US3859156A - Method for laminating warp and weft of fibrous materials in a wet manner - Google Patents

Method for laminating warp and weft of fibrous materials in a wet manner Download PDF

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US3859156A
US3859156A US434340A US43434074A US3859156A US 3859156 A US3859156 A US 3859156A US 434340 A US434340 A US 434340A US 43434074 A US43434074 A US 43434074A US 3859156 A US3859156 A US 3859156A
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Prior art keywords
belt
web
weft
cut
warp
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US434340A
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English (en)
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Masahide Yazawa
Haruhisa Tani
Setsuya Tsuyama
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Polymer Processing Research Institute Ltd
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Polymer Processing Research Institute Ltd
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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
    • B32B5/22—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • 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
    • D04H3/04—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 in rectilinear paths, e.g. crossing at right angles
    • 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
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0004—Cutting, tearing or severing, e.g. bursting; Cutter details
    • 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
    • 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
    • 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
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
    • Y10T156/1062—Prior to assembly
    • Y10T156/1075—Prior to assembly of plural laminae from single stock and assembling to each other or to additional lamina
    • Y10T156/1077—Applying plural cut laminae to single face of additional lamina
    • 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
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/12—Surface bonding means and/or assembly means with cutting, punching, piercing, severing or tearing
    • Y10T156/1317—Means feeding plural workpieces to be joined
    • Y10T156/1322—Severing before bonding or assembling of parts
    • Y10T156/133—Delivering cut part to indefinite or running length web

Definitions

  • ABSTRACT A laminate of warp and weft is prepared according to an efficient wet process by putting webs of wefts each consisting of a number of fibrous materials arranged in order in a flat layer and in a certain width, and cut to a length corresponding to the width of a warp web consisting of a number of fibrous materials arranged in order in a flat layer and in a certain width, on the surface of a circulating endless belt wetted with water to attach the cut weft webs onto the surface of the belt one by one with a certain spacing during the upper circulating course of the belt while maintaining the original state of the arrangement of the web by the surface tension of water; and dropping the cut webs one by one from said endless belt during the lower circulating course of the belt, upon the warp web, travelling crosswise below the circulating belt with a small gap, by pushing linear edges which are situated inside the back-surface of the cut weft web on the carrying
  • a wet process for laminating warp and weft fibrous materials which comprises putting out weft webs consisting of several hundreds or more of elongated fibrous materials arranged in a broad width, cut into a required weft length and attached on a wet belt, circulating along an upper and a lower horizontal circulating courses at a speed faster than the feeding speed of the weft web, upon a travelling warp web which consists of several hundreds or more of elongated fibrous materials arranged in a certain width eg, 1 m, by means of pushing down a number of parallel linear edges positioned crosswise to the cut weft web, from the backside thereof, to knock said web off the belt over the whole length and width of the cut weft web towards the warp web, and if necessary while utilizing a suction force from the back-side of the warp web, thereby to overlay each of the cut weft webs one by one crosswise upon the warp web without forming any gap between each of the cut
  • a thin, flat layer material composed of several hundreds or more of elongated fibrous materials substantially arranged in parallel in a certain broad width, say 1 meter wide, is denoted for simplicity as a web; a web used as a warp-side component is denoted as warp web" and that used as a weft-side component as weft web; that of a weft web cut into a required weft length is denoted as a cut weft web; and a product obtained by crossoverlaying weft webs on a warp web and bonding both the webs in one sheet of a laminate, is denoted as laminate of warp and weft" or non-woven fabrics of warp and weft case by case.
  • the cut weft web adheres to a wet belt, maintaining the arrangement of fibers at the time of feeding by the surface tension of water, and since the warp web also in most cases holds its arranged state by another wetted belt as explained later, there is no disadvantage of disturbance of fiber arrangement caused by static electricity and turbulence of surrounding air at the time of cross-overlaying as often encountered in the dry laminating process, and thus it is a notable feature of the present invention that such a high production rate of non-woven fabrics of warp and weft as about 100 m /min. can be easily attained with a high accuracy of fiber arrangement.
  • a means for knocking cut weft webs off the weftcarrying belt onto warp web there are provided a num ber of linear edges which are situated crosswise to the weft web, on the back side of wet cut weft web adhering to the belt and inside the course of circulation of said cut weft web, and circulated at a speed same with that of said belt.
  • the linear edges are pushed down and drawn back over the entire length and entire width of the cut weft web whenever the cut weft web comes to the position exactly crosswise overlapped with the warp web after overlaid.
  • the fibrous materials useful in the method of the present invention include spun yarns, filament yarns, bristles, stretched tapes, split yarns, uniaxially stretched films of a broad width, split webs which are composed of narrow tapes or fibers of reticular structure obtained by splitting uniaxially stretched films of a broad width, or webs of spread split webs into several times the original width, fine metal filament yarns, glass fiber yarns, carbon fiber yarns, carded webs having continuity and some extent of orientation of fibers, etc. made of natural or artificial materials of organic or inorganic origins.
  • fibrous materials are used as one kind of material or as a combination of more than one kind.
  • the fiber arrangement of a cross-overlaid product When the fiber arrangement of a cross-overlaid product is fixed for uses as non-woven fabrics, they are processed according to several different ways. Namely, fibrous materials for warp and weft webs are sized in advance and subjected to cross-overlaying or adhesive films are placed between warp and weft in the crossoverlaying step and then fixing of fiber arrangement thereof is carried out by heat-pressing adhesion, or warp and weft webs are sized and dried after crossoverlaying and then fixing of fiber arrangement is carried out by heat-pressing adhesion.
  • non-woven fabrics of laminates of warp and weft are sized, scattering of a small amount of (2-6g/m of pulp fibers having a length of l-3 mm or natural or aritifical short fibers having a length less than 5 mm onto the non-woven fabrics before winding-up can completely prevent blocking between wound-up layers in case where a soft and tacky sizing agent is used, and at the same time, the non-woven fabrics are strengthened by such scattered and attached short fibers. If carded staple fiber webs of slightly longer fibers are attached, the open spaces of crossed fiber materials of warp and weft layers are subdivided further by short fibers to give non-woven fabrics which do not permit small granular material or powder to come out therethrough.
  • a liquid for attaching fibrous materials of a warp or weft web onto a belt, a liquid, though it does not matter what kind of liquid may be used, generally water or a liquid obtained by adding a surfactant to water to improve the spreading or wetting property of water is used. Itgoes without saying that water which contains a sizing agent or the like as a viscidity-promoting agent is useful under certain circumstances.
  • FIG. 1 is a schematic view of the vertical crosssection of the apparatus useful for putting one embodiment of the present invention into practice.
  • FIG. 2 a is a schematic view of the cross-section of a web-carrying multiple belt composed of a number of narrow belts when it is running in the direction perpendicular to the plane of paper.
  • FIGS. 2b, 2c and 2d are schematic views showing the progress of relative positions of knocking off of wateradhering cut weft web from the belt toward and upon warp web by strings as linear edges.
  • FIGS. 3a and 3b are the vertical cross-sectional views of one end part of a lattice element including a device for pushing down and drawing back a string as one of linear edges for knocking offa cut weft web when a belt for carrying cut weft webs is a lattice belt.
  • FIGS. 3c, 3d and 3e are the vertical cross-sectional views showing the relative positions of knocking off a cut weft web from the belt by the movement of strings as linear edges in case of a lattice belt.
  • FIG. 4a is a vertical cross-sectional view of a lattice belt including pinch rollers, a weft web cutter and a ski edge in the present invention.
  • FIG. 4b is a vertical cross-sectional view of a knife type weft web cutter working upon weft web.
  • FIG. 4c is a vertical cross-sectional view of a melt type weft web cutter working upon weft web.
  • FIG. 5a is a vertical cross-sectional view of one lattice element of a lattice belt and edges of U-form thin plate during the upper circulating course ofa belt.
  • FIG. 5b is a vertical cross-sectional view of the lattice element of FIG. 5a during the upper circulating course of a belt viewed from the direction perpendicular to the section shown in FIG. 5a.
  • FIG. 5c is a vertical cross-sectional view of one lattice element of a lattice belt and edges of U-form thin plate during the lower circulating course of a belt.
  • FIG. 5d is a vertical cross-sectional view of the lattice element of FIG. 5c during the lower circulating course ofa belt viewed from the direction perpendicular to the section shown in FIG. 50.
  • FIG. 6 is a vertical cross-sectional view of the apparatus useful for an embodiment of the present invention in which cut weft webs are dropped upon an adhesive foil.
  • belt 2 is situated above warp web which is arranged in a certain width and moving horizontally in the direction perpendicular to the surface of paper, and
  • This belt is coated with a uniform thin water layer in an appropriate amount transferred from the bristles of brush roller 6, contacting with revolving roller 5, the lower half of which dips in surfactantcontaining water vessel 4.
  • Weft web which is arranged in a width similar to that of the warp web is continuously fed, through pinch rollers 7 and 7 and a cutting means, onto the belt at a position in the upper circulating course thereof, which belt is circulating under the feeding course of the weft web at a speed faster than the feeding speed of the weft web.
  • the cutting means After passing through the cutting means, at first the forward tip ends of the weft web and then successive parts thereof are caught onto the belt surface by surface tension of the water coating the belt while being slided on the belt.
  • the cutting means acts to cut the weft web into a cut weft web so that the fiber arrangement of the weft web at the time of feeding is practically maintained as it was in the cut weft web on the belt.
  • the cut weft web is attached onto the belt and travels together with it, leaving a space corresponding to the difference between feeding speed of the weft web and circulating peripheral speed of the belt, between each other.
  • the cutting means shown in FIG. 1 illustrates one example of such cutting means. It is constructed with a combination of lattice belt 9 having a peripheral length equal to that of cut weft web and another lattice belt 10 whch is circulating in engagement with lattice belt 9, as shown in the drawing. If it is so arranged that one of the lattice elements forming lattice belt 9 is replaced by a melt cutter, that is, heated rod 12 heated by electric current sent through leading wire 11 from a source, the weft web supplied continuously by roller 7 and 7' into the part between lattice belts 9 and 10 are cut to a unit length of cut weft web per one revolution of belt 9 and transferred onto belt 2 travelling in the vicinity below belt 9.
  • a melt cutter that is, heated rod 12 heated by electric current sent through leading wire 11 from a source
  • strings 15 under tension as an embodiment of linear edges of the present invention spaced apart by a fixed distance of 20 50 mm from each other and further contacting with the belt are circulated at a circulation velocity same with that of the belt and in this embodiment, cut-weft web adheres not only to these strings, but to the belt by means of water.
  • the circulating belt is a lattice belt in which a number of lattice elements are arranged in parallel and in the direction perpendicular to the circulation direc-' tion of the belt as in case of the embodiments of the present invention which are described in detail later
  • strings as linear edges can be installed in the gaps between the lattice elements inside the top surface of the lattice elements, and inside the back side of the cut weft webs and slightly apart therefrom. Accordingly, in the former case, unless extremely fine wire materials such as piano wire, bristle or the like is used, in other words if a thick string is used, the horizontal adhesion of cut weft webs to the belt surface is prevented, but,
  • ski edges 14 which perform a reciprocating movement off and to the belt passage for pushing tensioned strings forming one kind of the abovementioned linear edges are suddenly lowered at an appropriate time interval by way of cam-motion associated with the circulating belt. Then a number of parallel tensioned strings 15 are pushed downwards, and the cut weft web adhering onto the belt is knocked down upon warp web to be overlaid on the warp web.
  • the warp web is moving continuously, and if its speed is so controlled that a subsequent cut weft web falls just when the warp web has advanced by the distance corresponding to the width of the fallen cut weft web, the cut weft webs are laid side by side over the warp web without forming any gaps or overlappings.
  • the fiber density at the edge parts of weft web is made one half of that at other parts thereof at the time of fiber-arrangement, the fiber density at overlapped edge parts can be equalized to that at other parts on the product, when these edge parts of cut weft webs (i.e., forward end and backward end on the warp web) are overlapped with each other.
  • the gaps between the forward and backward ends of the cut weft web on the warp web can be made null.
  • the cross-overlaying operation is so slow as m /min. or less, there is no need of using a higher falling velocity and hence the vibration of fibrous materials of warp and weft webs, due to impact of falling cut weft webs is slight and disturbance of arrangement of fibrous materials does not take place.
  • the velocity of cross-overlaying operation becomes greater, that is, at such a high speed as 30 50 100 m /min., more rapid falling of the cut weft web becomes necessary; the energy possessed by falling cut weft webs becomes larger and fibrous materials in the warp web jump and leap due to the impulse at the time of cross-overlaying and the cut weft web is apt to show bouncing, resulting in fiber-disorder in warp and weft webs.
  • the vibration amplitude of the warp web will be reduced if piano wires are stretched and fixed under the warp web at a pitch of about 10 cm so as to touch and cross the warp web at right angle. However if the spaces between the fibrous materials of warp web are large, some parts of fallen weft web on the travelling warp web are disturbed by contacting with the piano wires through these large free spaces between warp fibrous materials.
  • the warp web to be cross-overlaid is arranged to adhere onto a wet belt means travelling at the same speed as that of the warp web, the impact energy of falling cut weft web is absorbed by the belt of a heavy weight and moreover since the belt is wetted with water, the fallen out weft webs are caught by the surface tension of water on the belt, eliminating the impulsive vibration of fibrous materials at the time of cross-overlaying.
  • crossoverlaying operation of ordered arrangement of fibers becomes possible even at a high speed operation without disturbing the ordered state of fibrous materials of both the warp and weft webs.
  • Particularly notable effectiveness can be attained by laying warp web on a wet belt in case of cross-overlaying fibrous materials of large count having a heavy weight, especially, glass fibers or thin metal wire having a large specific gravity. Namely, laying warp web upon a wet belt is not a necessary condition for a low speed operation but it is necessary for a high speed operation.
  • a belt is of a thin cloth or one sheet of an elastomer
  • broader width i.e., width broader than 1 m does not give preferable result because a belt under tension is apt to be creased, making the adhesion of weft web not uniform or a belt is apt to meander, making the travelling central line indefinite.
  • a multiple belt consisting of a number of narrow belts arranged over the width of wefts and each running at the same speed and guided by two sets ofcrowned pulleys, each set having the same center of axis is used.
  • the central line of each belt is maintained and no crease is formed even when belts of a thin material are used.
  • any density of arrangement can be taken irrespective of kinds of fibrous material which are reticulate webs or usual yarns or tapes etc.
  • the advantage of applying such a multiple belt as stated before lies in the simplicity and cheapness of belt construction.
  • strings as a number or linear edges on the multiple belt contacting therewith must be fixed to the chains circulating at the same speed as that of the belt on both the sides of the belt.
  • the pushing out and drawing back of strings can be made uniform throughout the whole surface by allowing a number of sets of ski-edges to descend through gaps between narrow belts constituting the multiple belt at an appropriate distance between each other e.g., a pitch of 150 200 mm.
  • ski-edges for pushing out and drawing back strings cannot be provided in the middle part of the belt.
  • string-supporting devices are provided at several positions of the entire width of lattice belt in such a way that adhesion of wefts is not thereby disturbed and the backs of this devices are equally beaten by ski-edges provided for them.
  • FIG. 2a shows one example of the above-mentioned multiple belt.
  • the belt composed of a parallel arrangement of 6 narrow belts 2', each of which is made to circulate as shown in FIG. 1, belt 2 by crowned pulleys 21 fixed to a common axis 22 driven by pulley 23 and pulleys on the other side with a common axis (not shown).
  • Strings 28 are laid on this multiple belt in contact therewith under tension via springs 26 and 27 which are connected to circulating chains 24 and 25, respectively.
  • the strings are kept always in contact with the surface of the multiple belt and circulate at substantially the same speed with that of the belt surface.
  • ski edges 29 and 29' provided one in each space between the side of the belt and the chain, if necessary, together with a number of ski edges provided between each narrow belts (though not shown in the drawing) are made to fall suddenly. Then the strings descend to a distance very close to the warp web, reverse the course to return rapidly to the belt surface and circulate together with the belt, whereby the strings are separated from the belt surface and cause the cut weft web attached onto the belt surface to drop on the warp web.
  • guide rails 32 and 33 are provided in order that strings circulating in parallel are always kept tensioned under a constant tension.
  • the width of weft web is 1 m
  • the length of lattice elements will be 1,100 to 1,200 mm.
  • the width of individual lattice element 41 is generally about 5 30 mm, and as shown in FIG. 3a, both its ends, right and left,
  • a circulating lattice belt is formed with a number of lattice element spaced apart from each other by 5-10 mm.
  • spring arm 43 is fixed to a lattice element at fixing point 44 which is positioned toward the central part of the lattice element, the tip of the arm takes usually a form rising from the surface of the end of lattice element toward the inside of circulation path, and to each tip of the arm, a string-supporting device 45 is fixed.
  • lower part 46 of string-supporting device as shown in FIG.
  • String-supporting point 47 of the string-supporting device is so constructed that string 48 under tension lies inside the circulating course of belt surface and in the gaps of lattice elements (at first in the lower circulating course of the belt as shown in FIG. 3a), and when cut weft web 50 comes to a position where it is overlapped wholly with warp web 31 after overlaid, ski-edge 49 rapidly descends on and knocks the rising end of spring arm 43 of the string-supporting device in the direction in which the spring arm comes in contact with the lattice as shown in FIG. 3b.
  • tensioned string 48 is lowered by lowering of string-supporting point 47, and cut weft web adhering on the lattice belt is knocked off through the course of FIG. 3c FIG. 3d FIG. 3e.
  • the string descends down to a very close distance to the warp web as shown in FIG. 3d, and reverses its course to the original position, and in the upper circulating course, the lattice element takes a form standing upside down to that of FIG. 3 a, i.e., the spring arm takes form projecting downwards from the lattice surface.
  • the characteristic feature of the use of this lattice belt lies in the points that sufficient tension can be applied to strings, because ech string is supported by stiff lattice element; when falling of the central part of string is, nevertheless, liable to be delayed, the falling of cut weft webs over the whole width can be made uniform and horizontal through falling of ski edges by providing string-supporting points with combined spring arm and ski edge, respectively, at several points in the middle part of lattice element with such an arrangement that string-supporting device does not project out above the lattice belt surface and pushing down of string can be made horizontal over its whole length, and that since there is no gap in the direction of width of lattice belt, the method of the present invention is useful not only in case of reticulate webs but also in case of common yarns wherein the pitch of arrangement of yarns i.e., density of yarns can be optionally selected.
  • FIGS. 5a, Sb, 5c and 5d As another embodiment of linear edges, in place of the above-mentioned tensioned strings for knocking off cut weft web from a weft-carrying lattice belt, a construction of one lattice element which constitutes the belt where thin plate edges are pushed down and returned to the original position, is shown in FIGS. 5a, Sb, 5c and 5d.
  • FIG. 5a is a figure of a cross-section of one lattice element to which there is attached a linear edge capable of knocking down and returning to the original position, and travelling in the upper circulating course of weft-carrying lattice.
  • FIG. 5b is an elevation showing that one end of lattice element is fixed to a chain.
  • Cut weft web 71 is transported by square lattice elements 72, onto the surface of which the web is attached with water.
  • thin plate 76 which surrounds the lattice element in U-form is supported by coil spring 75 inserted around stud bolt 74 set on lattice element 72, the one end of which is connected to chain 73, thereby to position the tip oflinear edge 77 inside the surface of the lattice belt and in the gap between two adjacent (front or rear) lattice elements.
  • ski edge 78 Whenever cut weft web is brought to a position where the web wholly overlaps with warp web after overlaid during the lower circulating course of the belt, ski edge 78 rapidly descends as shown in FIGS. 50 and d to knock down the backside of U-form thin plate whereby linear edges 77 of the tip of thin plate are pushed down from the lattice surface and cut weft web 71 adhering to the lattice surface is knocked down onto warp web (not shown).
  • the front half part of a cut weft web can hold the state of arrangement of fibers at the time of feed by the pull of surface tension of water on the surface of circulating belt, but the rear end part of cut weft web is liable to fall freely on the circulating belt immediately after being cut.
  • a lattice belt is used as shown in FIG. 4a.
  • the whole peripheral length of this belt is adjusted to an integer times of a unit section length which is slightly longer than the length of a cut weft web (four unit sections in FIG. 4a).
  • Weft web 52 fed continuously through pinch rollers 51 and 51 is caught on a belt by the surface tension of water, and rub-slided on the surface of the belt circulating at a speed slightly faster than the feeding speed of weft web thereby to maintain the fiber arrangement at the time of feed by drawing force of the belt due to surface tension of water wetting the belt.
  • the length of the weft web When the length of the weft web reaches a predetermined length of the cut weft web in each section, it is cut repeatedly into a cut weft web by a weft cutter 53, the cutting edge of which circulates around its own axis at substantially the same speed with that of a belt, and is engaged with the weft web fed at the position at the rear end of each section.
  • the peripheral length of the circulating course of the cutting edge is so adjusted as to have a length substantially equal to that of a cut weft web.
  • Front ends of each cut weft web 54 and 54', hitted by the cutter, are made to travel behind the rear part of each preceding section by the distance corresponding to the difference between the feeding velocity of weft web and that of circulating belt; the rear ends travel just at the parts hitted by the cutter on each section.
  • cut weft webs adhere to the belt by the surface tension of water, thereafter the webs are transferred at the velocity ofthe belt to the part above warp web positioned in the lower circulating course.
  • ski edge 55 is rapidly lowered by the method shown in FIGS. 3d- 3e.
  • cut weft web 54' is knocked off successively onto the warp web 56 at predetermined intervals by pushing a number of linear edges downward over the whole surface of weft web, while holding the arranged state at the time of feed without causing disturbance thereof, and the warp web is also moved by being carried on another wet belt means (not shown), moving at the same or about I percent faster velocity than that of feeding of the warp web, it is possible to obtain laminates of warp and weft with a highest grade of accuracy of arrangement.
  • FIG. 4b shows that in case where fibrous materials are glass yarns, one lattice element 58, on which rubber plate 59 is attached, is provided at the rear end of each section and revolving knife edge 57 is made to hit the plate. In this case, glass yarns are cut at the instant when they come to be nipped between the sharp edge of the knife and the rubber plate.
  • lattice belt 61 which is circulated at the same speed with weft-carrying circulating belt 60 through a triangular or circular course, and one lattice element of lattice belt 61 is replaced by heated rod 62 capable of sending electric current thereto, and if necessary, at the time when the rod is engaged with the circulating belt, this heated rod is forcibly pushed out toward inside belt 60, whereby wet fibrous materials are at first dried and immediately thereafter meltcut.
  • heated rod 62 capable of sending electric current thereto, and if necessary, at the time when the rod is engaged with the circulating belt, this heated rod is forcibly pushed out toward inside belt 60, whereby wet fibrous materials are at first dried and immediately thereafter meltcut.
  • the fiber-arrangement at the time of feed of the fibrous material for weft web is transferred onto a wet belt and cut while holding its arrangement, as it is.
  • a high accuracy of arrangement can be maintained.
  • each section is slightly longer than the length of cut weft web, and this percentage of difference corresponds to the difference between the feeding velocity of weft web and the velocity of circulating belt.
  • pushing down and drawing back motion of ski edge i.e., linear edge must be completed. Accordingly, the faster the pushing off and drawing back motion of ski edge is, the smaller the above-mentioned percentage.
  • yarns having a high Young's modulus such as glass fiber yarn, thin metal wire yarn, etc., or
  • Non-woven fabrics obtained by laminating warp and weft according to the present invention are presented for actual use in most cases through the steps of removing water with two pressing rollers after crossoverlaying of cut weft webs on the warp web, pasting, drying and fixation of arrangement of fibers of warp and weft.
  • a suitable one can be selected, but if unstretched and quenched foils of polymers belonging to the same type with the polymer of fibrous materials are used as a pasting material, it is possible to bond the stretched fibrous materials without reducing the strength of the stretched fibrous materials, because the softening point of the former is lower than that of the latter.
  • a high density polyethylene stretched material is used as fibrous material for the lamination of warp and weft
  • a low density, preferably quenched polyethylene foil, a foil of ethylenevinyl acetate copolymer, or the like between warp and weft webs gives preferable result due to the function of the latter as a hot-melt adhesive to the former as well as a function of laminated film without the danger of blocking between each layer when wound into a roll.
  • the same effect can be attained between stretched materials of polypropylene and unstretched quenched polypropylene foil.
  • Such adhesive foils can not only be used as an intermediate layer of warp and weft webs but also if further additional unstretched quenched foils are fixed onto both the sides, it is possible to prevent fluffing of fibrous materials and also to impart a water-proof effect and reinforcing effect to the resulting products. Moreover this lamination step of foil can be directly connected to the cross-overlaying step of warp and weft webs.
  • Adhesive quenched foil 83 is fed onto one group of warp web 82 picked up at a regular interval from the whole warps and fed through pinch rollers 81 and 81 while maintaining the original spacings between each other, and cut weft webs are successively dropped from weft-feeding circulating belt 84 provided above the warp web loading the foil as adhesives thereon, on the foil.
  • the rest group of warp web 87 As a presser of the cut weft web on the first group of warp web, the rest group of warp web 87, also maintaining the original spacings in the whole original warp web, is applied on the cut weft webs crossoverlaid on the first group of the warp web carrying the foil between pinchrollers 86 and 86'.
  • cut weft webs are dropped on an adhesive foil and warp web 82 is travelled together with the foil in contact therewith from the underside in most cases, but a warp web is not necessarily passed through under the weft dropping part. It is possible to arrange to pass only adhesive foil 83 through under the weft dropping part. Namely, after receiving dropped out weft webs, said adhesive foil is passed through pinch rollers 86 and 86' and put between tow upper side and underside warp webs there.
  • Underside warp web 82' is guided on roller 86 and put under said adhesive foil and weft-pressing warp web 87 is guided on roller 86 to give a sandwich structure consisting of upper warp web, dropped cut weft webs, adhesive foil and lower warp web in this order.
  • warp web 82 is passing through under the weftdropping part.
  • Both of the above-mentioned cases are intended to be included in the scope of claim of the present application.
  • the process of the present invention is irrespective of feeding position of warp.
  • Example 1 A foil of high density polyethylene having a width of 1,200 mm and a thickness of 0.06 mm was stretched to nine times the original length while it is hot, split with a splitting means, spread to about three times the original width, subjected to pasting with an emulsion of vinyl acetate-ethylene copolymer and dried to give a spread web having a width of 1,200 mm, and the resulting web was used as a fibrous material for both the warp and weft webs.
  • warp web guided on a wet belt was moving horizontally at a speed of 72 m/min.
  • weft web cut into a length of 1,220 mm and having a width of 1,200 mm, as cut weft webs were charged intermittently on a multiple belt as shown in FIG. 2a, (which was wetted with water containing a surfactant, circulating above said warp web in the direction perpendicular to said warp web, consisting of a number of belts each having rough surface and a width of 150 mm and a gap of 5 mm between each other and an overall width of 1,390 mm) and brought to the down-side course of its circulation.
  • ski edges were pushed to lower a number of strings arranged in parallel with a pitch of 30 mm, down to the lowest level corresponding to mm above the warp web and returned to the original position thereby to give cross-overlaying 60 times per minute. Thereafter the resultant product was separated from the warp web-guiding circulating belt and dried after being squeezed to remove water through pinch rollers.
  • Example 2 For warps, two hundred and one ends of glass fiber yarns (long fibers) of 100 tex. were divided into two groups having 101 and 100 ends, respectively.
  • the first warp web was prepared by arranging 101 ends of yarns in l m width with a pitch of 10 mm, mounted on a circulating wet belt for warp web and moved at a rate of 50 m/min. S'twisted glass fiber yarns of 50 tex. and Z- twisted glass fiber yarns of 50 tex. were doubled to one yarn of lOO tex. so as to cancel their tendency of natural twisting back property.
  • 200 ends of the resultant yarn were passed through a comb and arranged to give 200 ends of wefts in l in width which were fed on a wet circulating belt for weft web through pinch rollers 51 and 51 as shown in FIGS. 4a and 4b, at a rate of 50 m/min.
  • the weft-carrying belt was installed above the warp-carrying belt in the direction perpendicular thereto.
  • the belt for weft web was an endless circulating lattice belt of 1,200 mm wide, having a peripheral length of 6,000 mm and divided into 5 sections, each having 48 lattice elementsmade of stainless steel pipes of 20 mm square, arranged in a mm pitch with gaps of 5 mm between each other.
  • the circulation velocity thereof was 60 m/min. Since the weft web fed on this belt was caught the surface tension of water wetting the surface of the belt and rub-slided on the surface of the belt moving faster than the feed velocity of the fibrous material for weft web, under cancelling of the twisting back property of Sand Z-yarns, the pitch between arranged yarns on the belt was as it was at the time of feed, without disturbance.
  • the resulting product was separated from the wet belt on which the first warp web had been loaded, and the second set of warp web warped at a pitch of 10 mm was supplied onto the product during the pass of pinch rollers to be laminated in such a way that each yarn of the second warp web came to a position between yarns of the first running side by side.
  • the resulting product was pasted with a pasting agent of polyvinylalcohol type and squeezed. Thereafter onto the pasted product, free short single fibers prepared by fully opening short fiber waste formed in spinning mills were scattered and loaded at a rate of 5 glm and the whole was dried with hot air and then on hot drums, whereby non-woven fabrics of warp and weft containing glass fibers in an amount of 40 g/m were produced at a speed of 50 m /min. without any blocking of wound-up layers due to softening of adhesive.
  • Example 3 320 ends ofstretched tapes of polypropylene, each having a width of 6 mm and a denier of 1,000 were used as a fibrous material.
  • the tapes were arranged in parallel and flat, and split into split yarns during their course of travel.
  • the resulting yarns were passed through a comb and thereby the width was narrowed so as to be able to arrange 320 ends in 1 width. They were guided as a weft web onto a wet endless lattice belt consisting of five sections in the total periphery, each having 1.2 m length, during its upper circulating course as shown in FIG. 4a.
  • the yarns were cut to form a cut weft web by a melt cutter and the cut weft webs were one by one brought to the lower circulating course while being attached onto the belt.
  • the first set of warp web was fed in the manner as shown in FIG. 6, passing between pinch rollers 31 and 81', together with a quenched foil of polypropylene, having a thickness of 0.02 mm and a width sufficient to cover the width of the warp web, thereon.
  • the resulting overlaid product was dried by squeezing out water and heating on a hot drum and pressed on heating, whereby a non-woven fabric of laminate consisting of warp, weft webs and a foil as adhesive therebetween was obtained at a rate of 50 m/min.
  • two quenched polypropylene foils each having a thickness of 0.03 mm were supplied onto a heating drum so as to sandwich the above-mentioned laminate of warp and weft on both the sides thereof and pressed on heating.
  • the resulting laminate gave a substitute of water-proof heavy duty cloth having a fiber density of 70 75 g/m in both of the warp and weft directions and a strength of 65- 75 kg/50 mm width in both the warp and weft directions and containing 75- 80 g/m of the adhesive foil.
  • each single fibrous material in both the warp and weft directions is not exposed on adhesion surface of warp web and weft web and there may occur parts of bad adhesion of both webs.
  • carded webs of short fibers which are slightly longer than the above-mentioned are additionally laminated, free open spaces of crossed warp and weft fibrous materials are subdivided or filled with said short fibers, and reinforcement and covering effect are notably increased.
  • short fibers such as pulp fibers of 1-3 mm length
  • those which have sufficient length to be treated with a carding machine such as cotton or artificial staple fibers, short fibers for reuse, recovered from waste fibrous materials, etc. are all inexpensive raw materials for above-mentioned usage, they can perform very important roles in the reinforcement of non-woven fabrics of warp and weft and in expanding the utility and adaptability thereof.
  • said lattice belt has an overall peripheral length corresponding to an integer times the length of each of cut weft web-carrying sections having a length longer than that of the cut weft webs, and having at the rear end of each of said sections, a site accommodating parts of a weft-cutting means, and the weft web is cut by the weftcutting means at the rear end of each of said sections, into cut weft webs one by one while sliding on said lattice belt wetted with water, whereby the arrangement of fibrous materials of the original weft web is kept sufficiently as it was and the resulting cut weft webs are successively attached onto the belt, travel together with the lattice belt leaving a predetermined space between each other and are brought to the lower circulating course of the belt.
  • each one of the cut weft webs attached on the cut weft webcarrying belt wetted with water is pushed and knocked off from said belt by a number of rows of strings as linear edges, in the lower circulating course of the belt.
  • each one of the cut weft webs attached on the cut weft webcarrying belt wetted with water is pushed and knocked off from said belt by a number of rows of linear tip edges of thin plate as linear edges, in the lower circulating course of the belt.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Laminated Bodies (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Woven Fabrics (AREA)
US434340A 1973-01-18 1974-01-17 Method for laminating warp and weft of fibrous materials in a wet manner Expired - Lifetime US3859156A (en)

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Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3961531A (en) * 1973-03-23 1976-06-08 Peng Ting Fu Method and apparatus for adhering thermometer in liquid
US4052242A (en) * 1975-01-28 1977-10-04 Polymer Processing Research Institute Ltd. Method for producing a product comprising weft webs of large width continued in the warp direction
US4052243A (en) * 1975-01-28 1977-10-04 Polymer Processing Research Institute Ltd. Method for producing a cross-laminated cloth-like product from wide warp and weft webs
US4189339A (en) * 1977-10-31 1980-02-19 Johns-Manville Corporation Method for providing sections of wrapping material having a strip of adhesive tape attached to an end portion thereof
US4227960A (en) * 1979-02-14 1980-10-14 Johns-Manville Corporation Apparatus for applying tape material in continuously advancing sheet material
US5220858A (en) * 1989-06-13 1993-06-22 Samuel Jones & Co. Limited Method and apparatus for forming scored lines on sheet material
US5232533A (en) * 1989-01-25 1993-08-03 Nippon Petrochemicals Co., Ltd. Method for heat-setting cross-laminated non-woven fabrics
US5275678A (en) * 1992-07-13 1994-01-04 West Michael J Method of utilizing surface tension of water to transfer labels onto containers in automatic high-speed labeling machines
US5615000A (en) * 1992-03-11 1997-03-25 Canon Kabushiki Kaisha Convey belt and conveying apparatus with it
US6054086A (en) * 1995-03-24 2000-04-25 Nippon Petrochemicals Co., Ltd. Process of making high-strength yarns
US6063492A (en) * 1996-07-26 2000-05-16 Nippon Petrochemicals Company, Ltd Adhesive tape and its base fabric
US6127293A (en) * 1994-12-16 2000-10-03 Nippon Petrochemicals Co., Ltd. Laminated bodies and woven and nonwoven fabrics comprising α-olefin polymeric adhesion materials catalyzed with cyclopentadienyl catalyst
US20080047657A1 (en) * 2006-08-25 2008-02-28 Jander Michael H System for forming reinforcement layers having cross-directionally oriented fibers
US20090223587A1 (en) * 2006-03-08 2009-09-10 Berger Jogann Seat Belt Webbing, Method and Narrow Fabric Needle Loom for Production of Same
US9539797B2 (en) 2013-11-14 2017-01-10 Rayven, Inc. Traverse wound double-sided pressure sensitive adhesive tape

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JPS5540476U (ja) * 1978-09-08 1980-03-15
FI801415A (fi) * 1979-05-05 1980-11-06 Arthur Britton Arkmaterial
US4295905A (en) * 1979-12-14 1981-10-20 Orcon Corporation Fill strand transfer process for making non woven fabrics
JPS56148952A (en) * 1980-04-22 1981-11-18 Kobunshi Kako Kenkyusho Directional fiber web having regular crude and fine density
JPS58115162A (ja) * 1981-12-28 1983-07-08 積水ソフ株式会社 経緯積層布の製造方法
FR2849067B1 (fr) 2002-12-24 2005-04-29 Staubli Sa Ets Lisse, cadre de lisses et metier a tisser equipe d'un tel cadre

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US3250655A (en) * 1961-08-28 1966-05-10 Adler Solomon Method for producing non-woven fabric
US3340584A (en) * 1965-06-17 1967-09-12 Johnson & Johnson Apparatus for cross-laying fibrous material
US3345230A (en) * 1963-02-12 1967-10-03 Youngstown Sheet And Tube Co Method and apparatus for forming multi-ply tape of crossed plies of parallel strands
US3591434A (en) * 1967-08-21 1971-07-06 Swirltex Inc Bi-axial laminated non-woven fabric and method of manufacture
US3635776A (en) * 1968-06-29 1972-01-18 Basf Ag Production of bonded nonwovens by the wet method
US3765989A (en) * 1969-08-08 1973-10-16 Kimberly Clark Co Apparatus for crosslaying web materials

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US2889583A (en) * 1952-06-03 1959-06-09 Lohmann Kg Method and device for superposing of fibre-fleeces
US3250655A (en) * 1961-08-28 1966-05-10 Adler Solomon Method for producing non-woven fabric
US3345230A (en) * 1963-02-12 1967-10-03 Youngstown Sheet And Tube Co Method and apparatus for forming multi-ply tape of crossed plies of parallel strands
US3340584A (en) * 1965-06-17 1967-09-12 Johnson & Johnson Apparatus for cross-laying fibrous material
US3591434A (en) * 1967-08-21 1971-07-06 Swirltex Inc Bi-axial laminated non-woven fabric and method of manufacture
US3635776A (en) * 1968-06-29 1972-01-18 Basf Ag Production of bonded nonwovens by the wet method
US3765989A (en) * 1969-08-08 1973-10-16 Kimberly Clark Co Apparatus for crosslaying web materials

Cited By (19)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3961531A (en) * 1973-03-23 1976-06-08 Peng Ting Fu Method and apparatus for adhering thermometer in liquid
US4052242A (en) * 1975-01-28 1977-10-04 Polymer Processing Research Institute Ltd. Method for producing a product comprising weft webs of large width continued in the warp direction
US4052243A (en) * 1975-01-28 1977-10-04 Polymer Processing Research Institute Ltd. Method for producing a cross-laminated cloth-like product from wide warp and weft webs
US4189339A (en) * 1977-10-31 1980-02-19 Johns-Manville Corporation Method for providing sections of wrapping material having a strip of adhesive tape attached to an end portion thereof
US4227960A (en) * 1979-02-14 1980-10-14 Johns-Manville Corporation Apparatus for applying tape material in continuously advancing sheet material
US5232533A (en) * 1989-01-25 1993-08-03 Nippon Petrochemicals Co., Ltd. Method for heat-setting cross-laminated non-woven fabrics
US5220858A (en) * 1989-06-13 1993-06-22 Samuel Jones & Co. Limited Method and apparatus for forming scored lines on sheet material
US5615000A (en) * 1992-03-11 1997-03-25 Canon Kabushiki Kaisha Convey belt and conveying apparatus with it
US5275678A (en) * 1992-07-13 1994-01-04 West Michael J Method of utilizing surface tension of water to transfer labels onto containers in automatic high-speed labeling machines
US6127293A (en) * 1994-12-16 2000-10-03 Nippon Petrochemicals Co., Ltd. Laminated bodies and woven and nonwoven fabrics comprising α-olefin polymeric adhesion materials catalyzed with cyclopentadienyl catalyst
US6054086A (en) * 1995-03-24 2000-04-25 Nippon Petrochemicals Co., Ltd. Process of making high-strength yarns
US6063492A (en) * 1996-07-26 2000-05-16 Nippon Petrochemicals Company, Ltd Adhesive tape and its base fabric
US20090223587A1 (en) * 2006-03-08 2009-09-10 Berger Jogann Seat Belt Webbing, Method and Narrow Fabric Needle Loom for Production of Same
US7743794B2 (en) * 2006-03-08 2010-06-29 Berger Jogann Seat belt webbing, method and narrow fabric needle loom for production of same
US20100259090A1 (en) * 2006-03-08 2010-10-14 Berger Jogann Seat belt webbing, method and narrow fabric needle loom for production of same
US8066034B2 (en) * 2006-03-08 2011-11-29 Johann Berger Berger Seat belt webbing, method and narrow fabric needle loom for production of same
US20080047657A1 (en) * 2006-08-25 2008-02-28 Jander Michael H System for forming reinforcement layers having cross-directionally oriented fibers
US8028736B2 (en) * 2006-08-25 2011-10-04 Ocv Intellectual Capital, Llc System for forming reinforcement layers having cross-directionally oriented fibers
US9539797B2 (en) 2013-11-14 2017-01-10 Rayven, Inc. Traverse wound double-sided pressure sensitive adhesive tape

Also Published As

Publication number Publication date
JPS5040185B2 (ja) 1975-12-22
GB1424163A (en) 1976-02-11
FR2214779B1 (ja) 1976-05-07
FR2214779A1 (ja) 1974-08-19
IT1000412B (it) 1976-03-30
JPS4993662A (ja) 1974-09-05
DE2401124B2 (de) 1975-06-26
DE2401124A1 (de) 1974-07-25

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