WO2012052535A1 - Method and apparatus for producing a composite nonwoven - Google Patents

Method and apparatus for producing a composite nonwoven

Info

Publication number
WO2012052535A1
WO2012052535A1 PCT/EP2011/068408 EP2011068408W WO2012052535A1 WO 2012052535 A1 WO2012052535 A1 WO 2012052535A1 EP 2011068408 W EP2011068408 W EP 2011068408W WO 2012052535 A1 WO2012052535 A1 WO 2012052535A1
Authority
WO
Grant status
Application
Patent type
Prior art keywords
web
device
nonwoven
belt
means
Prior art date
Application number
PCT/EP2011/068408
Other languages
German (de)
French (fr)
Inventor
Markus Hones
Norbert KÜHL
Original Assignee
Hi Tech Textile Holding Gmbh
Priority date (The priority date 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 date listed.)
Filing date
Publication date

Links

Classifications

    • DTEXTILES; PAPER
    • D01NATURAL OR ARTIFICIAL THREADS OR FIBRES; SPINNING
    • D01GPRELIMINARY TREATMENT OF FIBRES, e.g. FOR SPINNING
    • D01G15/00Carding machines or accessories; Card clothing; Burr-crushing or removing arrangements associated with carding or other preliminary-treatment machines
    • D01G15/02Carding machines
    • D01G15/12Details
    • D01G15/46Doffing or like arrangements for removing fibres from carding elements; Web-dividing apparatus; Condensers
    • DTEXTILES; PAPER
    • D01NATURAL OR ARTIFICIAL THREADS OR FIBRES; SPINNING
    • D01GPRELIMINARY TREATMENT OF FIBRES, e.g. FOR SPINNING
    • D01G15/00Carding machines or accessories; Card clothing; Burr-crushing or removing arrangements associated with carding or other preliminary-treatment machines
    • D01G15/02Carding machines
    • D01G15/04Carding machines with worker and stripper or like rollers operating in association with a main cylinder
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/559Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving the fibres being within layered webs
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/56Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in association with fibre formation, e.g. immediately following extrusion of staple fibres

Abstract

The invention relates to a method for producing a composite nonwoven in a continuous process sequence, and to an apparatus for carrying out the method. Here, a fibrous web is formed by a carding device from a fibre strand, on the surface of which fibrous web subsequently a nonwoven layer of synthetic fibres is laid. To this end, the fibrous web is guided within a suction zone on a laydown belt to a melt-blowing device, in which the synthetic fibres are laid on the surface of the fibrous web by melt-blowing. The fibrous web which is covered with the nonwoven layer is subsequently laid by a nonwoven laying device in a plurality of layers to form the composite nonwoven.

Description

DESCRIPTION

Method and apparatus for producing a

Verbundylieses

The invention relates to a method for producing a composite nonwoven fabric in a continuous process sequence and a device for carrying out the method.

For production of composite nonwovens, it is generally known that the properties of the composite web substantially by the interaction of several

various non-woven layers are determined. Thus, for example, in the composite nonwovens which to

Noise reduction can be used, we have found that in particular the sealing material differences of the

Fleece layers lead to be compensated sound waves and little reflected. Such composite webs that are used for insulation and noise insulation, have a relatively low basis weight, so that special requirements are placed on their preparation.

From EP 1058618 Bl is a sound-absorbing

Thin film laminate is known, which consists of a foam or a nonwoven fabric and related meltblown fibers. The foam or the nonwoven fabric is drawn off in the form of a web from a first roll, and then sprayed with a contact adhesive and a

Inf arotstrahler partially dried and then combined with a second web of meltblown fibers. Both tracks are then shared by

out pinch rollers and connected to each other. Possibly. another outer layer of a nonwoven web can be applied to the thin-film laminate. These

Non-woven fabric cover layer can consist of a meltblown web, which is attached provisionally by ultrasound. The film laminate is then cut into blanks and supplied to a molding press.

From WO 2006/108364 Al, it is known to manufacture a single or multi-ply fabric of polymeric nanofibers obtained by electrospinning.

EP 0501842 Bl and DE 692 09 703 T2 is concerned with the preparation of a substance Stringing-fabric for clothing manufacture. A first nonwoven layer of microfibers manufactured by melt-blowing, wherein a second carded nonwoven layer is formed and then attached below the first layer. The two

Layers are entangled by jets of fluid and is connected, and then dried. The second carded nonwoven layer is preferably vorgenadelt. To connect the two layers an adhesive applied will also be distributed used. Furthermore, a third nonwoven layer may be added. In a

Embodiment can be directly applied to a second carded layer, a melt blown microfiber layer and formed.

The object of the present invention to provide an improved manufacturing technique for composite webs.

Another object of the invention is to carry a signal generated by a carding fiber web with the highest possible belt speed to form a composite web. Further, an object of the invention is the formation of a multilayer sound absorbing nonwoven member.

The problem is solved by the independent method and apparatus claims. Advantageous further developments of the invention are the respective by the features and feature combinations

Subclaims defined. In EP 0501842 Bl in a manufacturing process of a composite nonwoven fabric made of a fibrous web produced by a carder, and a nonwoven fabric layer manufactured by a melt blowing is formed. In meltblowing, the fibers with the lowest possible air pressure and far away as possible be generated for fiber web. But this does not fine fibers can be produced. Therefore, the known method and the known device are

Essentially only suitable for the production of composite webs with relatively high basis weights.

The claimed technique has the advantage that even very loose and light-laid fibrous webs can be safely combined with a melt blown nonwoven layer. One through the fiber stream of

Meltblowing turbulence and change of the fiber web caused is avoided that the batt into a holding zone, such as a suction zone, is guided so that the fiber web obtains an example, via the suction flow generated fixation to the deposit belt. the at

Synthetic fibers melt bubbles generated are stored in the region of the retaining or suction zone to a nonwoven layer directly on the fibrous web and thereby connected therewith to form a compound. The thereby occurring excess blowing air can also be advantageous over a

record suction zone and pay. The generated as a topsheet web layer in a structure of multiple

to embed batts, the batt can be taken out with non-woven layer of the suction zone and passed to a web-laying device. The

Web-laying means then combines a plurality of layers of the batt or compound to the composite nonwoven.

To safe entry of the fibrous web in the

Laying area to obtain the melt blowing apparatus and by the combined with the nonwoven layer batt of the laying area lead out, the development of the invention is particularly advantageous in which the fibrous web passes through several consecutive suction regions with separately adjustable suction capacities within the suction zone. This allows each to the state of

are generated batt adapted pressure conditions at the deposit belt, on the one hand to minimize a suction flow generated from the environment and on the other hand the blowing air generated by the meltblowing sure

take. In addition, can be explained by different

Print settings in addition affect the direct deposition of the synthetic fibers to produce specific structures within the nonwoven layers. Basically, the nonwoven web comprised of fibers and fiber mixtures of synthetic or natural fibers can be formed. For binding and hardening, however, has been found to be particularly advantageous if the fibers or fiber mixtures for the formation of the fibrous web are formed with a weight proportion in the range between 10% and 100% of synthetic fibers.

Here, the process variant is preferably used in which the fiber material of the synthetic fibers and the polymer melt are formed, for extruding the synthetic fibers from an identical base material. Thus, the recycling of such composite webs can be substantially improved. The nonwoven fabric layer on the surface of the batt is preferably placed with fine fibers in order for the

to get sound advantageous properties. Inasmuch as the process variant is preferably used in which the synthetic fibers in the melt blowing with a fine fiber cross section in the range of 0.2 to μπι

3 μπι be put to the nonwoven layer on the fibrous web. However, the composite fabric can be produced advantageously also with coarser synthetic fibers depending on the application.

The performance of the Carding is

in particular exhausted with the process variant in which the fibrous web after removing is performed until dropping continuously at a line speed in the range of 50 m / min to 200 m / min. In this case, substantially the capacity of the web-laying means is relevant for the limitation of the tape speed.

In order to produce different types of composite nonwovens, is a further process variant

proposed in which a plurality of fiber piles are juxtaposed parallel taken from the carding and sandwiched together by the melt blowing and depositing the synthetic fibers, wherein said nonwoven layer forms an intermediate layer between the fiber piles.

Such double batt layers are particularly suited to protect the non-woven layer of synthetic fibers obtained as an intermediate position with respect to the other treatments. The structure and distribution of synthetic fibers within the nonwoven layer remain unchanged and can therefore during the manufacturing process to the

required specific properties are set.

However, in principle it is also possible, both parallel fiber webs each having a batt layer to

prove that are combined to form a multi-layer fleece.

To ensure the cohesion of the superposed in several layers of fiber sheets, it is further proposed to supply the down through the web laying device nonwoven continuously to a solidifying device, and to solidify. The solidification can take place mechanically, chemically or thermally. In order to obtain as complete as possible, the respective nonwoven layers within the composite fabric of the synthetic fibers, the process variant is especially advantageous, in which the composite nonwoven is solidified by a thermal treatment in a belt dryer, the

Composite nonwoven during solidification by a

Calibration zone is guided, in which an acting relative to a guide strip adjustable Kalibrierband on a free upper surface of the composite web. In addition to the

Consolidation can also be set a certain thickness of the composite nonwoven. The melting of the

Synthetic fibers within the nonwoven layers can in this case advantageously avoid such that the fiber material of the synthetic fibers to the synthetic fibers of the fibrous web has a slightly higher melting point. This can be achieved advantageous even from the same base polymer by additives. For the further processing of such composite nonwovens is further contemplated that the composite nonwoven is accumulated in a storage device into a package or, alternatively, to a stack. In a stacker, the memory device additionally a

Cutting means in order to cut each of the composite nonwoven web into individual pieces, which are then stacked one upon another.

To carry out the claimed method, the inventive apparatus is provided. This preferably has a carder, a

Pickup device, a transport device and a further processing, in particular a web-laying means, wherein between the pickup device and the

Further processing or web-laying means comprises a station for producing a nonwoven layer made from synthetic fibers

is provided. To achieve the object of the invention is the station as a melt blowing

formed, which is associated with a holding, in particular suction means. The suction device is preferred

disposed below a depositing belt of the conveyor so that the guided on the deposit belt

Fibrous web fixed by means of a suction effect is retained on the deposit belt.

The suction device for suction of the deposit belt is, according to one advantageous development of the

device of the invention formed by a plurality of suction chambers that are connected to a vacuum source, wherein the suction chambers to set an individual negative pressure associated with separate control means. Thus, both the position of the bat and the filing of the synthetic fibers in the nonwoven layer lets in

influence .

In order to produce as little waste material in the manufacture of the composite nonwoven, the development of the device according to the invention is preferably used in which the melt blowing a movable

having spinning head formed between a

Operating position above the depositing belt and a

Rest position can be guided laterally adjacent to the deposit belt. Thus let piecing and approach

Melt blowing out of the operating position to perform, so that the spinning head held in the operating position of exclusively for producing

is available composite fabric.

In order to produce combinations of batts, the inventive device is especially so

further developed in that the collector device has two separate customer sites, which cooperates with two belt assemblies of the transport device for receiving and discharging a plurality of batts. To produce a sandwich-like Faserflorkombination with intermediate nonwoven sheet, the variant of the device is used in which one of the belt assemblies cooperating with the depositing belt and the second belt assembly with a

Transport section parallel to the deposit belt above the

Spinner is arranged. So can the

Calibrating removed batts without

Deflection in a plane are performed. Alternatively, however, it is also possible that the second belt assembly comprises a second deposition belt, and that the second deposit belt, a second spinning head of the melt blowing equipment is assigned. Thus can be created with combined nonwoven layer several batts.

The further treatment of the composite fleece takes place within the device by a conveyor means which connects the web-laying means having a solidifying device, and a memory device. Within the storage device, the composite nonwoven fabric can thus save into a roll or stack.

For solidification, it is proposed that the device comprises a belt dryer with a leader tape and a leader tape arranged above the Kalibrierbandes, wherein the Kalibrierband is formed relative to the guide band adjustable in height. Thus, in addition to consolidations and targeted material thicknesses of the

Composite nonwoven are produced. The inventive method is below with reference to some embodiments of the invention

described apparatus for producing a composite nonwoven detail with reference to the accompanying figures.

, In which:

1 schematically shows a first partial view of a first

Embodiment of an inventive

Device,

Figure 2 schematically illustrates a second partial view of the

Embodiment of Figure 1,

3 schematically shows a cross-sectional view of the

Melt blowing of the embodiment of Figure 1 in several operating positions, Figure 4 shows schematically a partial view of another

Embodiment of the inventive device, and

Figure 5 schematically shows a partial view of another

Embodiment of the invention

Device.

The invention relates to a method and an apparatus for producing a composite web (36) and a sound-absorbing nonwoven member made therefrom.

In Figures 1 and 2 show a first embodiment of the device according to the invention for carrying out the inventive method. Here, in Figure 1 is a partial view of the front half of the machine and shown a partial view of the rear half of the machine in FIG. 2

The inventive apparatus has in the front half of the machine according to Figure 1, a carding device (1). The carding device (1) cooperates at one end with a feed device (2) and at the opposite end with a pickup device (7). Between the feed means (2) and the pickup means (7) are a preturret (4) and a main drum (5) arranged to react for several carding elements (6) on its periphery.

Between the feed means (2) and the preturret (4), a plurality of feed system (3) provided to receive a through the feed means (2) fiber stream continuously provided and to cause the preturret (4). At the preturret (4) and the main drum (5) are carded fibers and via the in

Main drum (5) associated with the pickup device (7) taken as a batt. It should be specifically mentioned that the structure and the number of drums and carding used in the carding are exemplary.

In principle, carding with just one drum can be used.

The pickup device (7) is in this

Embodiment formed by a pickup roller system (8), which cooperates directly with a conveyor belt (10.1) of a transport device (9). The

Transport means (9) is in this embodiment by a first conveyor belt (10.1), a delivery belt (11) and a second conveyor belt (10.2) is formed, which cooperate together to form a batt (32)

continuously receiving from the carder (1) and to remove them. The depositing belt (11) is on an upper surface

Melt blowing equipment (12) and a holding device on an underside (17) is assigned. With the

Melt blowing equipment (12) on the surface of the fibrous web (32) a meltblown nonwoven layer (35) from

Synthetic fibers (33) is applied, for example with a

Pressure gas flow. The composite of fibrous web (32) and

Nonwoven layer (35) is hereinafter referred to as Compound. The holding device (17) can be applied to the fibrous web (32) and / or to a pressure of the gas stream

Melt blowing equipment (12) act. You can, for example, keep the fibrous web (32) on the deposit belt (11) and

in relation to the incident flow of pressurized gas with the

meltblown fibers (33) stabilize. It can also lead to pressure gas stream, and the stream of fibers

act. It can, for example, controls the flow of pressurized gas after the dispensing of the fibers (33) to said batt (32)

derived. The holding device (17) can, for example as

suction means be formed.

The storage tape (11) is gas permeable and the suction device (17) is guided over a total of three suction chambers (18.1, 18.2 and 18.3). The suction chambers (18.1, 18.2 and 18.3) of the suction device (17) are separate suction lines (19.1, 19.2 and 19.3) independently of one another with a vacuum source (not shown) connected via associated control means (20.1, 20.2, 20.3) independently in their suction power

adjustable.

Above the middle suction chamber (18.2), the

Melt blowing equipment (12) to a spinning head (13) which is by a melt line (34) with an extruder (14) is coupled. The spinning head (13) also includes a

Connection to a compressed gas supply (15), for example

Pressure air supply, which via a control valve (16) to a compressed air source (not shown) is connected. The spinning head (13) has on its

Bottom a melt-blowing, which in itself

Substantially over the entire width of the storage tape (11). The width of the meltblowing die of the spinner head

(13) is identical to the working width of the

Carding device (1). Thus, the working width of the carding device (1) may range from 2 m to 4 m and to be formed thereover. Accordingly, the width of the meltblowing die is also performed in the range of 2 m to 4 m.

The spinning head (13) and the extruder (14) are held in this embodiment, on a movable support (21) through which the spinning head (13) between an operating position and a rest position to and fro is feasible. For illustration is a sectional view of the melt blowing equipment (12) in Figure 3.1 in the

shown operating position and in Figure 3.2 in the rest position. In so far as 3.1 and 3.2 Reference is made at this point in addition to the figures.

In the operating position of the spinning head (13) of the melt blowing equipment (12) located immediately above the depositing belt (11) on its underside by the

Suction chamber (18.2) is subjected to suction. The suction chamber (18.2) is connected via the suction line (19.2) and a control means (20.2) with a non-illustrated negative pressure source.

The carrier (21) of the spinning head (13) and of the extruder

(14) is movable and can be

For example, a rail system, or

Pulley system transverse to the depositing belt (11) back and forth

move. Here, the connections remain in the

A spinning head (13) unchanged. Thus, the spinning head (13) above the melt line (34) to the extruder (14) is connected. Via the compressed air supply (15) and the control valve (16) is a connection to a pressure source is provided.

As shown in Figure 3.2, can be shifted in such a way, the support (21), that the spinning head (13) in a

Rest position to receive the side of the depositing belt (11). In this position, as well as maintenance work can be carried out at the process start piecing without a batt (32) on the depositing belt (11) is guided.

As shown in the illustration in FIG 1, in addition to the melt blowing equipment (12) has a web-laying means

arranged (22), between the melt blowing equipment (12) and the web-laying means (22) the conveyor belt (10.2) of the transport device (9) is held. The web-laying device (22) has no further description here

Depositing means to shown to the over the

Conveyor belt (10.2) supplied fiber web (32) or

Compound in constant and uniform eg float on a conveyor belt of a conveyor belt means

(23) to store multiple layers and with a selectable number of layers and to form a composite web (36). Here, the basis weight of the multi-layer composite web (36) can, if necessary, controlled or regulated according to requirement and in transverse and / or

be changed longitudinally continuous or locally (so-called. profiling).

The conveyor belt means (23) correspondingly in dependence on the number of layers, and

Shelf width run at a lower tape speed. The conveying direction of the conveyor belt means (23) is thus aligned perpendicular to the transport direction of the transport means (9). The following devices of the apparatus according to the invention form a second

Machine side to which the facilities

are arranged in the further processing of a composite web. As shown in Figure 2, that the web-laying means (22) in the further course is followed by a consolidation device (24) and memory means (28). In this embodiment, the solidification means (24) through a belt dryer (25) is formed, which is a

Guide belt (26) and disposed above the guide strip Kalibrierband (27) in a calibration zone. The Kalibrierband (27) is formed relative to the position of the guide strip (26) adjustable in height, so that a run on the guide band (26) composite nonwoven (36) can be solidified with a certain material thickness. The consolidation takes place via a

Heat treatment and is considered by experts

Thermobonding referred. Here, by melting the fiber material of some fibers inside the

Composite nonwoven fabric creates a more stable cohesion of all fibers. The through the web laying device (22) set,

multi-layer composite nonwoven (36) thereto by the

Conveyor means (23) to the solidification means (24) continuously fed. On the outlet side of the consolidating device (24) the memory means (28) is provided, which in this embodiment by a winding station (29) is formed. The winding station (29) generated from the continuously fed composite web (36) winding a non-woven (30).

Illustrated in Figures 1 and 2 according to the invention

Device is particularly suitable for carrying out the method for producing a composite web (36), which is used as an insulating material or insulating material.

Such composite fabrics typically have a relatively low basis weight and a relatively loose

Structure of the fibers contained within the composite nonwoven.

In the method, as shown in Figure 1 and Figure 2

first a continuous stream of fibers from fibers or fiber mixtures of the carding device (1) is shown, abandoned. The fibers (31) are on the

Feed means (2) and supplied within the

Carding device (1) via one or more

carded drum systems and as a batt (32)

decreased. The fibrous web (32) over the

added transport device (9) and continuously discharged. The conveyor belts (10.1) and (10.2) of the

Transport means (9) are thereby with a

operated tape speed in the range of 50 m / min to 200 m / min. The belt speed is carried the

Carding (1) or the web-laying means (22) is determined.

In the course of the fibrous web (32) of the first conveyor belt (10.1) of the depositing belt (11) is passed, that the fibrous web (32) leads to the melt blowing equipment (12), in which on the surface of the fibrous web (32) comprises a nonwoven layer (35) laid synthetic fibers (33) and the compound is formed. To receive and to produce the nonwoven layer (35) on the surface of the fibrous web (32) of the batt (32) on the depositing belt (11) by a suction zone a holding zone, for example, performed. The suction zone is formed in this embodiment by the three suction chambers (18.1, 18.2 and 18.3) In the suction zone the bottom of the depositing belt (11) which is designed to be gas-permeable and for example, a mesh belt or is

may be cloth tape, suctioned. This is a

generates holding force on the fibrous web (32), so that in the deposition zone of the synthetic fibers (33) the structure of the

retained despite power produced by melt blowing air currents batt (32). In the meltblowing a polymer melt is melted through an extruder (14) and fed to a spinning head (13). At the bottom of the spinning head (13) is a meltblowing die provided through which a plurality of synthetic fibers (33) are extruded, and in a

A spinning head (13) is also supplied to pressure gas, for example

Compressed air, and taken off in the direction of the depositing belt (11) is blown. The melt-blowing die, the melt flow rate and air pressure settings here are preferably chosen such that relatively fine synthetic fibers (33) are generated. have the synthetic fibers (33)

preferably a fine fiber cross section in the range from 0.5 to 3 on μτα μπι to the nonwoven layer (35) on the

to form the surface of the fibrous web (32).

The synthetic fibers (33) are preferably stored in the central area of ​​the suction zone on the fibrous web (32), so that by separately adjustable suction power of the suction chambers (01/18 to 03/18) in a lead-in area, in a contact region and in an outlet region of the

different fibrous web (32) in the meltblowing

Settings of suction capacities are possible. On the one hand can be arriving of the batt (32)

generate sufficient holding force to the fibrous web (32). On the other hand, the shelves of the synthetic fibers (33) can be influenced by different suction capacities. In addition, the blown air generated during the melt blowing can be integrated by the Saugkammerumgebungsluft in the filing process of synthetic fibers. So can thus additional effects and structures in the nonwoven layer produce.

After the batt layer (35) on the surface of the

is laid fibrous web (32) of the batt (32) to said batt layer (35), ie the compound, through the

Conveyor belt (10.2) delivered to the web-laying means (22). Through the web laying device (22) is applied to the batt (32) to the nonwoven layer (35) in several layers to the desired composite nonwoven (36). The composite nonwoven (36) has, for example at least two superposed layers of the batt (32) or several double layers of

Batt (32) or compound on. The composite nonwoven (36) is continuously discharged by the conveyor belt means (23) and fed to the solidification means (24). The belt speed of the conveyor belt means (23) is in this case in dependence on the number of layers and of the laying width of the web-laying means (22)

dependent .

Within the consolidating device (24), the

Composite nonwoven (36) thermally bonded, where in particular in a calibration zone on the interaction of the

Guide band (26) and the Kalibrierbandes (27) the

Thickness of the composite web (36) is determined.

After solidification, the composite nonwoven (36) is wound into the web roll (30).

In the example illustrated in Figures 1 and 2 Method and apparatus are used to form the batt (32)

preferably from 100% synthetic fibers.

Preferably the fiber material in this case be of the

synthetic fibers and the polymer melt to the

Extruding the synthetic fibers (33) from an identical base material formed. would as a base material

For example, a polyester or a polypropylene

suitable. Here, the specific properties of the fiber material of the synthetic fibers and the

matched to one another fiber material of the synthetic fibers (33) that only the synthetic fibers in the batt (32) are melted to solidification during the thermobonding substantially. In that regard, the

Fiber material of the synthetic fibers, also known as

Bikofasern may be formed with a slightly lower melting point compared to the

Synthetic fibers.

However, the embodiment of FIG. 1 and FIG. 2 could also be extended such that between the melt blowing equipment (12) and the

Web-laying means (22) includes a second carding device is arranged with a pickup device to produce a second nonwoven web. The second fiber pile would be put to the nonwoven layer so that the nonwoven layer

sandwiched between a lower and upper

Batt is held.

Basically, thereby the possibility of forming one or both of fibrous webs from a fiber blend of synthetic fibers and natural fibers. By thermobonding at a sufficient strength at least 10% of the fibers will receive constituted by synthetic fibers.

In the illustrated in Figure 1 and 2 embodiment, a single-ply fibrous web (32) for the production of the composite web (36) of the carding device (1) is removed. In principle, however, it is also

Possible to design the pickup device (7) having a plurality of customer locations. So a in Figure 4

Another embodiment of the invention

Apparatus for carrying out the invention

The method schematically shown in a partial view. The embodiment is substantially identical to above the aforementioned embodiment according to Figures 1 and 2, so only the differences are explained here and otherwise with respect to the

Description will be made. In the example shown in Figure 4, the pickup device (7) forms two pickup points

(37.1) and (37.2). In each of the pickup locations (37.1) and

(37.2) is in each case a pickup roller system (8)

provided to receive in each case one card web (32.1) and (32.2) and to supply the transport device (9). The transport device (9) comprises in this

Embodiment, a lower band arrangement (38.1) and an upper belt assembly (38.2) on. the under

Belt arrangement (38.1) is identical to the

Embodiment constructed according to FIG 1 and 2. FIG. The upper belt arrangement (38.2) has a transport section

(10.3) on which is parallel to the depositing belt (11) above the spinning head (13) is guided. The upper

Tape assembly (38.2) can in this case be formed by a plurality of multi-part conveyor belts or in one piece by a circulating conveyor belt.

In the area between the melt blowing equipment (12) and the Vlieslegeinrichtung (22) both are belt assemblies

(38.1) and (38.2) of the transport device (9) together such that the two fiber webs (32.1) and

(32.2) are sandwiched together and enclosing between them the nonwoven layer (35). Subsequently, the multi-layer non-woven or multi-layer compound of the web-laying means (22) thus formed is stored and fed in several layers to the composite web (36).

In the formation of nonwoven layer (35) by the

Melt blowing equipment (12) in this

Embodiment, the suction zone is formed only by a suction chamber (18) of the suction device (17). Here, the suction chamber (18) preferably such as to extend in the longitudinal direction of the depositing belt (11) that, immediately before or at the inlet of the fibrous web (32) in the storage zone of the

Melt blowing equipment (12) a retaining force on the

is produced fiber web (32) by the suction effect of the suction chamber (18).

Thus, with the example shown in Figure 4 embodiment, a multi-ply fibrous web (32.1,32.2) with inner nonwoven layer (35) can be generated.

However, in principle it is also possible that both fiber webs and (32.2) are coated with a nonwoven layer (35.1,35.2) of synthetic fibers (32.1). Thus in Figure 5 a further embodiment is shown schematically in a partial view, which is identical to the embodiment in Figure 4 substantially. Compared to the aforementioned embodiment of Figure 4, the band arrangements (38.1) and (38.2) are designed identically, so that the band arrangement (38.1) has a lower delivery belt

(11.1) and the belt assembly (38.2) has an upper receiving belt

comprises (11.2). Each of the depositing belts (11.1) and (11.2) is in each case a suction chamber (18.1) and (18.2) assigned to the intersucking independently the respective depositing belts (11.1) and (11.2). Above the depositing belts

(11.1) and (11.2) each is a spinning head (13.1) and

(13.2) of the melt blowing equipment (12). The spinning heads (13.1) and (13.2) are coupled together by an extruder (14).

Compared to the embodiment according to Figure 4 is in the embodiment of Figure 5 on each of the

Fiber webs (32.1) and (32.2) (35.1) and (35.2) generated in each case a nonwoven layer. The non-woven layers (35.1) and (35.2) can be made identical or different in their structure and their construction.

Subsequently, the two card webs (32.1) and are

(32.2) with the applied to the surfaces of the nonwoven layers (35.1) and (35.2) together and as a

Multi-layer fleece or multi-layer compound of

Web-laying means (22) supplied. In that regard, the method shown and the device shown can be flexibly extended in order to generate single-ply or multi-ply fibrous webs for producing composite webs. In an advantageous variant of the invention, three fibrous webs may for example simultaneously by means of a Kadiereinrichtung by three separate customer sites are provided, the three conveyor belt systems to a multi-layer non-woven or multi-layer compound

combined and a web-laying means are supplied. Between the Kadiereinrichtung and

Web-laying device could be two

Schmelzblaseinrichtungen be arranged that the

Conveyor systems are associated, so that two of the three fibrous webs are coated with a nonwoven layer of synthetic fibers before merging. With this variant of the invention advantageously multilayer webs can be produced which contain synthetic fibers of two different polymers.

Alternatively, the Schmelzblaseinrichtungen could also consecutively be associated with a conveyor belt system to store on a batt two nonwoven layers. In particular in Figures 1 and 2 shown

Means for producing the composite nonwoven fabric are exemplified. In principle, the inventive method and the inventive apparatus are also suitable for the production of laminated tiles, in which the solidification by chemical means or by mechanical means, such as a needle punching is generated. In addition, for storing the composite web can also be cut into individual nonwoven pieces and are then stacked to form a stack. Inasmuch as the winding station could be replaced by a stacking station. form further modifications in the illustrated and from above guide are possible in various ways. The holding device (17) may be formed by other means and arranged, such as electrostatic or mechanical holding means, which like the batt (32) with electrostatic forces, hooks or needles or. on the deposit belt (11, 11.1, 11.2) holds and stabilizes against blowing. The storage tape (11, 11.1, 11.2) may again be gas-permeable. A suction device can be dispensed with in these cases. A

Suction may be present, but alternatively configured weaker. It is also possible to use a

to arrange suction elsewhere. In the illustrated embodiments, it draws from the

Depositing belt (11, 11.1, 11.2) and acts on the underside of the upper run there. It may alternatively be located elsewhere and outside of the storage tape.

Instead of the described transport or conveyor belts, other conveying means for the batt (32)

be used.

In the shown and described embodiments, further processing (seinrichtung) (22)

Web-laying means (22) for example as a stacker,

in particular as a band Leger, executed, the

supplied monolayer or multilayer compound on the discharge belt (23) abtäfelt zigzag and with imbricated layer formation or deposits. Alternatively, a web laying device (22) as a carriage Leger, Camel-back-Leger or the like. Be formed. The single- or multilayer compound can be cut in another variation before deposition and divided into pieces, the pieces individually and optionally aligned above one another to form a multi-layer composite web (36) are stored sequentially. The nonwoven laying device (22) is formed for this purpose in accordance with a modified fashion. In the illustrated and preferred embodiments of the single or multilayered compound is supplied immediately after its formation of a web-laying means (22). In this variation, an intermediate step between the

Compound formation and a web-laying means (22) are inserted. Here, for example, of single- or multilayer compound can be recorded and stored, whereby it at a later time of a web-laying means (22) or other

Further treatment process is supplied. In which

An intermediate step, the said compound, for example, in

be stabilized properly, and wound. Further treatment may be formed in other ways. Here, for example, can be dispensed with a multi-layered formation of the composite web (36) by said single or multilayer compound directly like any other further treatment, eg a hardening, in particular a needle punching, thermal bonding or a. and optionally a storage is supplied.

From the single or multilayer composite nonwoven (36) can be mat-like, cup-like, or shaped in any other way sound insulation parts and sound-absorbing

Fleece items are produced. This may possibly a shaping process presses and possibly heating

be inserted. A multi-layer composite nonwoven (36) with an outer and / or inner nonwoven layer (35, 35.1, 35.2) has particular advantages for the

Sound insulation. The embodiments shown for a multi-layer or sandwich form the composite web (36) are particularly advantageous for this purpose. A nonwoven composite can also be made a single layer in the foregoing manner and used for insulation purposes. REFERENCE LIST

1 carding

2 feeder

3 feed system

4 preturret

5 main drum

6 carding

7 pickup device

8 pickup roller system

9 transport device

10, 10.1, 10.2 conveyor belt

10.3 Transport Section

11, 11.1, 11.2 depositing belt

12 melt blowing

13, 13.1, 13.2. spinning head

14 extruder

15 compressed air supply

16 control valve

17 holding device, suction device

18, 18.1, 18.2, 18.3 suction chamber

19, 19.1, 19.2, 19.3 suction line

20, 20.1, 20.2, 20.3 control means

21 support

22 further processing, fleece blank means

23 conveyor belt means

24 solidifying device

25 belt dryer

26 guide band

27 Kalibrierband

Memory means 28

29 winding station

30 Fleece Wrap

31 fibers

32, 32.1, 32.2 batt

33 synthetic fibers

34 melt line 35, 35.1, 35.2 nonwoven layer 36 composite nonwoven

37.1, 37.2 38.1 pickup point lower band arrangement 38.2 upper belt assembly

Claims

1.) A method for producing a composite web (36) in a continuous process sequence in several steps:
- feeding a continuous stream of fibers
consisting of fibers or fiber mixtures to a carding device (1),
- carding and removing the fibers to at least one fibrous web (32),
- guiding the fibrous web (32) to a holding area and retaining the fibrous batt (32) on a running conveyor within the holding zone,
- melt blowing a plurality of a
Polymer melt extruded synthetic fibers (33) and depositing the synthetic fibers (33) to a nonwoven layer (35) on the fibrous web (32) in the area of ​​the holding zone,
- feeding out of the fibrous web (32) with non-woven layer
(35) from the holding zone towards a
Further processing (22), in particular a
Fleece laying device.
2.) A process according to claim 1, characterized
in that the fibrous web (32) is sucked into a suction zone designed as a holding zone to the conveyor.
3.) A process according to claim 1 or 2, characterized
in that the fibrous web (32) passes through several consecutive suction regions with separately adjustable suction capacities within a suction zone.
4.) A process according to claim 1, 2 or 3, characterized
in that the fibrous web (32) with non-woven layer (35) in a web-laying means (22) is applied in several layers to form a composite web (36).
Method according to one of the preceding claims, characterized in that the fibers or fiber mixtures for the formation of the fibrous web (32) are formed with a weight proportion in the range between 10% and 100% of synthetic fibers.
Method according to one of the preceding claims, characterized in that the
Fiber material of the synthetic fibers and the
Polymer melt are formed, for extruding the synthetic fibers (33) from an identical base material.
Method according to one of the preceding claims, characterized in that
Synthetic fibers (33) in the meltblowing with a fine fiber cross section in the range of 0.2 μπι be placed on the batt (32) to 3μπι to the nonwoven layer (35).
Method according to one of the preceding claims, characterized, in that the
at a tape speed, preferably ranging is performed up to 200 m / min fibrous web (32) after the removal to drop continuously to 50 m / min.
Method according to one of the preceding claims, characterized in that a plurality of fibrous webs (32.1,32.2) one above the other by the
Carding means (1) are removed and after the melt-blowing and depositing the synthetic fibers (33) are sandwiched together, wherein the
Nonwoven layer (35) between the card webs (32.1,32.2) forms an intermediate layer.
Method according to one of the preceding claims, characterized in that a plurality of fibrous webs (32.1,32.2) each having a batt layer (35.1,35.2) are assigned and that the fiber webs (32.1,32.2) to the nonwoven layers (35.1,35.2) before further processing ( 22), in particular
Web laying device, are combined to form a multi-layer nonwoven (36).
11.) Process according to one of the preceding claims, characterized in that a (by a web laying device 22) Laid
Composite nonwoven (36) continuously to a
Solidification means (24) supplied, and
is solidified.
12.) Process according to one of the preceding claims, characterized in that a
Composite nonwoven (36) is solidified by a thermal treatment in a belt dryer, said composite web (36) is passed through a sizing zone during solidification, in which a relative to a guide strip adjustable Kalibrierband
(27) on a free upper surface of the composite web
(36) acts.
13.) Process according to one of the preceding claims, characterized in that a
Composite nonwoven (36) is fed to a storage means (28) and is accumulated as a wrapping or as a stack. 14.) An apparatus for producing a composite web (36), (with a carding device 1), a
Pickup means (7), a transport device (9) and with a further processing (22)
in particular a web-laying means, wherein between the pickup device (7) and the
Further processing (22) a station (12) for
Generating a nonwoven layer (35) is provided, characterized in that
Station is designed as a melt blowing equipment (12) and that the melt blowing equipment (12) is assigned a retaining device (17) which is arranged on the transport device (9).
15.) Device according to claim 14, characterized
in that the
Holding means (17) as a suction device
is trained.
16.) Device according to claim 14 or 15, characterized
Characterized that a
Suction means (17) is below a conveying means (11), in particular a deposit belt, which
Transport means (9) is arranged.
17) Apparatus according to claim 14, 15 or 16, characterized in that
Suction means (17) for adjusting a negative pressure separate control means (20) are assigned to intersucking of the depositing belt (11) a plurality of suction chambers (18.1, 18.2, 18.3) and at least one vacuum source, wherein the suction chambers (18.1, 18.2, 18.3).
18.) Device according to one of claims 14 to 17,
characterized, in that the
Melt blowing equipment (12) comprises a movable
having spinning head (13) which can be guided between an operating position above the conveyor (11), in particular the storage tape, and a rest position laterally next to the conveying means (11).
19) Device according to one of claims 14 to 18, characterized in that
Pickup means (7) comprises two separate
Customer locations (37.1, 37.2) which with two belt assemblies (38.1, 38.2) of the
Transport means (9) for receiving and discharging a plurality of fiber webs (32.1, 32.2) cooperate.
20.) Device according to one of claims 14 to 19, characterized in that one of the belt assemblies (38.1) with the depositing belt (11) cooperates and that the second belt assembly (38.2) (with a transport section 10.3) above the spinning head 13 parallel to the is disposed depositing belt (11).
21) Device according to one of claims 14 to 19, characterized in that a second belt assembly (38.2) comprising a second depositing belt (11.2) and (the second storage tape 11.2) a second spinning head (13.2) of
Melt blowing (12) is associated.
22) Device according to one of claims 14 to 20, characterized in that a web-laying means (22) having a
Conveyor means (23), a
Solidification means (24) and a
Memory means (28) cooperates with the specified through the web laying device (22)
Composite nonwoven (36) is guided in a storage station (29) into a coil (30) or a stack. Device according to one of claims 14 to 20, characterized in that the solidification means (24) includes a belt dryer (25) arranged with a guide band (26) and one above the guide strip (26) Kalibrierband
(27) and that the Kalibrierband (27) relative to the guide band (26) is designed height-adjustable. Sound-absorbing nonwoven member, characterized
in that the nonwoven member comprises a composite web (36) and is made of any one of claims 1 to 13.
PCT/EP2011/068408 2010-10-21 2011-10-21 Method and apparatus for producing a composite nonwoven WO2012052535A1 (en)

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DE102010049180 2010-10-21

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US13880861 US20130269154A1 (en) 2010-10-21 2011-10-21 Method and apparatus for producing a composite nonwoven
CN 201180050397 CN103180501B (en) 2010-10-21 2011-10-21 A method and apparatus for producing a composite nonwoven fabric

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EP2630287A1 (en) 2013-08-28 application
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US20130269154A1 (en) 2013-10-17 application
EP2630287B1 (en) 2016-02-24 grant

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