WO2016085435A1 - A unidirectional blowing system and a method for nonwoven fabric production - Google Patents
A unidirectional blowing system and a method for nonwoven fabric production Download PDFInfo
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- WO2016085435A1 WO2016085435A1 PCT/TR2015/050194 TR2015050194W WO2016085435A1 WO 2016085435 A1 WO2016085435 A1 WO 2016085435A1 TR 2015050194 W TR2015050194 W TR 2015050194W WO 2016085435 A1 WO2016085435 A1 WO 2016085435A1
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- Prior art keywords
- polymer melt
- air
- nonwoven fabric
- blowing
- flat plate
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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
- D04H13/00—Other non-woven fabrics
- D04H13/02—Production of non-woven fabrics by partial defibrillation of oriented thermoplastics films
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
- D04H1/43838—Ultrafine fibres, e.g. microfibres
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/56—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in association with fibre formation, e.g. immediately following extrusion of staple fibres
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
Definitions
- the present invention relates to a unidirectional blowing system and method for nano-microfiber nonwoven fabric production.
- Melt blowing method is the method wherein the polymer melt is thinned on the movable conveyor in guidance of air jet and the fibrous nonwoven structures are produced. Melt blowing is an old method the first examinations of which were made in 1950s, and it is an industrial process used for fiber in diameter range of 0.5 - 5 ⁇ in single step.
- thermoplastic polymer melt such as ⁇ , ⁇
- ⁇ , ⁇ thermoplastic polymer melt
- carrier conveyor in guidance of high pressurized air.
- fiber diameters in random micron and submicron levels are provided.
- the nonwoven surfaces which are obtained are transferred via conveyor system and wrapped around the roller. It was observed that fiber dimensions in nanometer diameters could be acquired by adjusting air pressure and polymer flowrate. However, for the webs produced with this method the fiber diameter usually shows deviation under 30%. In good situations, it is expected that the deviation goes under 10% 1 .
- melt blowing technique industrial production can be realized; however it cannot be decreased under 500nm fiber diameter.
- conventional melt blowing system requires high cost investment since it requires sensitive die design and high volume of air at high temperature.
- nonwoven fabric is obtained by using various gases (nitrogen, argon, helium, carbon) and various polymers (polyamide, nylon, polyaramide, polybenzimidazole, polyetherimide, poly aery lonitrile).
- gases nitrogen, argon, helium, carbon
- polymers polyamide, nylon, polyaramide, polybenzimidazole, polyetherimide, poly aery lonitrile.
- the operating voltage range of the system is given as 1-300 kV and the spinneret pressure range is given as 0.01-200 bars. It is disclosed in the patent that the oxygen concentration in the gas is reduced during blowing and drawing is performed, and thus oxidization is prevented .
- Mao Peng et. al. have acquired more regular fibers relative to electro spinning by increasing the drawing efficiency property in the study that they have realized with PMMA solution by using the electroblowing method.
- the pore diameters of the fibers formed by using electroblowing method were lower. Furthermore, it is
- nanofiber nonwoven fabric can be produced in electroblowing technique, safety will be an issue since high electric field is used.
- Spunbond technique which is another method is one of the most commonly used methods used in nonwoven fabric production.
- polymer material in granule form is transformed into nonwoven fabric on a continuous line 5 .
- spunbond technique there are polymer feeding, extruder, spin pump, die assembly, fiber spinning, fiber drawing and collecting, transforming into fabric form, connection unit, winding processes.
- Spunbond products are commonly used in areas such as single use medical applications, automotive industry, filtration, civil engineering, packaging applications, carpet padding applications, geotextile, long life papers, mattress, pillow, tiling 6 .
- spunbond technique only thick (in size of 5-50 microns) fibers can be produced. Furthermore, in this technique approximately 10 m of height is required in order to draw fiber. For these reasons, spunbond technique is a high cost system which requires a large area.
- Yarin et. al. produced fiber in core-shell structure by using solution blow spinning method from PMMA and PAN solutions in a study that they performed in 2010. Then, they removed PMMA in the core by applying thermal treatment. Then, they produced carbon tube with inner diameter of 50-100 nm and outer diameter of 400-600 nm with carbonization process .
- Zhuang et.al. used polyethylene oxide (PEO) with normal molecular weight of 50.000 by dissolving in N,N dimethylformamide (DMF) in concentration of 10% by weight.
- PEO polyethylene oxide
- DMF N,N dimethylformamide
- the solution is fed to the spinneret with peristaltic pump. Then, the pressurized air is sent to the spinneret such that it will surround it, and the polymer solution is forced to go out of the spinneret, then it is sprayed into the collecting surface with web like structure which is 45 cm far away.
- the inner diameter of the spinneret used in this study is 0.33 mm and its outer diameter is 0.55 mm.
- Zhuang et.al. stated that nanofiber can be produced at high feed flow rates such as 0.3-0.8 ml/m by using polymer solution in concentration range of 5- 20% 9 .
- Oliveira et. al. produced fiber with solution blow spinning method by using polylactide (PDLLA) solution, and they examined the effects of the parameters in this study. Polymer concentration, feeding flow rate and air pressure are the parameters examined in this study. Polymer concentration was determined to be the most important parameter. PDLLA fibers having diameter in rage of 70-2000
- Solution blow spinning method has production speed of 10-30 ml/hour/spinneret.
- the said method is more advantageous than the other three methods.
- the feeding flow rate is not in a desired level for industrial production since single feeding spinneret is used in the studies.
- the inventive unidirectional blowing system and method overcomes the said disadvantages and thus it enables to produce nano-micro fiber nonwoven fabric economically.
- the objective of the present invention is to provide a unidirectional blowing system and method for nano-microfiber nonwoven fabric production by using a polymeric solution or melt.
- Another objective of the present invention is to provide a unidirectional blowing system and method which operates in low pressure and has low energy consumption by means of high shear force due to the air shear in the unidirectional blowing system.
- a further objective of the present invention is to provide a unidirectional blowing system and method wherein the production speed can be increased in level of the channel by feeding the polymer solution from a channel in form of a line.
- Figure 1 is the schematic view of the unidirectional blowing system.
- Figure 2 is the steps of the unidirectional blowing method.
- the fibers which are formed being accumulated on the collecting surface (7) and forming the nonwoven fabric structure
- the unidirectional blowing system (1) developed to fulfill the objective of the present invention comprises
- At least one strip spreading apparatus (4) which enables the polymer melt/solution to be distributed homogenously, and which has a channel in form of a line,
- the blowing apparatus (2) is comprised of single piece or it is comprised by mounting separate parts end to end.
- hitting angle and the air transfer speed of the air shear (3) can be adjusted.
- the flat plate (5) is formed of a metal or ceramic material, and it has a tapered form.
- the collecting surface (7) has a perforated lattice structure comprised of a metal material.
- the unidirectional blowing method (100) developed to fulfill the objective of the present invention comprises the steps of
- the inventive unidirectional blowing method can be used both in melt blowing method which is used industrially, and in solution blowing method which is used in academic studies.
- nano-microfiber nonwoven fabric can be produced by using a co-axial spinneret. Since feeding is made from a single needle in these methods, the production speed is limited to the diameter of the needle. In the suggested method, the polymer solution is fed not from a single needle, but from a line formed channel. By this means, the production line is increased depending on the width of the channel, and 10-30ml/hour/spinneret levels can be achieved.
- the energy consumption is low and the system takes smaller place by volume.
- low fiber diameters for example about 200 TPU polymer
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
- Nonwoven Fabrics (AREA)
Abstract
The present invention relates to a unidirectional blowing system (1), which enables to produce nano-microfiber nonwoven fabric by using a polymeric material, essentially comprising at least one blowing apparatus (2) where the pressurized air or gases are sent to the polymer melt/solution, at least one air shear (3) which is provided on the blowing apparatus (2), which enables the polymer melt/solution to be transformed into fiber form by applying high shear forces, at least one strip spreading apparatus (4) which enables the polymer melt to be distributed homogenously, and which has a channel in form of a line, at least one flat plate (5) which is comprised of a surfaces wherein the polymer melt/solution going out of the strip spreading apparatus (4) contacting the pressurized air or gas, at least one conveyor band (6) which can be actuated in the horizontal direction and which provides the homogeneity of the nonwoven fabric that is formed, at least one collecting surface (7) which is provided on the conveyor band (6) and on which the fibers that are produced are collected, at least one vacuum system (8) which prevents the fibers on the collecting surface (7) from being dispersed by reducing the turbulence intensity generated by the air shear (3).
Description
DESCRIPTION
A UNIDIRECTIONAL BLOWING SYSTEM AND A METHOD FOR NONWOVEN FABRIC PRODUCTION
Field of the Invention
The present invention relates to a unidirectional blowing system and method for nano-microfiber nonwoven fabric production.
Background of the Invention
Several techniques are used for nonwoven fabric production. Melt blowing, electrospinning, electro blowing, spun bonding, and solution blow spinning methods are the most essentially used methods used for nano-microfiber nonwoven fabric production. The fabrics produced with these methods are used in filtration, energy storage, biomedical applications, sensors, and textile applications.
Melt blowing method is the method wherein the polymer melt is thinned on the movable conveyor in guidance of air jet and the fibrous nonwoven structures are produced. Melt blowing is an old method the first examinations of which were made in 1950s, and it is an industrial process used for fiber in diameter range of 0.5 - 5 μηι in single step.
In an application wherein melt blowing method is used, thermoplastic polymer melt (such as ΡΡ,ΡΕΤ) is passed through specially structured spin dies, and transferred onto the carrier conveyor in guidance of high pressurized air. By this means, fiber diameters in random micron and submicron levels are provided. The nonwoven surfaces which are obtained are transferred via conveyor system and wrapped around the roller. It was observed that fiber dimensions in nanometer diameters could be acquired by adjusting air pressure and polymer flowrate. However, for the webs produced with this method the fiber diameter usually
shows deviation under 30%. In good situations, it is expected that the deviation goes under 10%1.
In the industry, two rectangular channels are used in order to produce polymeric fibers in melt blowing process. The air jet going out of the said two channels spray the polymer melt by means of hot air. Spinneret diameter, air channel width, jet width, and air hitting angle are important system parameters affecting the fiber diameter. Polymer melt is formed under the direction between two air jets .
In the current melt blowing technique, industrial production can be realized; however it cannot be decreased under 500nm fiber diameter. Besides, conventional melt blowing system requires high cost investment since it requires sensitive die design and high volume of air at high temperature.
Hovanec in a recent invention aimed to improve nonwoven fabric production by using electro blowing method. (US7846374B2). In the patent, it is disclosed that nonwoven fabric is obtained by using various gases (nitrogen, argon, helium, carbon) and various polymers (polyamide, nylon, polyaramide, polybenzimidazole, polyetherimide, poly aery lonitrile). In the patent, the operating voltage range of the system is given as 1-300 kV and the spinneret pressure range is given as 0.01-200 bars. It is disclosed in the patent that the oxygen concentration in the gas is reduced during blowing and drawing is performed, and thus oxidization is prevented .
Mao Peng et. al. have acquired more regular fibers relative to electro spinning by increasing the drawing efficiency property in the study that they have realized with PMMA solution by using the electroblowing method. The pore diameters of the fibers formed by using electroblowing method were lower. Furthermore, it is
1 «Melt-blowing die for producing nonwoven mats»
2
H. M. Krutka, R. L. Shambaugh, ve D. V. Papavassiliou, «Effects of die geometry on the flow field of the melt-blowing process*, Ind. Eng. Chem. Res., v 42, no 22, p 5541-5553, 2003.
J. B. Hovanec, Blowing gases in electroblowing process. Google Patents, 2010.
stated in this study that fiber can be produced from PMMA solutions which is commercially available4.
Although nanofiber nonwoven fabric can be produced in electroblowing technique, safety will be an issue since high electric field is used.
In the inventive unidirectional blowing system, drive force is only a pressurized air, therefore there will be no such problem. However, polymer melt or solution can be charged with electrostatic in various positions if it is needed (especially when fiber separation is required).
Spunbond technique which is another method is one of the most commonly used methods used in nonwoven fabric production. In this technique, polymer material in granule form is transformed into nonwoven fabric on a continuous line5. Generally, in spunbond technique, there are polymer feeding, extruder, spin pump, die assembly, fiber spinning, fiber drawing and collecting, transforming into fabric form, connection unit, winding processes. Spunbond products are commonly used in areas such as single use medical applications, automotive industry, filtration, civil engineering, packaging applications, carpet padding applications, geotextile, long life papers, mattress, pillow, tiling6.
In spunbond technique, only thick (in size of 5-50 microns) fibers can be produced. Furthermore, in this technique approximately 10 m of height is required in order to draw fiber. For these reasons, spunbond technique is a high cost system which requires a large area.
In solution blow spinning technique, a co-axial spinneret is used and pressurized air is applied on the polymer solution, and technical textiles with nano-microfiber structure are produced. Polymer solution is fed from the inner channel of the
4 M. Peng, Q. Sun, Q. Ma, ve P. Li, «Mesoporous silica fibers prepared by electroblowing of a poly (methyl mefhacrylate)/tetraefhoxysilane mixture in< i> N</i>,< i> N</i>-dimethylformamide», Microporous Mesoporous Mater., v 115, no 3, p 562-567, 2008.
5 Z. Bo, «Effects of processing parameters on the filament fiber diameter of spunbonded nonwoven fabrics*, Polym. Eng. Set, v 47, no 4, p 510-515, 2007.
6 H. Lim, «A Review of Spunbond Process*, J. Text. Appar. Technol. Manag., v 6, no 3, 2010.
spinneret. Pressurized air is fed from its outer channel. The pressurized air completely surrounds the polymer solution and it makes possible to obtain nano- microfiber7.
Yarin et. al. produced fiber in core-shell structure by using solution blow spinning method from PMMA and PAN solutions in a study that they performed in 2010. Then, they removed PMMA in the core by applying thermal treatment. Then, they produced carbon tube with inner diameter of 50-100 nm and outer diameter of 400-600 nm with carbonization process .
Zhuang et.al. used polyethylene oxide (PEO) with normal molecular weight of 50.000 by dissolving in N,N dimethylformamide (DMF) in concentration of 10% by weight. In this study, the solution is fed to the spinneret with peristaltic pump. Then, the pressurized air is sent to the spinneret such that it will surround it, and the polymer solution is forced to go out of the spinneret, then it is sprayed into the collecting surface with web like structure which is 45 cm far away. The inner diameter of the spinneret used in this study is 0.33 mm and its outer diameter is 0.55 mm. Zhuang et.al. stated that nanofiber can be produced at high feed flow rates such as 0.3-0.8 ml/m by using polymer solution in concentration range of 5- 20%9.
Oliveira et. al. produced fiber with solution blow spinning method by using polylactide (PDLLA) solution, and they examined the effects of the parameters in this study. Polymer concentration, feeding flow rate and air pressure are the parameters examined in this study. Polymer concentration was determined to be the most important parameter. PDLLA fibers having diameter in rage of 70-2000
7
E. S. Medeiros, G. M. Glenn, A. P. Klamczynski, W. J. Orts, and L. H. Mattoso, Solution blow spinning. Google Patents, 2014.
8 S. Sinha-Ray, A. L. Yarin, ve B. Pourdeyhimi, «The production of 100/400nm inner/outer diameter carbon tubes by solution blowing and carbonization of core-shell nanofibers», Carbon, v 48, no 12, p 3575-3578, 2010.
9 X. Zhuang, X. Yang, L. Shi, B. Cheng, K. Guan, ve W. Kang, «Solution blowing of submicron-scale cellulose fibers*, Carbohydr. Polym., v 90, no 2, p 982-987, 2012.
nm were produced. Low polymer concentration results in lumps on the collecting surface. The fibers produced with this method can be collected on any surface such as human skin, non-metallic collectors and fabric. This situation shows that fiber can be produced without forming electric field, and by means of this advantage solution blow spinning method can easily be used in biomedical applications10.
Solution blow spinning method has production speed of 10-30 ml/hour/spinneret. The said method is more advantageous than the other three methods. However, the feeding flow rate is not in a desired level for industrial production since single feeding spinneret is used in the studies.
The inventive unidirectional blowing system and method overcomes the said disadvantages and thus it enables to produce nano-micro fiber nonwoven fabric economically.
Summary of the Invention
The objective of the present invention is to provide a unidirectional blowing system and method for nano-microfiber nonwoven fabric production by using a polymeric solution or melt.
Another objective of the present invention is to provide a unidirectional blowing system and method which operates in low pressure and has low energy consumption by means of high shear force due to the air shear in the unidirectional blowing system.
A further objective of the present invention is to provide a unidirectional blowing system and method wherein the production speed can be increased in level of the channel by feeding the polymer solution from a channel in form of a line.
J. E. Oliveira, E. A. Moraes, R. G. Costa, A. S. Afonso, L. H. Mattoso, W. J. Orts, and E. S. Medeiros, «Nano and submicrometric fibers of poly (D, L-lactide) obtained by solution blow spinning: Process and solution variables*, J. Appl. Polym. Sci, v 122, no 5, p 3396-3405, 2011.
Detailed Description of the Invention
The unidirectional blowing system and method developed to fulfill the objectives of the present invention is illustrated in the accompanying figures, in which: Figure 1 is the schematic view of the unidirectional blowing system.
Figure 2 is the steps of the unidirectional blowing method.
The components shown in Figure 1 are each given reference numerals as follows:
1. Unidirectional blowing system
2. Blowing apparatus
3. Air shear
4. Strip spreading apparatus
5. Flat plate
6. Conveyor band
7. Collecting surface
8. Vacuum system
The steps of the method shown in Figure 2 are each given reference numerals as follows:
100. Unidirectional blowing system
101. Sending the polymer melt/solution going out of the strip spreading apparatus (4) to the surface of the flat plate (5)
102. Compressing the polymer melt/solution between the flat plate (5) and the high speed air fed unidirectionally from the air shear (3)
103. Transferring the compressed polymer melt towards the sharp end of the flat plate (5)
104. The polymer melt/solution leaving the flat plate (5) being transformed into fiber form by means of high shear forces originating from the air shear (3)
105. The fibers which are formed being accumulated on the collecting surface (7) and forming the nonwoven fabric structure
The unidirectional blowing system (1) developed to fulfill the objective of the present invention comprises
- at least one blowing apparatus (2) where the pressurized air or gases are sent to the polymer melt/solution,
- at least one air shear (3) which is provided on the blowing apparatus (2), which enables the polymer melt/solution to be transformed into fiber form by applying high shear forces,
- at least one strip spreading apparatus (4) which enables the polymer melt/solution to be distributed homogenously, and which has a channel in form of a line,
- at least one flat plate (5) which is comprised of a surfaces wherein the polymer melt/solution going out of the strip spreading apparatus (4) contacting the pressurized air or gas,
- at least one conveyor band (6) which can be actuated in the horizontal direction and which provides the homogeneity of the nonwoven fabric that is formed,
- at least one collecting surface (7) which is provided on the conveyor band (6) and on which the fibers that are produced are collected,
- at least one vacuum system (8) which prevents the fibers on the collecting surface (7) from being dispersed by reducing the turbulence intensity generated by the air shear (3).
In a preferred embodiment of the inventive unidirectional blowing system (1), the blowing apparatus (2) is comprised of single piece or it is comprised by mounting separate parts end to end.
In a preferred embodiment of the inventive unidirectional blowing system (1), hitting angle and the air transfer speed of the air shear (3) can be adjusted.
In a preferred embodiment of the inventive unidirectional blowing system (1), the flat plate (5) is formed of a metal or ceramic material, and it has a tapered form.
In a preferred embodiment of the inventive unidirectional blowing system (1), the collecting surface (7) has a perforated lattice structure comprised of a metal material.
The unidirectional blowing method (100) developed to fulfill the objective of the present invention comprises the steps of
-sending the polymer melt going out of the strip spreading apparatus (4) to the surface of the flat plate (5) (101),
-compressing the polymer melt between the flat plate (5) and the high speed air fed unidirectionally from the air shear (3) (102),
-transferring the compressed polymer melt/solution towards the sharp end of the flat plate (5) (103),
-the polymer melt leaving the flat plate (5) being transformed into fiber form by means of high shear forces originating from the air shear (3) (104),
-the fibers which are formed being accumulated on the collecting surface (7) and forming the nonwoven fabric structure (105).
The inventive unidirectional blowing method can be used both in melt blowing method which is used industrially, and in solution blowing method which is used in academic studies.
In the blowing methods known in the state of the art, nano-microfiber nonwoven fabric can be produced by using a co-axial spinneret. Since feeding is made from a single needle in these methods, the production speed is limited to the diameter of the needle. In the suggested method, the polymer solution is fed not from a single needle, but from a line formed channel. By this means, the production line is increased depending on the width of the channel, and 10-30ml/hour/spinneret levels can be achieved.
In the unidirectional blowing method, the energy consumption is low and the system takes smaller place by volume. In addition to these advantages, low fiber
diameters (for example about 200 TPU polymer) can be achieved with the invention.
Claims
1. A unidirectional blowing system (1), which enables to produce nano- microfiber nonwoven fabric by using a polymeric material, essentially characterized by
- at least one blowing apparatus (2) where the pressurized air or gases are sent to the polymer melt,
- at least one air shear (3) which is provided on the blowing apparatus (2), which enables the polymer melt to be transformed into fiber form by applying high shear forces,
- at least one strip spreading apparatus (4) which enables the polymer melt to be distributed homogenously, and which has a channel in form of a line,
- at least one flat plate (5) which is comprised of a surfaces wherein the polymer melt going out of the strip spreading apparatus (4) contacting the pressurized air or gas,
- at least one conveyor band (6) which can be actuated in the horizontal direction and which provides the homogeneity of the nonwoven fabric that is formed,
- at least one collecting surface (7) which is provided on the conveyor band (6) and on which the fibers that are produced are collected,
- at least one vacuum system (8) which prevents the fibers on the collecting surface (7) from being dispersed by reducing the turbulence intensity generated by the air shear (3).
2. A unidirectional blowing system (1) according to claim 1, characterized by at least one blowing apparatus (2) which is comprised of a single piece or which is formed by mounting separate parts end to end.
3. A unidirectional blowing system (1) according to any one of the preceding claims, characterized by at least one air shear (3) the hitting angle and the air transfer speed of which can be adjusted.
4. A unidirectional blowing system (1) according to any one of the preceding claims, characterized by at least one flat plate (5) which is formed of a metallic or ceramic material, and which has a tapered end.
5. A unidirectional blowing system (1) according to any one of the preceding claims, characterized by at least one collecting surface (7) which is formed of a metallic material, and which has a perforated lattice structure.
6. A unidirectional blowing system (1), which enables to produce nano- microfiber nonwoven fabric by using a polymeric material, essentially characterized by the steps of
-sending the polymer melt going out of the strip spreading apparatus (4) to the surface of the flat plate (5) (101),
-compressing the polymer melt between the flat plate (5) and the high speed air fed unidirectionally from the air shear (3) (102),
-transferring the compressed polymer melt/solution towards the sharp end of the flat plate (5) (103),
-the polymer melt/solution leaving the flat plate (5) being transformed into fiber form by means of high shear forces originating from the air shear (3)
(104),
-the fibers which are formed being accumulated on the collecting surface (7) and forming the nonwoven fabric structure (105).
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| TR2014/14216 | 2014-11-28 | ||
| TR201414216 | 2014-11-28 |
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| WO2016085435A1 true WO2016085435A1 (en) | 2016-06-02 |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113910735A (en) * | 2020-07-08 | 2022-01-11 | 厦门巨锐自动化设备有限公司 | Test paper pad pasting equipment |
| CN113910735B (en) * | 2020-07-08 | 2023-12-08 | 厦门巨锐自动化设备有限公司 | Test paper pad pasting equipment |
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