US3929542A - Non-woven webs of filaments of synthetic high molecular weight polymers and process for the manufacture thereof - Google Patents

Non-woven webs of filaments of synthetic high molecular weight polymers and process for the manufacture thereof Download PDF

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US3929542A
US3929542A US195427A US19542771A US3929542A US 3929542 A US3929542 A US 3929542A US 195427 A US195427 A US 195427A US 19542771 A US19542771 A US 19542771A US 3929542 A US3929542 A US 3929542A
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filaments
air
cooling
crimping
cooling air
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Heinz Gehrig
Hermann Linge
Sepp Wagner
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BASF Farben und Fasern AG
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BASF Farben und Fasern AG
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    • 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
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/005—Synthetic yarns or filaments
    • D04H3/007—Addition polymers
    • 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
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/10—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically
    • D04H3/105—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically by needling
    • 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
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S428/00—Stock material or miscellaneous articles
    • Y10S428/91—Product with molecular orientation
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2922—Nonlinear [e.g., crimped, coiled, etc.]
    • Y10T428/2925—Helical or coiled

Definitions

  • ABSTRACT Apparatus and process for the manufacture of a nonwoven web consist of filaments of strands of filaments which show helical crimping with alternating directions of turn of the helices within the filament.
  • Preferred outlets are floor coverings, cover materials and filter mats.
  • the present invention relates to a non-woven web of filaments or strands of filaments of synthetic high molecular weight polymers, in which the filaments or strands of filaments hereinafter referred to as the filaments are laid down in looped configurations.
  • the invention also relates to a process and apparatus for the manufacture of such webs.
  • a filament, a group of filaments or a bundle of filaments coming from a conventional or specially designed spinneret may be taken up by a pneumatic jet or aspirator jet of a variety of types and transported to a lay-down area where a tangled web is produced by turbulent air.
  • Japanese Pat. No. 45-5057 describes a process for the manufacture of non-woven fabrics which uses conventional single-stage pneumatic jets having a circular cross-section and adapted to take up the filaments immediately after spinning or after mechanical stretching. These simple pneumatic jets are moved transversely across a moving belt, which procedure clearly leads to a web in which the filaments are predominantly transversely oriented. Such transverse orientation is inconvenient in most cases, as it produces variations in the properties of the web in the different directions in its plane. Another drawback of this process is that, the filament being uncrimped, only webs of a low specific volume can be obtained.
  • this object is achieved by providing each filament forming the fabric with helical crimping showing alternating direc- 2 tions of turn along the length of the filament, even if the latter is in a strand, the diameter of the helices being from 1 to 10 mm and the changes in the direction of turn thereof occurring after every 1 to 50 and preferably after every 5 to l5 turns.
  • the filaments forming the web are laid down in the form of perfect or imperfect trochoids, which trochoids show regular or random variations of orientation.
  • the web-formung filaments are of polypropylene, polyester, polyamide, polyethylene or polyurethane. They may be needle-punched, thermally bonded or bonded by means of dispersions of bonding agents such as polyacrylates.
  • a takeup zone which is immediately downstream of the cooling zone and is in the form of a single-stage or, preferably, multi-stage pneumatic jet;
  • the partially plastic filaments are crimped by periodic alteration of the position of one or more annular or cylindrical vortices of gaseous medium along the filaments at a high frequency with partial flow-off and replenishment of the vortex or vortices;
  • the laid-down web is bonded by mechanical, thermal or chemical means by known methods.
  • the filaments are normally partially plastic, which means that the pneumatic jets may be operated with cold air. If the filaments are over-cooled in the cooling zone, crimping may be achieved by using hot air or steam in the pneumatic jet. The crimps may be fixed by allowing the crimped filaments to relax under conditions of cooling to below their softening point. The use of steam in the cooling zone can influence the strength properties and resilience of the filaments and also the type of crimping obtained.
  • a cooling channel immediately downstream of said spinnerets and comprising means for feeding and appropriately distributing the cooling air and optionally means for deflecting the air to a direction of flow parallel to the filaments, and a passageway immediately downstream of said cooling channel, the lower end of said passageway having means for allowing the cooling air to escape or be sucked off 3 and, if desired, flaps for partially closing the outlet cross-section of the passageway; pneumatic jets downstream of the passageway, preferably of the two-stage or multi-stage type, and consisting of an outer housing having air-feed connections, an equalizing chamber with damming elements and inlet chambers downstream thereof, which inlet chambers communicate with an inner channel via inlets, slots or ducts at an angle of from 5 to 30, which inner chamber is provided, in its wall, with a screw-adjustable suction nozzle and, in the case of a multistage injector, increases in crosssection from stage to stage, optionally via a diffusor; d.
  • a crimping device downstream of the pneumatic jet and consisting of an inlet channel to which there is mounted via means for axial displacement such as a screw-thread connection a member of greater cross-section, for example a tube, the increase in cross-section starting with an undercut and continuing irregularly to form a chamber which ends in an irregular reduction of cross-section leading to sharp edges defining the commencement of a short outlet channel;
  • flexible connecting members e.g. flexible tubes, which are connected to the crimping device and are fitted with mouthpieces of constant cross-section or, preferably, of enlarged cross-section;
  • a moving belt optionally provided with suction means at the point where the filaments initially contact the belt;
  • a device for effecting mechanical, thermal or chemical bonding of the web optionally, a device for effecting mechanical, thermal or chemical bonding of the web.
  • the filaments are normally spun by means of spinnerets having a circular, oval, rectangular or similar shape and containing a plurality of spinning holes.
  • Spinnerets may also be used which have free spaces in their central region, through which cooling air may be blown into the bundles of filaments, which cooling air may be thermally screened from the spinnerets if necessary. It has been found convenient, for the purposes of the process of the invention, to pre-orientate the melt before it is extruded by subjecting it to strong shearing strains.
  • the first-mentioned spinning method has the advantage that spinnerets of simple design may be used.
  • the second method using spinnerets with free spaces in the central region still utilizes relatively simple designs compared with complicated spinnerets of special design. Consequently, further advantages of the process of the invention are as follows:
  • a. cold air may be used
  • the point of impingement of the pneumatic force is not close to the spinning hole but at a distance of at least about mm therefrom, this giving rise to a longer primary take-up zone;
  • the ratio of the cross-sectional areas of the melt and air at their respective nozzles is more advantageous, with the result that the specific air consumption is reduced for a given working pressure.
  • the process of the invention differes from other processes from the manufacture of nonwoven webs, for example the processes described in U.S. Pat. No. 3,117,055 and Japanese Pat. No. 45-5057, in that a definite cooling zone is provided, this being divided into sections for the introduction of cooling air and its deflection (if necessary), for parallel air-flow, and for the removal of the cooling air by suction or escape means.
  • the process of the invention differes from conventional spinning processes which also make use of a definite cooling zone in that the cooling air, which is caused to impinge on the filaments at an angle of from 0 to thereto, is deflected so that a substantial proportion thereof flows parallel to the filaments.
  • the various cooling methods have the common feature of impingement of the cooling air on the filaments from one side and, at least in the second section, strong air flow parallel to the filaments at an independent velocity.
  • Another important distinguishing feature of the present invention as compared with prior art processes for the manufacture of non-woven webs is evident at the end of the cooling zone, where the cooling air is removed from the process and not transported through the following main take-up means with the filaments.
  • the primary advantage of this embodiment of the process of the invention is that the spatial density of energy is very high for a given consumption of air energy and remains high over the length of the pneumatic jet because only a very small amount of air and not the entire stream of cooling air is sucked into the air jet.
  • cooling is effected in a much more economical manner in the present invention using air at a pressure of from approximately 50 to '200 mm of water, since the air pressure required to take up the filaments must be at least some thousands of mm of water to some atmospheres if satisfactory filament properties are to be achieved.
  • Another advantage resulting from the removal of the cooling air from the system is that when the web is laid down, the amount of air which has to be sucked off is several times (from 5 to 10 times) the amount of air impinging on the moving belt, this being necessary to prevent the web from being dislodged by the blast of air. In the present case therefore, only the relatively small amount of air used for taking up the filaments determines the suction power required, while the generally larger volume of cooling air has already been removed from the filaments before they are taken up.
  • the filaments are taken up by means of, preferably, two-stage or multistage pneumatic jets operated by an external air jet.
  • the type of pneumatic jet proposed by the invention makes it possible to operate all stages at an equally high pressure, by which means highly efficient filament take-up is achieved without the apparatus becoming blocking up.
  • the filament take-up apparatus of the invention increases in cross-section from stage to stage in order to accommodate the added volumes of working air.
  • Another distinguishing feature of the singlestage or multi-stage take-up apparatus as compared with prior art devices is that after the air has passed into the outer housing it initially flows into an antechamber where it is uniformly distributed before passing over damming elements and through inlet chambers to the inlet slots or ducts leading to the inner channel containing the filaments.
  • crimping device which is distinctly different from prior art devices for crimping filaments, for example for effecting aerodynamic compression crimping, aerodynamic false-twist crimping or crimping in a zone of a medium showing a high degree of irregular turbulence.
  • crimping is effected by periodically applying to and removing from the filaments, at a high frequency, one or more annular or cylindrical vortices of a gaseous medium with partial flow-off and replenishment of the vortex or vortices. Crimping is assisted by the previous one-sided cooling of the filaments under the action of the take-up forces.
  • the filaments When the filaments have been crimped, they pass to a diffusor zone where the crimped effect is fixed as the filaments solidify in a relaxed state. To obtain the crimping effect, it is first of all essential to effect proper temperature control in the cooling zone. If the filaments are over-cooled, they can no longer be shaped in the crimping zone unless hot gas or steam is used in the working stream of the aspirator jet. If the filaments are insufficiently cooled, they will adhere to each other in the take-up and crimping zones.
  • the bundles of filaments leaving the pneumatic jets and their associated crimping devices pass through movable elements, for example flexible tubes, to mouthpieces which are moved according to certain kinematic rules so as to describe perfect or imperfect trochoids.
  • movable elements for example flexible tubes
  • mouthpieces which are moved according to certain kinematic rules so as to describe perfect or imperfect trochoids.
  • webs are formed on the moving belt and have a structure complying to the said laydown movements.
  • the kinematics of the lay-down movements are composed of two superimposed swinging motions, preferably a rotating motion and a linear reciprocating motion effected transversely of the belt and referred to as the transverse motion, the ratio of the frequencies of the rotating and transverse motions being from 2:1 to 100:1 and preferably from 4:1 to 50:1.
  • the amplitudes of the linear transverse motion are advantageously many times greater than the diameter of the rotating motions.
  • the reciprocating transverse motion may cover the entire width of the belt or it may be effected to cover a number of overlapping zones. Depending on the degree to which the bundles of filaments have been opened up, the resulting webs show structures composed of strands of filaments or individual filaments.
  • the melts may be spun within various temperature ranges, the upper and lower limits of which may be anywhere in the range defined by the commencement of melting and the maximum temperature possible without the occurrence of chemical changes.
  • Pressure of melt the pressures applied to the melt are between about 1 and 150 atmospheres and preferably between 20 and atmospheres gage.
  • melt throughput the throughput through each spinning hole is from 0.1 to 10 g/min and mainly from 1 to 6 g/min.
  • rate of extrusion of the melt is generally between 0.5 and 15 m/min and preferably between 2 and 10 m/min.
  • Gas temperature the temperature of both the cooling air and the take-up air is conveniently in the range of normal room temperatures, that is from 20 to 30. However, the take-up air may have a temperature of up to about 150C. if desired, in order to achieve certain crimping characteristics for example. For the same reason, steam or a mixture of air and steam may be used.
  • Gas pressure the pressures applied to the cooling air are normally between 20 and 5,000 mm of water and preferably between 50 and 500 mm of water.
  • the takeup air is usually under a pressure of between 0.5 and 50 atmospheres and preferably between 1 and 10 atmospheres gage.
  • the velocity of the cooling air is between 1 and 50 and preferably between 2 and 8 m/sec. In the suction tube of the pneumatic jet velocities of from 10 to 500 and preferably from 50 to 200 m/sec may occur.
  • the velocity of the take-up air on entering the inner tube of the pneumatic jet is generally approximately equal to the speed of sound or just below, after which the air undergoes expansion with local supersonic velocities being possible. Subsequent mixture of the take-up air with air drawn in from the atmosphere reduces it velocity to below that of sound and it achieves values between about and 300 m/sec. in the crimping zone this velocity is further reduced the values between 10 and 100 m/sec.
  • Specific gas consumption (defined as the ratio of amount of gas to amount of melt in kg/kg or m /kg (STP): in the case of the main take-up air, this ratio is approximately within the limits 1 to 50 and preferably 5 to 20.
  • Suitable plastics materials for the process described above are as follows:
  • Post-chlorinated polyethylene having a chlorine content of up to 40% is also suitable.
  • the proportion of comonomers in the total polymer may be up to 30% by weight.
  • Polymers in a wide range of molecular weights, measured in terms of melt index (according to ASTM D1238-S7 T) are suitable, melt indices Ml c C being from 1 to 100 and preferably from 5 to 20.
  • Polypropylene and polybutelen-l and their copolymers with each other and with other l-olefms e.g. ethylene
  • the proportion of comonomers may be up to 15% by weight, and the range of molecular weights is as above (melt index range Ml c C being from 0.1 to 50 and preferably from l to 20).
  • Polyamides for example pure polycondensates of caprolactam or dicarboxylic acids such as adipic and sebacic acids and diamines, for example hexamethylene diamine.
  • Copolymers for example copolymers of the above starting materials, are also suitable.
  • K 7 molecular weights may vary between K 50 to K 90 and preferably between K 70 to K 80 (K value calculated from the relative viscosity 1 /17,, as measured according to German Standard Specification DIN 53,726).
  • Polyesters particularly suitable are the linear saturated polyesters having average molecular weights between l0,000 and 50,000, such as polyethylene terephthalate (e.g. from terephthalic acid diglycol ester), and the polyesters obtainable from hydroxycarboxyolic acids such as m-hydroxydecanoic acid or 4-(B-hydroxyethoxy)benzoic acid.
  • a general group of suitable polyesters comprises the linear saturated polyesters obtainable from glycols and aliphatic or aromatic dicarboxylic acids, provided they give products having the high range of molecular weights specified above. Not only the carboxylic acids but also their anhydrides, esters or acid chlorides may be used.
  • Polyvinyl chloride homopolymers and copolymers with vinyl esters (e.g. vinyl acetate).
  • suitable plasticizers e.g. phthalic esters or adipic esters with monohydric and dihydric alcohols in proportion of up to 40% and preferably from 20 to 30% by weight).
  • Molecular weight range (expressed in K values): 50 to 80.
  • all of the said polymers may have incorporated therein a variety of auxiliaries as used in conventional spinning processes, for example heat stabilizers, light stabilizers, U.V. stabilizers, dyes, flame retardants, crystallization accelerators, etc.
  • auxiliaries for example heat stabilizers, light stabilizers, U.V. stabilizers, dyes, flame retardants, crystallization accelerators, etc.
  • Filament thicknesses between 1 and 200p,m and preferably between 10 and 100 um, equivalent to about 1 to 100 g/ 10,000 m (l to 100 dtex).
  • the number of helical crimps-in the filament is from about 1 to 40 and preferably from 5 to 20 per cm, the diameters of the helices being from about 1 to mm.
  • the spinning speeds are between 1,000 and 5,000 m/rnin, tensile strengths being between between 2 and 6 g/dtex and elongations being between and 300%.
  • the webs made from the crimped filaments are particularly suitable, on account of their favorable elastic and damping properties, for making carpets and also as filling materials for stuffing matresses, upholstery, quilts, sleeping bags, anoraks, etc., as insulating mats, tapestries and as backing materials, e.g. for artificial leather; or for use in tires.
  • Other applications include, for example, filters, home furnishings and certain articles of clothing, and also packaging materials, in which latter case webs having only weakly crimped filaments are of primary importance.
  • FIG. 1 is a diagram of an apparatus for carrying out the process of the invention.
  • FIG. 2 shows special embodiments of a cooling channel with means for feeding and removing the cooling air.
  • FIG. 3 illustrates a Z-stage pneumatic jet and a filament crimping zone downstream thereof.
  • FIG. 4 is an elevation of a preferred embodiment of the lay-down means.
  • FIG. 5 shows diagrammatically a plan view of the lay-down means shown in FIG. 4 and a non-woven web of the invention.
  • the filaments are extruded through spinnerets l of circular, oval or rectangular shape, or, as shown in FIG. 2d, through spinnerets 1 having a free space in the center.
  • the melt is extruded through a number of spinning holes 2 of circular of profied cross-section.
  • the ratio of axial length to diameter is preferably at least 2.5 and the center-tocenter distance between adjacent holes is at least 5 times and preferably 10 times the diameter of the holes.
  • holes 2 are arranged either in concentric circles or ellipses or in straight lines, the free space in the embodiment shown in FIG. 2d being either in the center of the circles or ellipses or between the lines of holes.
  • FIGS. 1 and 2a to 2d The various possibilities of the direction of feed of the cooling air between and 0 to the direction to travel of the filaments are diagrammatically illustrated in FIGS. 1 and 2a to 2d, and the cooling blower (not shown) may operate by suction or by pressure blowing or by both, i.e. by sucking and blowing simultaneously.
  • the cooling air impinges on the filaments at right angles to their direction of travel after it has passed through equalizing wire gauze or grid 12.
  • the side opposite the air inlet 11 may be in the form of, say, a finescreen such that only a small proportion of the cooling air flows horizontally through cooling channel 10, the remainder passing vertically down through passageway 14 which may have a circular or rectangular cross-section.
  • FIG. 1 The various possibilities of the direction of feed of the cooling air between and 0 to the direction to travel of the filaments are diagrammatically illustrated in FIGS. 1 and 2a to 2d, and the cooling blower (not shown) may operate by suction or by pressure blowing or by both
  • the feed of cooling air is effected through a Venetianblind-type baffle grid 13, by means of which the angle of impingement of the air on the filaments may be adjusted from 0 to 90.
  • the flow of cooling air may be caused by suction or blowing.
  • the angle of impingement may again be from 0 to 90
  • the cooling air is fed to the bundle of filaments by an injector effect, passing in from the ambient atmosphere at small angles down to 0.
  • a throttling element 18 for example a grid or gauze, on the upstream side of inlet slot 17.
  • the cooling air is blown in parallel to the filaments through a free space in a spinneret l or between two adjacent spinnerets 1.
  • the filaments are cooled-from the inside of the bundle.
  • pressure blowing it is practically only possible to use pressure blowing.
  • the cooling air when not already introduced in a direction parallel to the filaments, is deflected at least to a major extent so as to continue its flow parallel to the filaments and thus to effect a primary take-up action in addition to its cooling action, the point of impingement of this take-up air not being directly in the outlet plane of the holes 2 but at a distance of at least 3 to 10 cm therefrom.
  • the inlet portions of the cooling zones described above merge into a second zone in the form of a passageway 14, through which the filaments and air pass in parallel directions, the velocity of the air being relatively high.
  • the total length of cooling zone l0, 14 is primarily determined by the polymer used and by the thicknesses of the filaments and the type of filament (degree of crimping) desired. Suitable lengths are of the order of about 1 to 15 m and preferably about 2 to m.
  • the cooling air is removed. If the cooling air 'is pressureblown into cooling zone 10, 14, it is allowed to escape to the atmosphere through perforated section (see FIG. 1).
  • a suction chamber surrounds the perforated section 15 and is connected by a. suction tube to a suction blower (see FIG. 2a
  • the cooling zone is closed by adjustable flapsl6, which reduce the outlet cross-section of passageway 14 and thus prevent unwanted air from being sucked in from below.
  • these flaps 16 may be omitted.
  • the air extracted from the perforated section 15 or from the moving belt by suction means 61 is passed through an air-conditioning apparatus in which the temperature and humidity are adjusted and the conditioned cooli ng air is then returned to the cooling channel 10 through feed connection 11, with or without the additionjexth air.
  • a main take-up apparatus in the form of a single-stage or, preferably, multi-stage pneumatic jet 20 operated by an external air jet.
  • the two-stage embodiment of pneumatic jet 20 shown in FIG. 3 consists of an outer'hous' ing 21 with an air inlet connection 22 and an inner tube or channel 27 which is located within the housing 21 and forms, together with damming elements 24, an antechamber or equalizing chamber 23.3 cap nut 31 holds inner tube 27 and outer housing 21 together.
  • each side of damming elements 24 there is located an inlet chamber 25 from which the air passes through inlet passages 26 (slots or bores) to the interior of inner tube 27 at an angle of from 5 to as a result of which the filaments are drawn in and taken up through the preferably funnel-shaped suction nozzle 29.
  • the length of the suction nozzle 29 is usually from 5 to 50 times its internal diameter or internal width.
  • the length of inner channel 27 including a diffusor 30-integral which is fitted with a mouthpiece 51 and is adapted to carry out lay-down motions.
  • the mouthpiece 51 may be asimple tube, a tube which increases in cross-section regularly or irregularly, or a slotted nozzle for fanning out the strand of filaments. Fanning of the filaments may be alternatively effected by directing two of the filament-laden air nozzles at an angle to each 1 other. 1
  • FIG. 4 An apparatus 59 suitable for the subsequent step of laying down structured non-woven webs is shown diagrammatically in FIG; 4. It is composed of theaforementioned mouthpiece 51, which are connected to the flexible connecting pieces 50 and are also secured to a strip 52 via bearings which permit a tilting movement, for example self-aligning ball bearings, the said strip 52 being inthe form of a connecting rod extending between rotating discs 53.
  • the discs 53 are mounted in a frame 54 whichalso carries the driving unit 55 for the said discs-Theframe 54 is suspended for linear reciprocating motion onhanging bars 56 and is hingedly con- 7 in FIG. 5 resulting from the rotating motion with superimposed linear reciprocating motion and the move- .ment of belt 60.
  • Lay-down is preferably effected with :overlapping of at least 50%. Such overlapping is not shownin FIG.- 5 for the sake of clarity.
  • the spirals drawn. in FIG. 5- represent eithersingle crimped filaments or bundlesof crimped filaments. To obtain a uniform web, it is recommended to operate a number of the aforementioned spinning units in parallel and to cause the groups of filaments to be laid down in overlapping relationship.
  • The'moving belt 60 is preferably uprovided with suction means 61, this being particularly therewith, as measured between the two inlet points 26,
  • connecting piece 41 remote from the pneumatic jet is connected to a crimping device 40 which consists of saidconnecting piece 41 acting as inlet channel, to which there is fittedvia axial displacement means, for example a screw thread 42, a member 43 of enlarged cross-section, the increase in cross-section commencing in an undercut and continuing irregularly until a chamber'is formed, at the end of whichthe cross-section again diminishes irregularly, to a final point 45 atwhich-a'sharp edge is formed, from which point 45 -a short outlet channel 46 extends in the downstream directionn
  • the axial length of the crimping zone 40v is adjusted by means .of a setting device 42 in such a mannerthat the annular or cylindrical vortices formed at point 47 move away from point 47 at a high frequency, drift topoint 48 and spring back to point 47 with partial flow-off
  • the crimping zone 40 is directly connected to a flexible connecting piece 50, for example a plastic hose,
  • the reference numeral indicates adevice for effecting mechanical, thermal or chemical bonding of the web, for example by needle punching, steaming, calendering, impregnation (spraying or dipping), followed by drying.
  • a conventional mechanical stretching .device having take-up godets and stretching godets may be provided between passageway 14 and pneumatic jet 20.
  • crimping zone 40 had a diameter of 12 mm and a length of 30 mm.
  • the pneumatic jet was operated at 1 atmospherere gage of air and a speccific air consumption of kg/kg of melt.
  • the filaments were passed through a flexible connecting piece 50 and emerged from a mouthpiece 51 which, guided bya moving mechanism 59, executed a rotating motion of 3 'c/s and a superimposed linear reciprocating motion of about 0.5 c/s.
  • the weight constancy of the webin its central test area was The speed of travel of the belt was adjusted so that a web having a weight of 750 g/m was formed. Some slight needlepunching of the very voluminous, colored web (specific volume 25 cc/g) was carried out and the web-was finished by subjection to two further needlepunching operations. There was obtained a needleloom material which, after usual impregnation and provision of backing in the form of waffle foam, was eminently suitable as a floor covering.
  • Pneu- --matic jet 20 was of the single-stage type and was connected to a crimping'zone 40.
  • the resulting crimped piece 50 and the moving mouthpiece 51, asdescribed 'in Example 1, were laid down to form a web weighing 400 g/m.
  • the diameter of the filaments was 20pm and they possessed from 8 to 10 crimps per cm.
  • Their tensile strength was 3 g/dtex and their elongation was 180%.
  • the web was slightly needle-punched and was then'in a condition suitable for use as backing fora furtherlayer of carpet material to be secured thereto by needle-punching in the manufacture of needlefpunched floor coverings.
  • Polyester having a K value of 6 l was fed, at 40 atmospheres gage and 300C, to a spinneret 1 having bores 2 of l mm in diameter.
  • the filaments were cooled by means of a suction fan connected to the bottom end of cooling zone l0, 14 having a length of 3 m.
  • the filaments were taken up by a two-stage pneumatic jet 20 operating at a pressure of 2 atmospheres gage.
  • the resulting filaments were slightly crimped and had a diameter of about 10pm and comprised from 3 to 4 helices of 2 mm in diameter per cm of filament.
  • the filaments were laid down to form a voluminous web having a weight of 450 g/m.
  • the web was sprayed with an aqueous dispersion of a curable acrylic ester such that after drying and curing the web consisted of 90% of filaments and 10% of binder.
  • the coherent, resilient non-woven webthus obtained was highly suitable for use as stuffing in quilts and winter clothing.
  • cooling air is caused to impinge on the extruded filaments from one side at an angle of from 0 to to the direction of travel of the filaments, all or at least part of which air is deflected to a direction of flow parallel to the filaments, by which means the filaments are asymmetrically cooled and a primary take-up of the filaments is effected;
  • a takeup zone which is immediately downstream of the cooling zone and is in the form of a single-stage or, preferably, multi-stage pneumatic jet;
  • the partially plastic filaments are helically crimped by periodic alteration of the position of one or more annular or cylindrical vortices of gaseous medium along the filaments at a high frequency with partial flow-off and replenishment of the vortex or vortices in conjunction with said asymmetrical cooling of the filaments whereby the diameter of the helices is from 1 to mm and a ments are relaxed and simultaneously cooled after the crimping stage, such that the crimping is fixed as the filaments solidify.
  • a process as claimed in claim 2 wherein the pneumatic jets are operated with hot gas or steam or both in order to modify the filament characteristics 4.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
  • Nonwoven Fabrics (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
US195427A 1970-11-03 1971-11-03 Non-woven webs of filaments of synthetic high molecular weight polymers and process for the manufacture thereof Expired - Lifetime US3929542A (en)

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DE19702053918 DE2053918B2 (de) 1970-11-03 1970-11-03 Verfahren und vorrichtung zur herstellung gekraeuselter faeden aus synthetischen hochpolymeren

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BE (1) BE774816A (fr)
DE (1) DE2053918B2 (fr)
FR (1) FR2112416B1 (fr)
GB (2) GB1363680A (fr)
IT (1) IT942258B (fr)
NL (1) NL7114958A (fr)

Cited By (32)

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US4172174A (en) * 1977-04-30 1979-10-23 Sadaaki Takagi Cushioning material and process for preparing the same
US4204301A (en) * 1978-04-26 1980-05-27 Greentex Incorporated Strand handling system and method therefor
US4241002A (en) * 1978-05-24 1980-12-23 Standard Oil Company (Indiana) Process for producing homogeneous curly synthetic polymer fibers
US4392286A (en) * 1977-04-05 1983-07-12 Teijin Limited Apparatus for taking up a bundle of filaments
US4961695A (en) * 1988-03-07 1990-10-09 Grunzweig & Hartman Ag Facility for generating fibers, in particular mineral fibers, from a molten mass
US4997611A (en) * 1987-08-22 1991-03-05 Carl Freudenberg Process for the production of nonwoven webs including a drawing step and a separate blowing step
US4999080A (en) * 1988-05-27 1991-03-12 Corovin Gmbh Apparatus for producing a nonwoven fabric from continuous filaments
US5034182A (en) * 1986-04-30 1991-07-23 E. I. Du Pont De Nemours And Company Melt spinning process for polymeric filaments
US5045271A (en) * 1986-01-17 1991-09-03 J. H. Benecke Gmbh Process for the production of irregular non-woven material sheets
US5141700A (en) * 1986-04-30 1992-08-25 E. I. Du Pont De Nemours And Company Melt spinning process for polyamide industrial filaments
US5336071A (en) * 1990-03-14 1994-08-09 Mitsui Petrochemical Industries, Ltd. Air gun for the production of non-woven fabric and non-woven fabric producing apparatus
US5427845A (en) * 1990-06-08 1995-06-27 Kimberly-Clark Corporation Crimped melt-spun copolymer filaments
US5439364A (en) * 1992-10-26 1995-08-08 Karl Fischer Industrieanlagen Gmbh Apparatus for delivering and depositing continuous filaments by means of aerodynamic forces
US5460500A (en) * 1993-04-16 1995-10-24 Reifenhauser Gmbh & Co. Maschinenfabrik Apparatus for producing a nonwoven spun-filament web of aerodynamically stretched filament of a plastic
US5582905A (en) * 1994-05-26 1996-12-10 Beck; Martin H. Polyester insulation
US5800840A (en) * 1995-02-15 1998-09-01 Reifenhauser Gmbh & Co. Maschinenfabrik Apparatus for producing a spun-bond web from thermosplastic endless filaments
WO2000005439A1 (fr) * 1998-07-23 2000-02-03 Barmag Ag Dispositif et procede permettant de filer un fil synthetique
EP1065300A1 (fr) * 1999-06-28 2001-01-03 Uni-Charm Corporation Tissu non-tissé élastiquement étirable et procédé de fabrication
US6379136B1 (en) * 1999-06-09 2002-04-30 Gerald C. Najour Apparatus for production of sub-denier spunbond nonwovens
US20030114066A1 (en) * 2001-12-13 2003-06-19 Clark Darryl Franklin Uniform distribution of absorbents in a thermoplastic web
US20040086588A1 (en) * 2002-11-01 2004-05-06 Haynes Bryan David Fiber draw unit nozzles for use in polymer fiber production
US20050238774A1 (en) * 2004-04-22 2005-10-27 Gold Medal Products Co. Cotton candy machine
EP1726700A1 (fr) * 2005-05-25 2006-11-29 Reifenhäuser GmbH & Co. KG Maschinenfabrik Procédé et dispositif pour la fabrication d'un non-tissé
US20070264520A1 (en) * 2002-12-10 2007-11-15 Wood Willard E Articles having a polymer grafted cyclodextrin
US20070262485A1 (en) * 2003-05-28 2007-11-15 Davis Trent W Synthetic blown insulation
US20090321982A1 (en) * 2007-01-19 2009-12-31 Oerlikon Textile Gmbh & Co. Kg Apparatus and method for depositing synthetic fibers to form a non-woven web
CN1869307B (zh) * 2005-05-25 2011-06-22 赖芬豪泽机械工厂有限及两合有限公司 制造纺粘织物的方法及其装置
CN102776708A (zh) * 2012-08-22 2012-11-14 成都彩虹环保科技有限公司 一种纤维加工装置
US8334343B2 (en) 2002-12-10 2012-12-18 Cellresin Technologies, Llc Grafted cyclodextrin
CN103710768A (zh) * 2012-10-03 2014-04-09 日本Tmt机械株式会社 熔融纺丝装置
WO2014064029A1 (fr) * 2012-10-27 2014-05-01 Oerlikon Textile Gmbh & Co. Kg Appareil de production de non-tissé
US20230040916A1 (en) * 2019-12-31 2023-02-09 Jiangsu Hengli Chemical Fibre Co., Ltd. Recycled polyester filament and preparation method therefor

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JPS51130334A (en) * 1975-05-06 1976-11-12 Murata Machinery Ltd Apparatus for making spun yarns
US4322027A (en) * 1980-10-02 1982-03-30 Crown Zellerbach Corporation Filament draw nozzle
US4472886A (en) * 1982-01-25 1984-09-25 Crown Zellerbach Corporation System and method for venting cooling air from filaments
DE3541128A1 (de) * 1985-11-21 1987-05-27 Benecke Gmbh J Verfahren zur herstellung eines vlieses aus endlosfaeden und vorrichtung zur durchfuehrung des verfahrens
DE3541127A1 (de) * 1985-11-21 1987-05-27 Benecke Gmbh J Verfahren zur herstellung eines vlieses aus endlosfaeden sowie vorrichtung zur durchfuehrung des verfahrens
DE3701531A1 (de) * 1987-01-21 1988-08-04 Reifenhaeuser Masch Verfahren und anlage zur herstellung von einem spinnvlies
DE3713861A1 (de) * 1987-04-25 1988-11-10 Reifenhaeuser Masch Verfahren und spinnvliesanlage zur herstellung eines spinnvlieses aus synthetischem endlosfilament
US5312500A (en) * 1989-01-27 1994-05-17 Nippon Petrochemicals Co., Ltd. Non-woven fabric and method and apparatus for making the same
US4995333A (en) * 1989-09-15 1991-02-26 Kimberly-Clark Corporation Sprayed adhesive system for applying a continuous filament of theroplastic material and imparting a swirling motion thereto
DE4014414C2 (de) * 1990-05-04 1996-08-08 Reifenhaeuser Masch Anlage für die Herstellung einer Spinnvliesbahn aus verstreckten Kunststoff-Filamenten
US5196207A (en) * 1992-01-27 1993-03-23 Kimberly-Clark Corporation Meltblown die head
PL3771760T3 (pl) * 2019-07-30 2023-09-11 Asahi Kasei Kabushiki Kaisha Sposób i urządzenie do wytwarzania włókniny wykonanej z karbikowanych włókien syntetycznych

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US3432590A (en) * 1963-07-10 1969-03-11 Nat Plastic Products Co Inc Process for spinning elastic polypropylene fibers
US3423266A (en) * 1964-01-10 1969-01-21 British Nylon Spinners Ltd Process for the production of a nonwoven web of a continuous filament yarn
US3512230A (en) * 1965-07-29 1970-05-19 Snia Viscosa Method and apparatus for the production of nonwoven fabrics
US3509009A (en) * 1966-02-10 1970-04-28 Freudenberg Carl Kg Non-woven fabric
US3341394A (en) * 1966-12-21 1967-09-12 Du Pont Sheets of randomly distributed continuous filaments
US3485428A (en) * 1967-01-27 1969-12-23 Monsanto Co Method and apparatus for pneumatically depositing a web
US3488819A (en) * 1968-05-17 1970-01-13 Monsanto Co Method and apparatus for making dimensionally stable nonwoven fabric

Cited By (47)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4392286A (en) * 1977-04-05 1983-07-12 Teijin Limited Apparatus for taking up a bundle of filaments
US4172174A (en) * 1977-04-30 1979-10-23 Sadaaki Takagi Cushioning material and process for preparing the same
US4204301A (en) * 1978-04-26 1980-05-27 Greentex Incorporated Strand handling system and method therefor
US4241002A (en) * 1978-05-24 1980-12-23 Standard Oil Company (Indiana) Process for producing homogeneous curly synthetic polymer fibers
US5045271A (en) * 1986-01-17 1991-09-03 J. H. Benecke Gmbh Process for the production of irregular non-woven material sheets
US5141700A (en) * 1986-04-30 1992-08-25 E. I. Du Pont De Nemours And Company Melt spinning process for polyamide industrial filaments
US5034182A (en) * 1986-04-30 1991-07-23 E. I. Du Pont De Nemours And Company Melt spinning process for polymeric filaments
US4997611A (en) * 1987-08-22 1991-03-05 Carl Freudenberg Process for the production of nonwoven webs including a drawing step and a separate blowing step
US4961695A (en) * 1988-03-07 1990-10-09 Grunzweig & Hartman Ag Facility for generating fibers, in particular mineral fibers, from a molten mass
US4999080A (en) * 1988-05-27 1991-03-12 Corovin Gmbh Apparatus for producing a nonwoven fabric from continuous filaments
US5336071A (en) * 1990-03-14 1994-08-09 Mitsui Petrochemical Industries, Ltd. Air gun for the production of non-woven fabric and non-woven fabric producing apparatus
US5427845A (en) * 1990-06-08 1995-06-27 Kimberly-Clark Corporation Crimped melt-spun copolymer filaments
US5439364A (en) * 1992-10-26 1995-08-08 Karl Fischer Industrieanlagen Gmbh Apparatus for delivering and depositing continuous filaments by means of aerodynamic forces
US5460500A (en) * 1993-04-16 1995-10-24 Reifenhauser Gmbh & Co. Maschinenfabrik Apparatus for producing a nonwoven spun-filament web of aerodynamically stretched filament of a plastic
US5582905A (en) * 1994-05-26 1996-12-10 Beck; Martin H. Polyester insulation
US5800840A (en) * 1995-02-15 1998-09-01 Reifenhauser Gmbh & Co. Maschinenfabrik Apparatus for producing a spun-bond web from thermosplastic endless filaments
WO2000005439A1 (fr) * 1998-07-23 2000-02-03 Barmag Ag Dispositif et procede permettant de filer un fil synthetique
US6716014B2 (en) 1998-07-23 2004-04-06 Barmag Ag Apparatus and method for melt spinning a synthetic yarn
US6379136B1 (en) * 1999-06-09 2002-04-30 Gerald C. Najour Apparatus for production of sub-denier spunbond nonwovens
US6689703B1 (en) 1999-06-28 2004-02-10 Uni-Charm Corporation Elastically stretchable nonwoven fabric and process for making the same
SG85197A1 (en) * 1999-06-28 2001-12-19 Uni Charm Corp Elastically stretchable nonwoven fabric and process for making the same
EP1065300A1 (fr) * 1999-06-28 2001-01-03 Uni-Charm Corporation Tissu non-tissé élastiquement étirable et procédé de fabrication
US6890466B2 (en) 1999-06-28 2005-05-10 Uni-Charm Corporation Elastically stretchable nonwoven fabric and process for making the same
US20020127938A1 (en) * 1999-06-28 2002-09-12 Toshio Kobayashi Elastically stretchable nonwoven fabric and process for making the same
US20030114066A1 (en) * 2001-12-13 2003-06-19 Clark Darryl Franklin Uniform distribution of absorbents in a thermoplastic web
US7014441B2 (en) 2002-11-01 2006-03-21 Kimberly-Clark Worldwide, Inc. Fiber draw unit nozzles for use in polymer fiber production
US20040086588A1 (en) * 2002-11-01 2004-05-06 Haynes Bryan David Fiber draw unit nozzles for use in polymer fiber production
US8334343B2 (en) 2002-12-10 2012-12-18 Cellresin Technologies, Llc Grafted cyclodextrin
US8501308B2 (en) 2002-12-10 2013-08-06 Cellresin Technologies, Llc Grafted cyclodextrin
US8129450B2 (en) * 2002-12-10 2012-03-06 Cellresin Technologies, Llc Articles having a polymer grafted cyclodextrin
US20070264520A1 (en) * 2002-12-10 2007-11-15 Wood Willard E Articles having a polymer grafted cyclodextrin
US20070262485A1 (en) * 2003-05-28 2007-11-15 Davis Trent W Synthetic blown insulation
US20050238774A1 (en) * 2004-04-22 2005-10-27 Gold Medal Products Co. Cotton candy machine
US20080210363A1 (en) * 2005-05-25 2008-09-04 Reifenhauser Gmbh & Co. Maschinenfabrik Process and apparatus for manufacturing spun-bonded fabric
JP2006328627A (ja) * 2005-05-25 2006-12-07 Reifenhaeuser Gmbh & Co Kg Maschinenfabrik スパンボンド不織布の製造方法及びその方法を実施するための装置
CN1869307B (zh) * 2005-05-25 2011-06-22 赖芬豪泽机械工厂有限及两合有限公司 制造纺粘织物的方法及其装置
EP1726700A1 (fr) * 2005-05-25 2006-11-29 Reifenhäuser GmbH & Co. KG Maschinenfabrik Procédé et dispositif pour la fabrication d'un non-tissé
US7922849B2 (en) 2005-05-25 2011-04-12 Reifenhauser GmbH & Co. KG. Maschinenfabrik Process and apparatus for manufacturing spun-bonded fabric
US8231370B2 (en) * 2007-01-19 2012-07-31 Oerlikon Textile Gmbh & Co. Kg. Apparatus and method for depositing synthetic fibers to form a non-woven web
US20090321982A1 (en) * 2007-01-19 2009-12-31 Oerlikon Textile Gmbh & Co. Kg Apparatus and method for depositing synthetic fibers to form a non-woven web
CN102776708A (zh) * 2012-08-22 2012-11-14 成都彩虹环保科技有限公司 一种纤维加工装置
CN103710768A (zh) * 2012-10-03 2014-04-09 日本Tmt机械株式会社 熔融纺丝装置
CN103710768B (zh) * 2012-10-03 2017-06-20 日本Tmt机械株式会社 熔融纺丝装置
WO2014064029A1 (fr) * 2012-10-27 2014-05-01 Oerlikon Textile Gmbh & Co. Kg Appareil de production de non-tissé
CN104755667A (zh) * 2012-10-27 2015-07-01 欧瑞康纺织有限及两合公司 用于制造纺粘型无纺织物的设备
US20230040916A1 (en) * 2019-12-31 2023-02-09 Jiangsu Hengli Chemical Fibre Co., Ltd. Recycled polyester filament and preparation method therefor
US12221724B2 (en) * 2019-12-31 2025-02-11 Jiangsu Hengli Chemical Fibre Co., Ltd. Recycled polyester filament and preparation method therefor

Also Published As

Publication number Publication date
DE2053918A1 (de) 1972-05-10
FR2112416B1 (fr) 1975-07-18
GB1363680A (en) 1974-08-14
FR2112416A1 (fr) 1972-06-16
BE774816A (fr) 1972-05-03
IT942258B (it) 1973-03-20
GB1363679A (en) 1974-08-14
DE2053918B2 (de) 1976-09-30
NL7114958A (fr) 1972-05-05

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