Method for manufacturing a nonwoven product, a nonwoven product

Details Method for manufacturing a nonwoven product, a nonwoven product Method for manufacturing a nonwoven product, a nonwoven product

1993-03-01

1995-10-03

Crowder, C. D.

Textiles: fiber preparation

Assembling

Formed web

28101, D01G 2500

Patent

active

054541450

DESCRIPTION:

BRIEF SUMMARY
The present invention relates to a method for manufacturing nonwoven products.
This invention also relates to a nonwoven product which can be obtained by this method.
The present invention is also concerned with an installation for the manufacture of said nonwoven product.
It is known to manufacture nonwoven fabrics by producing a web of longitudinal parallel fibers, the web being fed to a spreading and lap-forming machine which forms a lap by depositing said web in successive pleats which overlap in a zigzag pattern on a delivery belt, the belt being so arranged as to move at right angles to the direction of feed of the web.
The lap thus obtained has two "privileged" orientations of the fibers which correspond to the orientations of the fibers present in superposed web sections in the lap. These two privileged orientations are usually symmetrical with respect to the transverse direction of the delivery belt and relatively close to this transverse direction.
As a rule, the fibers are then fixed to each other, for example by means of a needle-punching operation which interlaces the fibers having different orientations.
There is thus obtained a product having poor uniformity of weight, low tensile strength in the longitudinal direction since the fibers are essentially directed transversely, and high shrinkage in width at the time of needle-punching since this operation calls for the application of a pulling stress in the longitudinal direction at the exit of the needle-punching unit.
It is also known to pass fibers successively into two paired units each consisting of a card and a spreading and lap-forming machine. This is simply intended to achieve better mixing of fibers which are different in nature or color but fails to solve the difficulties mentioned earlier.
The object of the present invention is to overcome these difficulties.
In accordance with a first object of the invention, the method for manufacturing a nonwoven product is distinguished by the fact that it involves the use of an intermediate product in which the majority of the fibers present therein are distributed in two orientations which form an angle with each other, and that this intermediate product is fed to a spreading and lap-forming unit which deposits the intermediate product in alternate pleats on its delivery belt so as to form a lap of superposed layers such that the majority orientations of the fibers in each layer form an angle with the majority orientations of the fibers of the contiguous layers, and the lap is subjected to a fixing treatment, for example by needle-punching.
Thus the fibers are distributed in four different orientations within the lapped product which is accordingly endowed with very good uniformity and very high tensile strength in all directions. This is advantageous not only for subsequent treatment but also for the mechanical properties of the final product to be obtained.
In accordance with a second object of the invention, the nonwoven product is distinguished by the fact that the majority of the fibers in said product are distributed in four privileged orientations.
In accordance with a third object of the invention, the installation for the manufacture of a nonwoven product is distinguished by the fact that it comprises in series, in this order, a card, a first spreading and lap-forming unit, a drawing frame and a second spreading and lap-forming unit.
Other features and advantages of the invention will appear from the following description, taken in connection with non-limiting examples.
In the accompanying drawings:
FIG. 1 is a schematic view of an installation for manufacturing an intermediate product which can be employed in the method in accordance with the invention.
FIG. 2 is a schematic view in elevation showing the interior of a drawing frame which forms part of the installation of FIG. 1.
FIG. 3 shows in elevation a detail of FIG. 2.
FIGS. 4 to 7 are schematic views showing the privileged orientations of the fibers in the textile product at different stages of manufacture.
FIGS. 8 and 9 are sc

REFERENCES:
patent: 1733170 (1929-10-01), Robertson et al.
patent: 1999169 (1935-04-01), Jackson
patent: 2927350 (1960-03-01), Nelson
patent: 3183557 (1965-05-01), Hollowell
patent: 3660868 (1972-05-01), Weightman
patent: 3682734 (1972-08-01), Burger
patent: 5182835 (1993-02-01), de 'Giudici

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