US3925866A - Method and needle machine for the production of pile fabrics - Google Patents

Method and needle machine for the production of pile fabrics Download PDF

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Publication number
US3925866A
US3925866A US443719A US44371974A US3925866A US 3925866 A US3925866 A US 3925866A US 443719 A US443719 A US 443719A US 44371974 A US44371974 A US 44371974A US 3925866 A US3925866 A US 3925866A
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US
United States
Prior art keywords
web
needle
take
roll
pile
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
Application number
US443719A
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English (en)
Inventor
Herbert Lochner
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.)
Cikalon Vlies
CIKALON-VLIESSTOFFWERK GmbH
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Cikalon Vlies
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Filing date
Publication date
Priority claimed from DE19732308516 external-priority patent/DE2308516C3/de
Application filed by Cikalon Vlies filed Critical Cikalon Vlies
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Publication of US3925866A publication Critical patent/US3925866A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • 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
    • D04H18/00—Needling machines
    • D04H18/02—Needling machines with needles

Definitions

  • the take-up roll positioned therebelow is moved horizontally to accommodate web material accumulating thereon in order to maintain the location of the incoming web constant and accommodate build-up in the diameter of the accumulated web roll.
  • the invention relates to a method andto a needling machine for theproduction of non woven pile webs (3-dimensional non-woven needled web material with a pile formed thereon) from a non-woven web comprising one or more adjacently disposed individual-nonwoven fibre webs which are preconsolidated by ne edling.
  • needled felt also known as non-woven needled web
  • Such methods are used to a large extent, more particularly in the manufacture of so-called needled felt 'or non-woven needled web carpet backs.
  • the material is manufactured by the mechanical consolidation through needling machines of one or more non-woven fibre webs which are produced on carding engines from synthetic staple fibres, for example polyamide,'polyacrylic, polyester or polypropylene fibres, resulting in the production of surface structures which are known as needled non-woven webs or needled nonwoven w'eb materials, which are mechanically consolidated to a greater or lesser extent depending on the construction of the needles and in accordance with the intensity of needling.
  • they comprise a large number of parallelized fibre webs (pile) which are compressed by mechanical consolidation through needling from an initially relatively large volume into a relatively shallow structure, depending on the degree of needling.
  • Structures which have been substantially .needled in the manner described herein above are referred to as 2- dimensional to the extent to which they are to be used as carpet backs because the fibres are disposed substantially horizontally in accordance with the original arrangement of the individual fibre piles.
  • Mechanical consolidation by needling is followed by chemical impregnation, preferably with latex, more particularly when carpet backs are produced in accordance with this method. Needled felts have a very useful 'value. They have a textile character but generally comprise rather shallow structures which occupy a lower quality grade in the range of carpet backs.
  • the manufacturing stage which is decisive for such needled felts employs needling machines in order to obtain mechanical bonding of the individual layers by interbinding of the individual fibres.
  • the needling machine is therefore provided with a horizontally disposed needle board which is moved vertically up and down by mechanical means against a needle bed.
  • the fibre web which is to be needled is disposed between the needle board and the needle bed.
  • the needle board is usually provided with several thousand needles which are mounted in the needle board in a regular pattern. Apertures or slits of limited length in the needle bed enable the needles to penetrate through the fibre web into the needle bed.
  • a stripper in the form of a perforated plate is disposed between the needle board and the needle bed in order to prevent the non-woven fibre web, hereinafter referred toas fibre web, being 'drawn up after needling during the return motion of the needle board.
  • the needles themselves are provided with differently orientated barbs for the needling operation in order to obtainthe most extensive possible binding of thefibre web.
  • Needling machines which deviate from the above described construction both with regard to the needles employed to this end as well as with regard to the needle bed used for the purpose, have been developed in order to achieve this object with needling processes.
  • So-called bifurcated needles the free ends of which are constructed in a bifurcated manner and whose function it is to form a pile loop or pile filament when penetrating the fibreweb, are used in place of the normal employed needles with laterally disposed barbs which point in different directions.
  • piles with a height of betweena few mm up to, for example, 15 mm while at the same time consolidating the web in the base stratum.
  • a needle bed with reeds for-ribs disposed in the cloth feed direction are therefore used in the'production of such pile webs, the said reeds or ribs having no interruption over the entire length of the needle bed width.
  • the width of the needle board and of the needle bed are limited because the mechanical needling of the pile rows into themarrow slits between the reeds or ribs involves severe frictional resistance when the needled Web is advancedover or through the needle bed, particularly when pile of substantial height is being produced.
  • the method according to the invention is characterised in that the fibre web is moved forward when suspended in the direction of its longitudinal axis while being subjected simultaneously from both sides to needling, the needles of oppositely moved needle boards being staggered in an offset configuration.
  • a needling machine which is characterised in that the fibre web feed direction is vertical, adjoining a roller pair adapted to move the fibre web in the forward direction and the said fibre web moves between the horizontal and oppositely movable needle boards of at least one needle board pair, a takeup drum for the needled web being slidably supported directly below the lowest needle board pair and in relation to the needled web which is fed in vertically and is to be coiled up so that the vertical direction of motion of the needled web is retained as far as the coiling up line independently of the number of needled web layers that have already been coiled.
  • Support rollers for the guiding of the fibre web between the needle boards which move opposite to each other can be omitted in a machine of this kind according to the invention because supporting is provided directly by the needle boards and the vertical suspended position of the fibre web is retained during the needling operation.
  • the web material mentioned in the description above and below is described as fibre webprior to the needling operation and as needled web after the needling operation.
  • Reversing backing rolls can be entirely omitted since a take-up drum for the needled web is disposed according to the invention below the lowest needle board pair and is slidably supported with respect to the vertically arriving needled web that is to be coiled so that the vertical direction of motion of the needled web is retained as far as the coiling line, independent of the number of needled web layers that has already been coiled.
  • the sliding velocity of the take-up drum during the take-up operation can be adapted by conventional tracing means to the increasing diameter of the take-up drum so that the fibre web is always moved perpendicularly between the needle boards of the needle board pairs.
  • the needle rows of at least some of the serially disposed needle boards may be laterally offset with respect to each other to produce a general consolidation of the pile rows.
  • the needle boards may be movably guided perpendicularly to the vertical direction in guide ways and can be adapted to move against the fibre web and away there- 4 from by means of rotating eccentrics.
  • This kind of drive for the needle boards is particularly simple and provides individual adjusting facilities for the needle boards in the sense that the length of stroke of the needle boards can be varied in accordance with a further feature of the invention or that the needle boards can be advanced towards the fibre web or away therefrom independently of the stroke so that the needling penetration depth can be varied independently of the stroke of the needle board.
  • one or more further fibre webs can be fed in between the two needle board pairs in addition to webs which have already been partially needled and can be advanced together with the fibre webs that have already been needled so that the thickness of the web can be increased in the course of the web passing through the machine and a varying intensity of needling can be obtained within the individual strata, for example so that one or both outer strata can be made softer.
  • different needle boards can be provided with different needles, preferably the needle boards of the first needle board pairs with needles for preneedling and subsequent needle board pairs with needles for pile needling.
  • FIG. 1 shows a needling machine as an exemplified embodiment according to the invention which is explained hereinbelow by reference to the process according to the invention.
  • FIG. 2 shows diagrammatically how the needled web is produced with pile formation on both sides by needling with three needle board pairs from two fibre webs which are preconsolidated by needling.
  • the diagrammatically illustrated needling machine comprises a frame, referenced in its entirety with the numeral 1 and adapted to accommodate the elements which are required for the needling operation.
  • two preneedled fibre webs 2 and 3, which adjoin each, other travel through the needling machine on a vertical path to which end the fibre webs 2 and 3 are moved downwardly by the roller pairs 4, 5.
  • the needle boards 11 which are provided in pairs and are adapted to move opposite to each other are actuated by their corresponding drives in the horizontal direction for the needling operation.
  • the needle boards 11 are detachably mounted on slides 9 of box-shaped cross-section.
  • the slides 9 are horizontally slidably guided in guide frames 10 and are hinged to an eccentric crank 23 which is driven by the drive pulley 13 and thus performs stroking motions.
  • the drive pulley 13 is supported by a slide 14 which is adjustable in the frame 15 by adjusting means which are not shown. This enables the initial position of the slide 14 to be varied either continuously or in steps in relation to the fibre web 8 so that the penetration depth of the needles 12 into the web 8 can be varied independently of the stroke which in turn can also be varied by altering the eccentricity of the radius rod system of the eccentric crank 23.
  • the drive pulley 13 is driven by a motor 17 via the drive belt 16 on which a resiliently supported jockey with the arrangement of the needles, it follows that the pile thus produced remains unchanged because all guide rollers between which the needled web 8 is moved are omitted in the illustrated machine.
  • the needles of oppositely disposed needle boards 11 are offset with respect to each other.
  • the needle rows of the individual needle boards 11 which come into operation successively are laterally offset with respect to each other so that every needling operation by one of the needle board pairs causes the density of the pile rows to be increased to enable a very dense needling effect to be achieved so that the pile rows are positioned in closely adjacent configuration in the finished web material.
  • the fibre webs 2 and 3 or the needled web 8 is fed through the machine freely suspended by the drive of the feed rollers 4 and 5.
  • a take-up drum 25 is supported on the slide 26 and can be driven via the belt 28 by means of the motor 27 that is mounted on the slide, the take-up speed being adapted by a steplessly variable transmission to the feed rate of the web 8 through the needling machine.
  • the slide 26 is moved to the right on the bed 29 and is thus continuously adapted to the take-up operation so that the vertical position of the needled web is retained at all times.
  • the sliding motion is automatically applied by a motor through transmission elements such as a gear rack, pinion or the like, a sensor 30 which is in contact with the vertically descending needled web 8 being utilized for control purposes.
  • the sensor may be a mechanically acting or a photoelectrically acting sensor.
  • FIG. 2 is a diagrammatic view of the needling operation.
  • the two preconsolidated, fibre webs 2 and 3 bear upon each other and move vertically between the three needle board pairs 11 which are disposed one below the other and are provided with needles 12.
  • the pile is formed on both sides at a specific height designated with a during the needling operation by the first needle board pair.
  • the pile height is increased during the second needling operation to the height h and this is followed by an increase to the height 0 during the third needling operation.
  • This is accompanied by consolidation of the core of the needled web thus produced so that the core d can be regarded as a carrier web which becomes progressively thinner in the course of needling, that is to say with an increasing pile height and therefore with an increasing pile formation and increasing height of the pile.
  • Needling apparatus for producing needled pile web from 'fibre'web passed therethrou gh comprising, in combination, roller guide means for guiding said fibre web through said apparatus in a direction extending vertically downwardly therefrom, a take-up drum disposed substantially directly below said roller guide means adapted to have said needled pile web wound thereabout in an accumulated web roll, at least one pair of directly opposed horizontally movable needle boards located between said roller guide means and said takeup drum and arranged to perform needling operations from opposite sidesthereof upon fibre web passing therebetween in order to form pile layers thereupon, means for sensing the amount of web material accumulated upon said take-up roll, and means for moving said take-up roll in response to said sensing means in accordance with the amount of material accumulated thereupon to retain substantially constant the location through which portions of said web material incoming to said take-up roll are passed.
  • said needle boards comprise aplurality of needles arranged in rows and wherein said rows of needles are offset laterally with respect to each other.
  • Apparatus according to claim 1 including guide ways having said needle boards guided therein for movement in directions perpendicular to the direction of movement of said fibre web through said apparatus, and rotating eccentric means for driving each of said needle boards of said at least one pair with a reciprocating stroke against said fibre web in opposed directions.
  • Apparatus according to claim 4 including means for varying the reciprocating stroke of each of said needle boards.
  • Apparatus according to claim 4 including a plurality of serially arranged pairs of needle boards between which said fibre web may be sequentially passed, said needle board pairs being provided with needles having differing configurations.
  • serially arranged pairs of needle boards include a first pair through which said fibre web is first passed, and wherein said first pair of needle boards are provided with needles for preneedling with the other of said needle board pairs being provided with needles for pile needling.
  • a method for producing needled pile web from fibre web comprising the steps of moving said fibre web vertically downwardly between vertically aligned roller guide means and a take-up drum therebelow while passing said web between at least one pair of opposed horizontally moving needling boards which perform needling operations upon said web from opposite sides thereof in order to form pile layers thereupon, winding 7 8 said needled pile web upon said take-up roll to form an web thereupon to maintain substantially constant the accumulated web roll, sensing the amount of web acculocation through which incoming web material accumulated upon said take-up roll and moving said take-up mulated upon said take-up roll is passed.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Nonwoven Fabrics (AREA)
US443719A 1973-02-21 1974-02-19 Method and needle machine for the production of pile fabrics Expired - Lifetime US3925866A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE19732308516 DE2308516C3 (de) 1973-02-21 Verfahren und Nadelmaschine zur Herstellung von genadelten Polvliesen

Publications (1)

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US3925866A true US3925866A (en) 1975-12-16

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US443719A Expired - Lifetime US3925866A (en) 1973-02-21 1974-02-19 Method and needle machine for the production of pile fabrics

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US (1) US3925866A (enrdf_load_stackoverflow)
AT (1) AT336293B (enrdf_load_stackoverflow)
BE (1) BE811261A (enrdf_load_stackoverflow)
CH (1) CH575491A5 (enrdf_load_stackoverflow)
FR (1) FR2218416B1 (enrdf_load_stackoverflow)
GB (1) GB1404307A (enrdf_load_stackoverflow)
NL (1) NL7402410A (enrdf_load_stackoverflow)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4035881A (en) * 1974-03-12 1977-07-19 Josef Zocher Method and apparatus for producing non-woven textile product
US5196037A (en) * 1990-07-02 1993-03-23 Rossi Robert J Products for use in polishing and the like and process for producing same
US5481786A (en) * 1993-11-03 1996-01-09 Spartan Mills Method of manufacturing a recyclable carpet
CN103727145A (zh) * 2013-12-31 2014-04-16 汕头三辉无纺机械厂有限公司 一种针刺机的耦合器组合
CN111648029A (zh) * 2020-05-19 2020-09-11 陈宗涛 一种全锦纶皮革基布的生产工艺

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5636420A (en) * 1992-11-23 1997-06-10 Asselin Needling machine and needling method related thereto
FR2698386B1 (fr) * 1992-11-23 1995-01-06 Asselin Aiguilleteuse et procédé d'aiguilletage s'y rapportant.

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US502376A (en) * 1893-08-01 Fritz ochs
US2377564A (en) * 1942-09-18 1945-06-05 Thomas A Unsworth Interlacing needle loom
US3110951A (en) * 1962-02-08 1963-11-19 Narrow Fabric Company Combination creel and warper apparatus
US3497927A (en) * 1967-05-13 1970-03-03 Leesona Ltd Method and apparatus for winding beams
US3602967A (en) * 1970-06-01 1971-09-07 Singer Co Twin-action felting machine
US3774273A (en) * 1970-02-20 1973-11-27 Toray Industries Needle felting apparatus

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE71319C (de) * F. ochs in Fürth Verfahren und Vorrichtung zur Herstellung eines Vliefses aus gekräuselten Rofshaaren und sonstigem Fasermaterial

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US502376A (en) * 1893-08-01 Fritz ochs
US2377564A (en) * 1942-09-18 1945-06-05 Thomas A Unsworth Interlacing needle loom
US3110951A (en) * 1962-02-08 1963-11-19 Narrow Fabric Company Combination creel and warper apparatus
US3497927A (en) * 1967-05-13 1970-03-03 Leesona Ltd Method and apparatus for winding beams
US3774273A (en) * 1970-02-20 1973-11-27 Toray Industries Needle felting apparatus
US3602967A (en) * 1970-06-01 1971-09-07 Singer Co Twin-action felting machine

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4035881A (en) * 1974-03-12 1977-07-19 Josef Zocher Method and apparatus for producing non-woven textile product
US5196037A (en) * 1990-07-02 1993-03-23 Rossi Robert J Products for use in polishing and the like and process for producing same
US5481786A (en) * 1993-11-03 1996-01-09 Spartan Mills Method of manufacturing a recyclable carpet
CN103727145A (zh) * 2013-12-31 2014-04-16 汕头三辉无纺机械厂有限公司 一种针刺机的耦合器组合
CN111648029A (zh) * 2020-05-19 2020-09-11 陈宗涛 一种全锦纶皮革基布的生产工艺

Also Published As

Publication number Publication date
NL7402410A (enrdf_load_stackoverflow) 1974-08-23
DE2308516B2 (de) 1977-05-05
FR2218416A1 (enrdf_load_stackoverflow) 1974-09-13
AT336293B (de) 1977-04-25
BE811261A (fr) 1974-06-17
GB1404307A (en) 1975-08-28
CH575491A5 (enrdf_load_stackoverflow) 1976-05-14
DE2308516A1 (de) 1974-08-29
FR2218416B1 (enrdf_load_stackoverflow) 1976-06-25
ATA135174A (de) 1976-08-15

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