (en) * 1964-03-18 1968-07-16 Algemene Kunstzijde Unie Nv High-frequency zig-zag welding
US3436304A (en) * 1965-05-19 1969-04-01 Dow Chemical Co Method for manufacturing nonwoven fibrous products from gel fibers
US3439085A (en) * 1963-10-25 1969-04-15 Freudenberg Carl Kg Process for the production of non-woven elastic polyurethane fabric
US3481818A (en) * 1964-09-29 1969-12-02 Carolite Inc Embossed laminated plastic panel and method of making same

Patent Citations (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2207279A (en) * 1937-12-07 1940-07-09 Firestone Tire & Rubber Co Cord fabric and method of making the same
US2493968A (en) * 1946-10-17 1950-01-10 Hepner Charles Method and apparatus for making batt-covered sheets
US2621139A (en) * 1947-08-12 1952-12-09 Messing Benjamin Laminated sheet material and methods of making such material
US2760881A (en) * 1953-12-04 1956-08-28 Ohio Commw Eng Co Tile and method of making
US2938821A (en) * 1955-02-18 1960-05-31 Union Carbide Corp Manufacture of flexible metal-coated glass filaments
US3255064A (en) * 1961-07-17 1966-06-07 Du Pont Process for mechanical crimping of fibers in sheet form
US3221738A (en) * 1962-04-05 1965-12-07 Gustaf E Ekberg Method for manufacturing diapers and the like, and a diaper manufactured in accordance with this method
US3327708A (en) * 1963-06-07 1967-06-27 Kimberly Clark Co Laminated non-woven fabric
US3439085A (en) * 1963-10-25 1969-04-15 Freudenberg Carl Kg Process for the production of non-woven elastic polyurethane fabric
US3311519A (en) * 1964-01-28 1967-03-28 Eastman Kodak Co Additive filter
US3393110A (en) * 1964-03-18 1968-07-16 Algemene Kunstzijde Unie Nv High-frequency zig-zag welding
US3308220A (en) * 1964-04-22 1967-03-07 U N I Corp Plastic mesh producing machine
US3481818A (en) * 1964-09-29 1969-12-02 Carolite Inc Embossed laminated plastic panel and method of making same
US3436304A (en) * 1965-05-19 1969-04-01 Dow Chemical Co Method for manufacturing nonwoven fibrous products from gel fibers

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3819452A (en) * 1970-12-08 1974-06-25 Celanese Corp Apparatus for the production of spray spun nonwoven sheets
US3972760A (en) * 1971-11-02 1976-08-03 Fishair Incorporated Method of making a fishing lure component
US4198735A (en) * 1978-03-29 1980-04-22 Wwg Industries Inc. Method for forming temporary fabrics
US20020036062A1 (en) * 1999-08-13 2002-03-28 Michael Kauschke Nonwoven with non--symmetrical bonding configuration
US6872274B2 (en) 1999-08-13 2005-03-29 First Quality Nonwovens, Inc. Method of making nonwoven with non-symmetrical bonding configuration

Also Published As

Publication number Publication date
BE725153A (en)) 1969-05-16
DE1813960A1 (de) 1969-07-31
NL6818121A (en)) 1969-07-04
GB1215847A (en) 1970-12-16

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