Textiles: fiber preparation – Working – Carding
Reexamination Certificate
2001-01-16
2001-08-21
Calvert, John J. (Department: 3765)
Textiles: fiber preparation
Working
Carding
C019S0650CR, C019S145500, C019S145700, C019S200000
Reexamination Certificate
active
06276028
ABSTRACT:
BACKGROUND OF THE INVENTION
The instant invention is directed to a system for forming fabric webs or non-woven fabrics of evenly and throughly blended fibers.
Fabric webs or non-woven fabrics are well known throughout the textile industry. Normally, these webs or batts are formed by producing carded or air lay webs and passing a plurality of these webs through a cross-lapper to produce the fiber web of sufficient height with entangled fibers for web unity. A major drawback to this system is that the fiber directions are generally in line with the direction of carding thus placing the fibers of the stacked or lapped webs in X,Y positions. This results in a web which has a tendency to separate.
Another problem with this type of system is that production is limited to the speed of the cross-lapping machine.
It is the object of the instant invention to provide a system capable of producing a fabric web or non-woven fabric in which the fibers are disposed in all directions thus forming a more stable fabric or web.
Another object of the invention is a system capable of producing non-woven fabrics or fabric webs at increased speeds.
Another object of the invention is a system for producing non-woven fabrics or webs of selectively variable widths.
Another object of the invention is to provide a system for producing non-woven fabrics or webs without a cross-lapper.
Another object of the invention is to provide a system for the production of non-woven webs or fabrics structured with sufficient stability, loft, and resilience to be used as pillow stuffing, upholstery padding, mattress stuffing and other similar products.
SUMMARY OF THE INVENTION
The invention is directed to a non-woven fabric or web with high resilience and high loft which operates with increased productivity and quality. It comprises a first and second carding system which is arranged in parallel and which card fibers from separate first and second fiber supplies. A doffer is associated with each carding system for removing the carded fibers therefrom. A transport is connected with each doffer and acts to transport the carded and doffed fibers into independent blending and feed chutes.
A housing is provided to receive the carded and blended fibers from the feed chutes for further blending. A feed roll is located within the housing and adjacent the discharge ends of each of the blending and feed chute for withdrawing the fibers from the blending and feed chutes and delivering them into the housing for further opening and blending. A beater roll is provided for removing the further opened and blended fibers from the housing into a non-woven fabric forming chute. Here the fibers are compacted and intertangled into a non-woven fabric of desired high fiber loft and high resilience.
The first and second carding systems may each comprise between one and four carding machines. When there is more than one machine per system, they may be arranged in tandem or in series.
There may be a reserve fiber supply unit located between the carding machines and the blending and feed chutes. In this arrangement the transport comprises first and second units, the first unit connecting the carding machine output with the reserve fiber supply and the second unit connecting the reserve fiber supply unit with the blending and feed chutes.
The doffers may be air doffers or roll doffers and the transport may be air transport or conveyor belt transport.
The feed roll of the system comprises first and second feed rolls, one adjacent each discharge end of the blending and feed chutes. Each of the rolls are driven at selected RPMs which allow the fibers from each of the blending and feed chutes to be delivered into the housing in selected volumes. This is an individual electric motor for driving the beater roll and the first and second feed rolls are each driven by independent motors wherein RPMs for each may be independently adjusted.
The non-woven fabric forming chute includes a packing belt along one surface thereof and a vibrator plate along a second surface opposite said one surface which work together to compact the fibers therein into a non-woven fabric of high resilience.
A system for forming a non-woven fabric with high resilience and high loft comprising in a continuous operation. The system includes first and second carding machines arranged in parallel and carding fibers delivered from a first and second fiber supply.
A first and second doffer may be associated with each carding machine for removing carded fibers therefrom. A first transport is associated with each first doffer for transporting the carded and doffed fibers to a respective intermediate reserve supply chamber. A second transport is associated with each second doffer for transporting the carded or doffed fibers to the respective intermediate reserve supply chamber. A third transport is associated with each intermediate reserve supply chamber and a blending and feed chute for transporting the carded and doffed fibers to respective of the blending and feed chute.
A housing receives the carded and blended fibers from the feed chutes for further blending of the fibers and for delivery to a fiber web forming chute where the fibers are formed into a non-woven fabric or web with high loft and great resilience.
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Calvert John J.
Flint & Kim, P.A.
Welch Gary L.
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