CA1147113A - Process for the production of a nonwoven fabric - Google Patents
Process for the production of a nonwoven fabricInfo
- Publication number
- CA1147113A CA1147113A CA000326588A CA326588A CA1147113A CA 1147113 A CA1147113 A CA 1147113A CA 000326588 A CA000326588 A CA 000326588A CA 326588 A CA326588 A CA 326588A CA 1147113 A CA1147113 A CA 1147113A
- Authority
- CA
- Canada
- Prior art keywords
- plate
- members
- fibers
- porous
- collecting
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
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
- 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
-
- 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
Abstract
Jap. 50,745/78 ABSTRACT OF THE DISCLOSURE
This invention relates to an improvement of the collector of non-woven fabrics made by the melt blowing process. In this invention, a fiber stream is blown into a valley space between a drum collector and a niproll having many holes set in contact with the drum collector so that, fine fibers may not splash out in the air and that fibrics uniform in thickness be produced.
This invention relates to an improvement of the collector of non-woven fabrics made by the melt blowing process. In this invention, a fiber stream is blown into a valley space between a drum collector and a niproll having many holes set in contact with the drum collector so that, fine fibers may not splash out in the air and that fibrics uniform in thickness be produced.
Description
~7~3 This inventiorl relates to a process ~or the
2 production o a nonwoven fabric comprising spinning
3 continuously a fused thermoplastic resin from a plur-
4 ality of spinning holes provided in a spinning apparatus, ~imultaneously blowing a g~s .at high speed from gas . 6 exhaust holes provided adjacent to the spinning holes 7 to stretch fibers of the thermoplast}c resin and to 8 form a fiber stream comprising the fibers and ~sas and 9 then c~llecting the fibers from the fibér stream.
. 1~ Methods for the production of a nonwoven fa~ric 11 comprising melt spinning a thermoplastic resin and blow-12 ing i~c as fi~e fibers agalnst a moving collecting plate 13 have b~en known as the so-called "melt-blowing process"
14 (Japanese Patent Public Disclosure Nos. 10,258/1974, 48,921/^1974, 121,570/1975 and 46,972/1975) or "jet-16 splnning process" (Japanese Patent Publication Nos 17 25,821/lg69 and 26~977/1969).
18 In these known methods, however, the above des-19 cribed fiber stream is only collected on a flat or hollow-cylindrical collecting plate having a mlmber of 21 holes and these methods have the disadvantages that a part 22 of the fiber stream blown a~;ains~ a collectin~s plate 23 tends to be scattered by the blowing gas or the thickness 24 and basis weight of the nonwoven fabric collected on the collecting plate are uneven. In the case-of producing a 26 nonwoven fabric consisting of fine fibers such as those 27 ~avin3; a fiber diameter of several microns, in particular, 28 a bulky nonwoven fabric, for example, scattering of 2g fibers is violent, re~ulting in not only an undesirable workability and working environment but also an uneven 31 prQduct. In order to prevent thi~ phenomenon~ there has 32 been proposed a method comprising exhaust~ng forcedly 33 the gas blown against the collecting plate by providi~g 34 an exhaust means at the back side of the collecting plate.
However, this method is uneconomical because of the~need 36 for power for the exhaust. It has the additional dis-37 advantage that the rate o:E exhaus~ has a limit; if the 3~ rate of exhaust is increased3 a nonwoven fabric in con~
39 t~ct with the surface o~ the collerting plate is pulled 40 in too and the density thereof is increased, resul~ing 41 in difficulty in obtainlng a uniform and bulky nonwoven 4~ fabric.
43 The prior art method, r'urthermore, produces 44 only a nonwoYen fabric wherein fibers are parallel with '7~3 1 t~e surface ~nd it is imposs~ble to produce a nonwoven 2 fabric wherein fiber~ are arranged in a direction perpen-3 dicular to the sur~ace (i.e. parallel to the thickness 4 dlrection).
The present inven~ion provides a process for 6 producing a bulky and uniform nonwoven fabric comprising 7. fine fibers wherein such a nonwoven fabric is obtained by 8 blowin~ a fiber stream of thermoplastic resin into a 9 valley~like space formed by two thin p~ates having a lp number of holes in parti~ular, a nonwoven f~bxic wherein 11 fibers are perpendicular to the ~urface of the nonwoven 12 fabric (in paralle~ with the thickness direction) can 13 be obtained by blowing a fiber stream into such a valley-14 li~e space between the two thin plates.
~ That is to say, in accordance with the present 16 invention, there is provided a proce~s for the production 17 of a nonwoven fabric co~prising spinning c~ntinuously a 18 fused thermoplastic resin from a plurality of spinning l9 holes provided in a spinning apparatus, simultaneously.
blowing a gas at high speed from gas exhaust holes ad-21 jacent to the spinning holes to stretch the fibers and 2~2 to form a fiber stream comprising the fibers and gas 23 providing a collecting plate having a number of holes 24 and a coacting press plate having a number of holes in such a manner that they are movable9 and in contact with 26 each other through the fibers at their nearest point or 27 llne and a fiber collecting section is formed with such 28 a form that the interval betwe~n the collecting plate 29 and press plate in the opposite direction to the movement .of thP collecting plate is increased with the increase 31 of the distance from the contact portion, and wherein `32 the fiber stream is blown in such a manner that the 33 central surface of the fiber stream is directed to the 34 fiber blow portion in the :Eiber collecting section and collecting the fibers from the ~ber stream.
36 The inventiQn will be bet~er understood fro~
37 the following descriptiorl taken with the accompanying 38 drawing wherein:
39 Fig. 1 and Fig. 2 are schematic views of embodiment~ according to the process o the present inven~
41 ~ion;
42 Fig. 3, Fig. 4~ Fig. 5 9 Fig 7 6 and Fig; 7 are 43 schematic views of embodirnents of the flbe~ collecting 44 section according to the present in~ent~on~
~'7~ ~ 3 1 , Fig. 8 shows cros5 sectional views o examples 2 of the shape in the thickness di~ec~ion of a collecting 3 plate and press pla~e;
4 ; Fig. 9 is a sehematic view showing one example
. 1~ Methods for the production of a nonwoven fa~ric 11 comprising melt spinning a thermoplastic resin and blow-12 ing i~c as fi~e fibers agalnst a moving collecting plate 13 have b~en known as the so-called "melt-blowing process"
14 (Japanese Patent Public Disclosure Nos. 10,258/1974, 48,921/^1974, 121,570/1975 and 46,972/1975) or "jet-16 splnning process" (Japanese Patent Publication Nos 17 25,821/lg69 and 26~977/1969).
18 In these known methods, however, the above des-19 cribed fiber stream is only collected on a flat or hollow-cylindrical collecting plate having a mlmber of 21 holes and these methods have the disadvantages that a part 22 of the fiber stream blown a~;ains~ a collectin~s plate 23 tends to be scattered by the blowing gas or the thickness 24 and basis weight of the nonwoven fabric collected on the collecting plate are uneven. In the case-of producing a 26 nonwoven fabric consisting of fine fibers such as those 27 ~avin3; a fiber diameter of several microns, in particular, 28 a bulky nonwoven fabric, for example, scattering of 2g fibers is violent, re~ulting in not only an undesirable workability and working environment but also an uneven 31 prQduct. In order to prevent thi~ phenomenon~ there has 32 been proposed a method comprising exhaust~ng forcedly 33 the gas blown against the collecting plate by providi~g 34 an exhaust means at the back side of the collecting plate.
However, this method is uneconomical because of the~need 36 for power for the exhaust. It has the additional dis-37 advantage that the rate o:E exhaus~ has a limit; if the 3~ rate of exhaust is increased3 a nonwoven fabric in con~
39 t~ct with the surface o~ the collerting plate is pulled 40 in too and the density thereof is increased, resul~ing 41 in difficulty in obtainlng a uniform and bulky nonwoven 4~ fabric.
43 The prior art method, r'urthermore, produces 44 only a nonwoYen fabric wherein fibers are parallel with '7~3 1 t~e surface ~nd it is imposs~ble to produce a nonwoven 2 fabric wherein fiber~ are arranged in a direction perpen-3 dicular to the sur~ace (i.e. parallel to the thickness 4 dlrection).
The present inven~ion provides a process for 6 producing a bulky and uniform nonwoven fabric comprising 7. fine fibers wherein such a nonwoven fabric is obtained by 8 blowin~ a fiber stream of thermoplastic resin into a 9 valley~like space formed by two thin p~ates having a lp number of holes in parti~ular, a nonwoven f~bxic wherein 11 fibers are perpendicular to the ~urface of the nonwoven 12 fabric (in paralle~ with the thickness direction) can 13 be obtained by blowing a fiber stream into such a valley-14 li~e space between the two thin plates.
~ That is to say, in accordance with the present 16 invention, there is provided a proce~s for the production 17 of a nonwoven fabric co~prising spinning c~ntinuously a 18 fused thermoplastic resin from a plurality of spinning l9 holes provided in a spinning apparatus, simultaneously.
blowing a gas at high speed from gas exhaust holes ad-21 jacent to the spinning holes to stretch the fibers and 2~2 to form a fiber stream comprising the fibers and gas 23 providing a collecting plate having a number of holes 24 and a coacting press plate having a number of holes in such a manner that they are movable9 and in contact with 26 each other through the fibers at their nearest point or 27 llne and a fiber collecting section is formed with such 28 a form that the interval betwe~n the collecting plate 29 and press plate in the opposite direction to the movement .of thP collecting plate is increased with the increase 31 of the distance from the contact portion, and wherein `32 the fiber stream is blown in such a manner that the 33 central surface of the fiber stream is directed to the 34 fiber blow portion in the :Eiber collecting section and collecting the fibers from the ~ber stream.
36 The inventiQn will be bet~er understood fro~
37 the following descriptiorl taken with the accompanying 38 drawing wherein:
39 Fig. 1 and Fig. 2 are schematic views of embodiment~ according to the process o the present inven~
41 ~ion;
42 Fig. 3, Fig. 4~ Fig. 5 9 Fig 7 6 and Fig; 7 are 43 schematic views of embodirnents of the flbe~ collecting 44 section according to the present in~ent~on~
~'7~ ~ 3 1 , Fig. 8 shows cros5 sectional views o examples 2 of the shape in the thickness di~ec~ion of a collecting 3 plate and press pla~e;
4 ; Fig. 9 is a sehematic view showing one example
5 of the relation ~f a collecting plate and press plate . 6 in the moving direction;
7 Fig; 10 ~nd Fig. 11 are schematic views of 8 gas currents during collection of fiber stresms, Fig.
9 10 showing the case of the present inventlon and Fig.
11 showing the case of the prior art, 11 Fig. 12, Fig. 15~ Fig, 16, Fig. 17 and Fig.
12 19 are schematic views showing embodiment~ according to 13 the presen~ invention;
14 . Fig. 13 and Fig. 14 show, in plan and cross, section; one example of holes made in the side wail of 16 a drum for holding a collecting plate; and 17 ~ Fig~ 18 and Fig. 20 are cross sectional views 18 of nonwoven fabrics obtained according to the present 19 . invention~ ~
Referring now to the drawings in detail, as 21 sh~wn in Fig. 1 ~nd in Fig. 2, which corresponds to a 22 partially enlarged view of Fig..l, two thin plates each 23 having a number of holes, collecting plate 3 and press 24 plate 4 (in this specification~ for the convenience ~f illustration9 a porous or perforated plate again~t which 26 the fi~er stream is blown will hereinafter be called 27 "collecting plate" and a second such plate coactlng there-28 with will be called "press pla~e") are provided in such 29 a manner that they are movable and relatively postioned with a predetermined interval so as to sat~sfy that 31 nor,mal Y-Y' of point A on the surface of collec~ing 32 plate 3 coincides with that of point A' on the surface 33 of press plate 4 in the cross sectlon in para~lel with -34 the movement dire~tion ~4--) of collecting pl~t~ 3 and being perpendicular to collecting plate 3 at at least 36 one position, and ~n such a manner that fiber collecting 37 section 6 (see Fig. 5) is formed with-such a form that 38 the i~terval between point B distant by distance a 39 from point A in the opposite direction to the movement direction (as shown by the ~rrow) of colleeting plate 3 41 on the surface of collecting pl~te 3 and point Bl dis-42 tant ~y distance a from point A' on the surface of press 43 plate 4 in the opposite direction to the movement direc-44 tion of collecting plate 3 (length of line BB') is in-, ~'7~ 3 1 creased with the increase of distance a. In flber 2 co~lecting section 6 formed in this way, ~ fiber stream 3 is blown again~t collecting plate 3 in such a ~anner 4 .that the center of w-Ldth C in the cross section of fiber stream 7 is appl.ied to point P distant by dlstance b
7 Fig; 10 ~nd Fig. 11 are schematic views of 8 gas currents during collection of fiber stresms, Fig.
9 10 showing the case of the present inventlon and Fig.
11 showing the case of the prior art, 11 Fig. 12, Fig. 15~ Fig, 16, Fig. 17 and Fig.
12 19 are schematic views showing embodiment~ according to 13 the presen~ invention;
14 . Fig. 13 and Fig. 14 show, in plan and cross, section; one example of holes made in the side wail of 16 a drum for holding a collecting plate; and 17 ~ Fig~ 18 and Fig. 20 are cross sectional views 18 of nonwoven fabrics obtained according to the present 19 . invention~ ~
Referring now to the drawings in detail, as 21 sh~wn in Fig. 1 ~nd in Fig. 2, which corresponds to a 22 partially enlarged view of Fig..l, two thin plates each 23 having a number of holes, collecting plate 3 and press 24 plate 4 (in this specification~ for the convenience ~f illustration9 a porous or perforated plate again~t which 26 the fi~er stream is blown will hereinafter be called 27 "collecting plate" and a second such plate coactlng there-28 with will be called "press pla~e") are provided in such 29 a manner that they are movable and relatively postioned with a predetermined interval so as to sat~sfy that 31 nor,mal Y-Y' of point A on the surface of collec~ing 32 plate 3 coincides with that of point A' on the surface 33 of press plate 4 in the cross sectlon in para~lel with -34 the movement dire~tion ~4--) of collecting pl~t~ 3 and being perpendicular to collecting plate 3 at at least 36 one position, and ~n such a manner that fiber collecting 37 section 6 (see Fig. 5) is formed with-such a form that 38 the i~terval between point B distant by distance a 39 from point A in the opposite direction to the movement direction (as shown by the ~rrow) of colleeting plate 3 41 on the surface of collecting pl~te 3 and point Bl dis-42 tant ~y distance a from point A' on the surface of press 43 plate 4 in the opposite direction to the movement direc-44 tion of collecting plate 3 (length of line BB') is in-, ~'7~ 3 1 creased with the increase of distance a. In flber 2 co~lecting section 6 formed in this way, ~ fiber stream 3 is blown again~t collecting plate 3 in such a ~anner 4 .that the center of w-Ldth C in the cross section of fiber stream 7 is appl.ied to point P distant by dlstance b
6 ` from point A on the surfzce of collecting pla~e 3 in
7 the opposite direction ~o ~he movement direction of ~ collecting plate 3, and the fibers are collected to thus g produce a nonwoven fabric. If necessary, the thus collected ibers are formbd into a predetermined thlck-11 ness by collecting plate 3 and press plate 4~
12 A thermoplastic resin is f2d to extruder 1 13 from hopper ~1 of extruder 1. The thermoplastic resin 14 fed to extruder 1 is kneaded by a screw ~not shown~
dri~en by motor 12 and power transmitting mechanism 16 13, fed to die 2 in the fused state, spun from spinning 17 holes 21 and stretched by a gas (air is usually used 18 but depending upon the varlety of a resin usèd, a gas ~9 inert to the resin such as nitrogen may be used) blown at a high speed fro~ gas exhaust hole 22 provided ad-21 jacent to spinning holes 21 to be fine fibers, whereby 22 fiber stream 7 is formed with the gas. Then, fiber 23~ stream 7 is-blown against collecting plate 3 in such ~
24 manner that the central plate (appearing as line W ) of 25~ the cross section of the fiber stream 7 is applied to 26 point P on the surface of collecting plate 3 within the 27 range of~alley-like fiber collecting section formed by 28 collecting plate 3 and press plate 4. Fiber stream 7 29 is thus blown against collecting plate 3 and the fibers and gas are separated thereon to form nonwoven 31 fa~ric 5. Nonwoven fabric 5 is ordinarily formed in a 3~ prede~ermined ~hickness by collect~ng plate 3 and press 33 plate 4 and taken up to give a product. In this case~
34 the degree of forming under pre~sure by the collecting plate and press plate should suitably be chosen depend-36 ing upon the properties o nonwoven fabric to be pro-37 duced, in partlcular, ~he apparent density thereof~ bu~
38 this ;Eorming is no~ always necessary depending on the 39 obj ect of use .
The impartant feature of the present invention 41 is that fiber collecting sec~ion 6 has such a form that ~ collecting plate 3 and press plate 4 are in contact with 43 each other through collected fibers and the interval 44 between collecting plate 3 and press plate 4 in the ~L7~l~3 opposite directlon to the moving direction of collectlng 2 plate 3 from the contact portion is increased wi~h the 3 increase of the distance from the contact portion.
4 That is to say, the fiber collecting section 5~ has ~ valley-like shape formed by the collecting p~ate 6 and pr`ess plate, the slopes of which correspond to the 7 collecting p~ate and the press plate and the bottom $ of which corresponds to the portion where both the plates 9 are in contact with each,o.ther through fibexs (e~g.
10 shaded portions of Fig, 3 ~o Fig, 7). Thus ~he 11 respective plates are separated from each other at the 12 contact poi~ts by a distanc~ equal to the thickness o 13 the nonwoven fabric product, MorP speciicslly, refer~
14 ring to Fig, 1 and Fig. 2, the fiber collecting sect~pn is a space surrounded by collecting plate 3 and press 16 plate 4 in such a range that angle a, between t~ngen~
17 X-X'-at point A on the surface of collecting plate 3 18 and a tangent at point B distant by distance a in the - 19 opposite~ direction to the moving direction of collecting plate 3 from point A is O to 90 degress and angle a2 21 bètween tangent Xl-Xl' at point A' on the sur~ce of 22 press.plate 4 and a tangent at~.point B' distance by ~3 di~tance a in the opposite direction to the moving 24 d~ rection of collecting plate 3 from point A' is 0 to 90 degress and.~ l + d~2 ~ ~ pre~erably O~c~ 1 26 ~ 2 ~ l~0 degrees, 27 ~ The fiber blow portion is a line of intersection 28 of the central sur~ace in the longitudinal dir~ction of ^ .
29 the fiber stream and the collecting plate, which is .shown, in Fig. 1 and Fig. 2 by point P of intersection 31 o~ central line U-U' in the wid~h direct~on of the fiber 32 stream (fiber stream is preferably p~rallel to the 33 line of intersection of the normal surface CDmmOn to ~he 34 collecting pla~e and press plate with the collecting 35 plate or press plate~ but this is not always requirèd) -36 with the surface of collecting plate 3. Fiber blow 37 portion P must be in ~he rànge of fiber collecting 38 section 5 and more preferably, it is positioned at a 39 distance from point A on the surface of collecting plate 3 of within a range of at most 5 times~ particularly 41 at most 3 times as l~ong as width C of fiber stream 7 42 on the surface of co~lecting plate 3 (correctly" ~ dth 43 C means the width of fiber stream 7 in the absence of 44 collecti;ng plate 3 at the position in the case of assum-.. .
7~3 -- 6 ~
ing the presence of collecting plate 3 of fiber stream 2 7) or it is positioned on t~ point of intersection of 3 line A-A' between point A on collecting plate 3 and 4 p~in~ A' on press plate 4 wi~h central line ~-U' of 5 fiber. stream 7 ( ~ . O) .
6 The die used in the present in~ention ls a 7 . die provided with a plurality of spinning holes and gas
12 A thermoplastic resin is f2d to extruder 1 13 from hopper ~1 of extruder 1. The thermoplastic resin 14 fed to extruder 1 is kneaded by a screw ~not shown~
dri~en by motor 12 and power transmitting mechanism 16 13, fed to die 2 in the fused state, spun from spinning 17 holes 21 and stretched by a gas (air is usually used 18 but depending upon the varlety of a resin usèd, a gas ~9 inert to the resin such as nitrogen may be used) blown at a high speed fro~ gas exhaust hole 22 provided ad-21 jacent to spinning holes 21 to be fine fibers, whereby 22 fiber stream 7 is formed with the gas. Then, fiber 23~ stream 7 is-blown against collecting plate 3 in such ~
24 manner that the central plate (appearing as line W ) of 25~ the cross section of the fiber stream 7 is applied to 26 point P on the surface of collecting plate 3 within the 27 range of~alley-like fiber collecting section formed by 28 collecting plate 3 and press plate 4. Fiber stream 7 29 is thus blown against collecting plate 3 and the fibers and gas are separated thereon to form nonwoven 31 fa~ric 5. Nonwoven fabric 5 is ordinarily formed in a 3~ prede~ermined ~hickness by collect~ng plate 3 and press 33 plate 4 and taken up to give a product. In this case~
34 the degree of forming under pre~sure by the collecting plate and press plate should suitably be chosen depend-36 ing upon the properties o nonwoven fabric to be pro-37 duced, in partlcular, ~he apparent density thereof~ bu~
38 this ;Eorming is no~ always necessary depending on the 39 obj ect of use .
The impartant feature of the present invention 41 is that fiber collecting sec~ion 6 has such a form that ~ collecting plate 3 and press plate 4 are in contact with 43 each other through collected fibers and the interval 44 between collecting plate 3 and press plate 4 in the ~L7~l~3 opposite directlon to the moving direction of collectlng 2 plate 3 from the contact portion is increased wi~h the 3 increase of the distance from the contact portion.
4 That is to say, the fiber collecting section 5~ has ~ valley-like shape formed by the collecting p~ate 6 and pr`ess plate, the slopes of which correspond to the 7 collecting p~ate and the press plate and the bottom $ of which corresponds to the portion where both the plates 9 are in contact with each,o.ther through fibexs (e~g.
10 shaded portions of Fig, 3 ~o Fig, 7). Thus ~he 11 respective plates are separated from each other at the 12 contact poi~ts by a distanc~ equal to the thickness o 13 the nonwoven fabric product, MorP speciicslly, refer~
14 ring to Fig, 1 and Fig. 2, the fiber collecting sect~pn is a space surrounded by collecting plate 3 and press 16 plate 4 in such a range that angle a, between t~ngen~
17 X-X'-at point A on the surface of collecting plate 3 18 and a tangent at point B distant by distance a in the - 19 opposite~ direction to the moving direction of collecting plate 3 from point A is O to 90 degress and angle a2 21 bètween tangent Xl-Xl' at point A' on the sur~ce of 22 press.plate 4 and a tangent at~.point B' distance by ~3 di~tance a in the opposite direction to the moving 24 d~ rection of collecting plate 3 from point A' is 0 to 90 degress and.~ l + d~2 ~ ~ pre~erably O~c~ 1 26 ~ 2 ~ l~0 degrees, 27 ~ The fiber blow portion is a line of intersection 28 of the central sur~ace in the longitudinal dir~ction of ^ .
29 the fiber stream and the collecting plate, which is .shown, in Fig. 1 and Fig. 2 by point P of intersection 31 o~ central line U-U' in the wid~h direct~on of the fiber 32 stream (fiber stream is preferably p~rallel to the 33 line of intersection of the normal surface CDmmOn to ~he 34 collecting pla~e and press plate with the collecting 35 plate or press plate~ but this is not always requirèd) -36 with the surface of collecting plate 3. Fiber blow 37 portion P must be in ~he rànge of fiber collecting 38 section 5 and more preferably, it is positioned at a 39 distance from point A on the surface of collecting plate 3 of within a range of at most 5 times~ particularly 41 at most 3 times as l~ong as width C of fiber stream 7 42 on the surface of co~lecting plate 3 (correctly" ~ dth 43 C means the width of fiber stream 7 in the absence of 44 collecti;ng plate 3 at the position in the case of assum-.. .
7~3 -- 6 ~
ing the presence of collecting plate 3 of fiber stream 2 7) or it is positioned on t~ point of intersection of 3 line A-A' between point A on collecting plate 3 and 4 p~in~ A' on press plate 4 wi~h central line ~-U' of 5 fiber. stream 7 ( ~ . O) .
6 The die used in the present in~ention ls a 7 . die provided with a plurality of spinning holes and gas
8 exhaust holes adjacent to the spinning holes and having
9 such a structure that a thermoplastic resin may be fed
10. to the spinning holes and continuously spun into fibers,
11 while a gas is blown at high speed from the gas exhaust -
12 holes to stretch the ibers and to form fine fibers.
13 Any of such dies can be used in the present invention,
14 for example 8S disclosed in Japanese Patent Publie Disclosure Nos. 10,258/1974, 48,921/1974, 121,570/1975, 16 4,672/1975 and 67,411/1976 and Japanese Patent Publication 17 Nos.`25,~71/1969 and 26,977/1969 and in particular~ the 18 dies having the stru~ture describ~ed in Japanese Patent 19 Publication No. 25,871/1969 and Japanese Patent n bllc Disclosure Nos. 48,921/1974 and 67,411/1976 are prefer-21 ably used.
2~ Useful examples of the thermoplastic resin of 23 the present invention are homopolymers of ~-olefins such 24 as ethylene, propylene, butene-l and 4-methylpenten~
copolymers of these monOmeFS or mixtures o thes~ polymers, 26 polyamides such as nylon 6, nylon 66, nylon 612 and nylon ~7 12 (commercial name or general name~ or mixtures thereof, ~8 polyester resins such as polyethylene t~rephthalate and 29 polybutylene tereph~halate, polyurethane resins? in particular, thermoplastic polyurethane resins, e~hylene~
31 vinyl acetate copolymers, ethylene methacrylic acid ester 32 copolymers and graft copolymers of polyolefins with un-33 saturated carboxylic acids or derivatives thereo, or 34 mixtures of these thermoplastic resins.
3S In the present invention9 these thermoplastic 36 resins are spun and simultaneously~ are stretched by 37 a high speed gas to give fine fibers, and a f~ er stream 38 consisting of the fibers and gas is blown against point 39 P on the surface of collecting plate 3. The blowing angle, i.e. the angle B of the central pla~e (line U~U' 41 of Fig. 1, Fig. 2 an~ Fig. 10) in the eross seetlon of 42 the fiber stream and tangent R-R' at point P is génerally 43 0 to 90 degrees, preferably 0 to 60 degrees. When B is 44 0 degreqs, i.e. the fiber stream is parallel with the .
~7~ ~ 3 1 ta~gent a~ P, the fiber s~ream is blown between collect-2 ing plate 3 ant press plate 4. In this case, bo~h the 3 plates can be designated at "collecting plate"~ since 4 the collecting plate and press plate are distinguished 5. only for the convenience of ~llustration as set forth 6 above. As a special example in the case of ~ = 0, it 7. is possible ~o AdjUSt central plane (line U-U') of ~iber 8. stream 7 to between point A of collecting plate 3 and . 9 point A' of press plate 4.. When ~3 i5 ne~r 0 degrees as described above~ it is.possible to produce a nonwo~en 11 fabric in which fibers 121 (Fig. 18) are substantially 12 vertical to ~urface 120 of the nonwoven fabric depend-13 ing upon ~he relationship between width C of fiber stream 14 7 and distance AA' as shown in Fig~ 18 (~) to (c).
When the nonwoven fabric of this type is used for filters, 16 carpets, synthetic leathers3 etc., a product better in 17 hand can be produced due to rising of the ibers, which 18 hand has not been obtained in the.prior art no~woven 19 f~brics.` In particular, the nonwoven fabric of this type has the adv~ntage that a ~aised nonwoven fabric as 21 shown in Fig. 18 (d) can be obtained therefrom by divid-22~ ing into two sheets at the central surface in the thick-23 ness direction7 which ~nwoven fabric has hereto not been 24~ obtained.
In addition, a ra.ised nonwoven fabric as 26 shown in Fig. 20 (b) can be obtained by blowing against 27 woven or nonwoven fabrics 130 ~ibers the same as or 28 different from those in the woven or nonwoven abric 29 as shown in Fig. ~9 to prepare a nonwoven fabric consist-lng of three layers as shown in Fig. 20 (a~ and th~n 31 di~iding the fabric so formed into two sheets at the 3~ central portion.
33 ~he collecting plate and press plate used in 34 the present invention are plates having a number o~
pores or holes, for example, perforated plates pr~pared 36 by making holes in a thin plate of a metal or synthetic 37 resin by a mechanical or chemlcal method, nets prep~red 38 by weaving wires vf a metal or synthetic resin or by 39 fixing wires of a metal or synthetic resin at a pre determined interval to give s~its, snd woven or nonwoven 41 abrics. These perfo~ated pl~tes can be used indiv-42 idually, but in order to increase the mechanical s~reng~h, 43 it is preferable to use two or mor~ perforated plates 44 in layers. In ~hls case9 it is desirable to use ~ thin 1 perforated plate ~ith small h~les as an upper layer 2 and a thick perforated pl~te with large holes as a 3 lower layer. ~Ioreover, the foregoing woven fabric or 4 nonwoven fabric can be wound round ~he perfora~ed plate S a~ an upper layer. The shape, size and distribution 6 density of the holes of these perforated plates can ` 7 optionally be determined to ~ome extent depending upon 8 the property of the nonwoven fabric to be prepared and 9 generally it is desirabLe to use a pl:mched perfora~ed lp pla~e sr woven net of ~ metal or syn~hetic resin with a 11 network size o 5 to 200 meshes, preferably Io to 40 12 meshes. The collecting plate and press plate have gen-13 erally the shape of a belt or ring~ preferably a shape 14 su~ported by a roll or drum or ~ hollow-cylindrical sha~e.~
16 Examples of the shapes of collecting plate 3 17 and press plate 4 ~or forming fiber collecting sect~ ~ 6 1~ are shown in Fig. 3 to Fig. 7. Fig. 3 shows fiber 19 collecting Section 6 formed by t~e flat part of belt-like or ring-like collecting plate 3 and press plate 4 21 wound partly round hollow-cylindrical drum 41 having many 22 holes on ~he side wall. In this case, drum or roll 31 23~ for holding collecting pl~te 3 is preferably a hollow 24 cylinder having many holes on the side wall, but if the diameter thereof ~s smalL, provision o~ these holes is 26 not always nece~sary. Thi~ drum or roll 31 can be omitted 27 depending on the method of holding collecting plate 3, 28 for example, where collecting plate 3 is wound round 29 other rolls in the form o an endless belt, Fig. 4 shows a case where the relation of collecting plate 3 31 and press plate 4 is reversed to that o Fig. 3. Fig.
32 S shows a case wherein collecting plate 3 and press 33 plate 4 are respec~ively wound abou~ hollow-cylindrical 34 druMs 31 and 41 each having a numb~r of holes. Fig. 6 show~ a case where collec~ing plate 3 and press pla~e 4 36 are both hollow and cylindrical. Fig. 7 shows a case 37 where collecting plate 3 ls hollow and cylindrical and 38 press plate 4 is an annular perforated plate 41 wound 39 rou~d hollow-cy~indrical drums 41 and 41'. ~n these cases, the shape of the surface of collec~ing pla~e 3 41 and press plate 4 is ordinarily linear in the cross 42 section containing normal Y-Y' of collecting plate 3 43 and axes 32 and 42 of ~he drum~ roll~ collecting plate 44 or press plate, but may be va~ied as shown ~n Fig0 8.
7~L3 ,, g 1 Mo~eover~ the movement directions of collecting plate 3 2 and press plate 4 are preferably the same, at least, at 3 points A and A' shown in Fig~ 1 and Fig. 2 However, 4 this is not necessarily essentia~, but it is sufficient that the vectors of the moving directions of these plates . 6 c~incide at points A and A' only. For example, the 7 relative relationship of the moving directions of collect-8 ing plate 3 and press plate 4 as shown in Fig 1 can be 9 -designe~ as shown in Fig. 9. If the moving directions of both the plates are set.as described above (Fig. 9 11 and the blowing angle of the fiber stream is adjusted 12 ~o 0 degrees, a nonwoven fabric wherein fibers are greatly 13 entangled is obtained, This embodiment is thus desirable.
14 According to the present invention9 in a fiber collecting section wherein a collecting plate having a 16 number of holes and a press plate having ~ number of 17 holes are placed so as to form a valley-like portion, 18 a fiber stream containing fine fibers is blown against -19 th`e collecting plate at a high speed in such a ~anner that the central surface of the fiber stream is applied 21 to a fiber blow portion and the fibers are thus collected~
22 as described above. Therefore, the gas can readily be 23 exhausted through the holes of press plate 4 and collect-24 ing plate 3 ~nd a uniform nonwoven fabric can be pro~uced without scattering fibers even if there i~ provided no 26 suction apparatus. That is, as shown in Fig~ 10, the 27 gas in fiber stream 6 is readily exhausted through per-28 forated pistes at both sides of point P. Consequently~ ;
29 the turbulence of the gas current on the collecting plate is decreased and, in particular, there is iittle 31 gas.current passing over the surface of the nonwoven 32 abric, so that the fibers are not scattered and even 33 if partly scattered~ they are collected by collecting 34 plate 3 and press plate 4~ In the case of the present 35 invention, in particular~ there are no fibers adhered -36 on the parts o collectLng plate 3 ~nd press plate 4 37 ~rom which the gas of flber stream 7 is exhausted, and, 38 according~y, the gas can be exhausted without any dis-39 turbance. In the case of the second die 2' when using 40 two dies as shown in Fig. 16 or in the case of using a 41 nonwoven fabric or woven fabric as the collecting ~2 plate and press plate as shown in Fig. 19~ the g~s is 43 hard to pass through the woven or nonwoven fabric having 44 a fine network even if the hardness depends somewhat on the mesh size of the network~ but the 46 scattered fibers can be collected7 ~ 3 1 more readily as compared with the prior art method, on 2 ~ the colLecting plate and press plate. Thus the advan~ages 3 of ~he present invention can sufficiently be realized in 4 these cases.
On the other hand, when using a fla~ or cylin-6 drical ~ollecting plate having a number of holes only as<
7 in the.priOr art me~hod, a fiber stream o thermoplastic resin is blown against point P on the collecting pla~e g` and the fibers are collected at or near point P as shown in Fig~ 11, so the holes on the area of s~de X of point P
11 on the collecting plate ~in the moving direction o the 12 collecting plate) are closed and9 on the area of side X
13 of point P on the colleoting plate (in the opposite 14 direction to the moving direction of the collecting plate), the gas is exhausted through the holes of the 16 collec~ing plate. On the area of side X of point P on 17 collecting plate 3, the gas does not pass th~ ugh the 18 holes of collecting plate 3, but 10ws toward side X
lg of point P on the surface of the collected ~ibers ~in the moving .direction~, thus causing ~ lowered collecting 21 efficiency of fibers and a ~catter of the collected fibers.
22 It is further found that in the prior art method, the 23 balance of the gas current is lost at both the sides of - 24 point P on~the collecting plate~ which af~ects sometimes 2~ the fiber s~ream and causes a diffieulty in obtaining a 26 uniform nonwoven fabric 27 According to the process of the presen~ invention, 28 the gas can readily be exhausted th~ ugh the holes of the 29 collecting plate and press plat~ and, consequently~ there 30 occurs scarcely a turbulenee of gas current at both the 31 sides of point P as set forth above, whereby the above 32 described disadvantages of ~he prior art can be o~ercome~
~3 The other feature of the present invention consists in 34 that a nonwoven abric with a uniform thickness can be obtained~ if nec~ssary, by pressing the colleeted fibers 36 to a pr~determ~ned thickness by a collecting plate and 3~ pre~s plate) and, in addition~ a nonwoven abrlc com-38 prising fibers in the vertlcaL direction to the surf~ce 39 of the nonwoven fabric can be obtained by selecting suitably a position against which a fiber stream ~s 4~ blown, as set forth above.
42 The present invention will now be illustrated-43 in greatex detail by examples.
44 Flg. lZ ~o Fig. 20 s~ow examples of apparatus ~7~3 1 suitable for carrying out the process of the present 2 invention, ~he main parts ~hereof o~ly being shown with 3 details omitted.
4 Referring to Fig. 12, a system for spinning comprises extruder 1~ hopper ~1 of extruder 1, motor 12, 6 power transmit~ing mechanism 13, die 2, spinning holes 21, 7 gas exhaust hole~ 22 and gas feed inle~ 23. Gas feed 8 inlet 23 is connected with a préssure gas feeding 9 apparatus (not shown) . 3 is a collectir~g plate, i. e .
lQ net or perforated plate made of a metal such as stainless 11 steel or synthetic resin such as fluorine resin~ poly-12 amide or polyester and having a network size of 5 to 13 200 meshes, preferably 10 to 40 meshes. 31 is a hollow-14 cylindrical drum for holding collecting plate 39 having a diameter of about 1 m and a number of holeson the side 16 thereof (not the bottoms thereof) as shown in Fig. 13 and 17 Fig. 14. Collecting plate 3 is provided on the side 18 surface. The two ends of the hollow cylindrical drum 19 are preferably supported to be rotatable by such a met~od as having openings (not shown, e.g.-method of using 21 spokes for a wheel, method of holding the inner wall of 22 a drum by roils, etc.)7 but it is not always to provide 23 openings on~the two ends. Driving of drum 31 is carried ~4 out by a known method selec~ed from a method compris~ng connecting central axle 32 with a motor and ~ method 26 comprising dri~ing through the inner wall or outer 27 circumerence of the drum. The shape of hole 33 on ~he 28 side of d~um 31 is not particularly limited as long as 29 the exh~ust of gas is not hindered. For example, any 30 circular or sli~-like forms can be used3 but~ in parti- -31 cular, the so-called circular tapered hole wherein the 32 outer diame~er at opening portion 35 is largsr than the 33 inner diameter at opening port~on 34i as shown, in plan 34 and cross section, in Fig. 13 and Fig. 14,is a preferred example. ~he size of the hole in the side wall of d~um 31 36 can optionally be determined depending on the relation wi~h 37 structure of collecting plate 39 but, in general, it is 38 in a range of 1 to 50 m~ preferably 5 to 20 mm~ In 39 this igure,-colfecting plate 3 is held by holding drum 329 but as occasio~ demands, the side w~ll itself of the 41 ho~ding drum can be used as such a collecting plate. 4 ~
42 is a press plate, i~e. annular net or perforated plate 43 made of a met~l such as st~inless steel or a synthetic 44 resin such as polyester, polyamide or fluorine resin, ~ `
wh,ich is wound round hollow-~ylindrical dru~n 41 or 2 holding drum 41' having a number of holes in the side 3 wall and a diame~er of about 20 cm A flber stre~m 4 consisting of fibers spun ~rom spiming holes 21 of die 2 and a-gas blown at a high speed from gas exhaust hole . 6 22 is blown agains~ point P (which is a point in the 7 cross section~ but which is correctly a line parallel 8 to central axis 32 on rollecting plate 3) on the surface g of col~ecting plate 3 to collect fibers, pxessed to a predetermined.thickness by collecting pl~te 3 and 11 press plate 4 to form nonwoven fabric 5 and then taken up 12 by roll 8 through rolls 71 and 71' to give a product.
13 9 is 8 sprayer for feeding water drops to cool the 14 collecting plate . In this example, furthermore9 a
2~ Useful examples of the thermoplastic resin of 23 the present invention are homopolymers of ~-olefins such 24 as ethylene, propylene, butene-l and 4-methylpenten~
copolymers of these monOmeFS or mixtures o thes~ polymers, 26 polyamides such as nylon 6, nylon 66, nylon 612 and nylon ~7 12 (commercial name or general name~ or mixtures thereof, ~8 polyester resins such as polyethylene t~rephthalate and 29 polybutylene tereph~halate, polyurethane resins? in particular, thermoplastic polyurethane resins, e~hylene~
31 vinyl acetate copolymers, ethylene methacrylic acid ester 32 copolymers and graft copolymers of polyolefins with un-33 saturated carboxylic acids or derivatives thereo, or 34 mixtures of these thermoplastic resins.
3S In the present invention9 these thermoplastic 36 resins are spun and simultaneously~ are stretched by 37 a high speed gas to give fine fibers, and a f~ er stream 38 consisting of the fibers and gas is blown against point 39 P on the surface of collecting plate 3. The blowing angle, i.e. the angle B of the central pla~e (line U~U' 41 of Fig. 1, Fig. 2 an~ Fig. 10) in the eross seetlon of 42 the fiber stream and tangent R-R' at point P is génerally 43 0 to 90 degrees, preferably 0 to 60 degrees. When B is 44 0 degreqs, i.e. the fiber stream is parallel with the .
~7~ ~ 3 1 ta~gent a~ P, the fiber s~ream is blown between collect-2 ing plate 3 ant press plate 4. In this case, bo~h the 3 plates can be designated at "collecting plate"~ since 4 the collecting plate and press plate are distinguished 5. only for the convenience of ~llustration as set forth 6 above. As a special example in the case of ~ = 0, it 7. is possible ~o AdjUSt central plane (line U-U') of ~iber 8. stream 7 to between point A of collecting plate 3 and . 9 point A' of press plate 4.. When ~3 i5 ne~r 0 degrees as described above~ it is.possible to produce a nonwo~en 11 fabric in which fibers 121 (Fig. 18) are substantially 12 vertical to ~urface 120 of the nonwoven fabric depend-13 ing upon ~he relationship between width C of fiber stream 14 7 and distance AA' as shown in Fig~ 18 (~) to (c).
When the nonwoven fabric of this type is used for filters, 16 carpets, synthetic leathers3 etc., a product better in 17 hand can be produced due to rising of the ibers, which 18 hand has not been obtained in the.prior art no~woven 19 f~brics.` In particular, the nonwoven fabric of this type has the adv~ntage that a ~aised nonwoven fabric as 21 shown in Fig. 18 (d) can be obtained therefrom by divid-22~ ing into two sheets at the central surface in the thick-23 ness direction7 which ~nwoven fabric has hereto not been 24~ obtained.
In addition, a ra.ised nonwoven fabric as 26 shown in Fig. 20 (b) can be obtained by blowing against 27 woven or nonwoven fabrics 130 ~ibers the same as or 28 different from those in the woven or nonwoven abric 29 as shown in Fig. ~9 to prepare a nonwoven fabric consist-lng of three layers as shown in Fig. 20 (a~ and th~n 31 di~iding the fabric so formed into two sheets at the 3~ central portion.
33 ~he collecting plate and press plate used in 34 the present invention are plates having a number o~
pores or holes, for example, perforated plates pr~pared 36 by making holes in a thin plate of a metal or synthetic 37 resin by a mechanical or chemlcal method, nets prep~red 38 by weaving wires vf a metal or synthetic resin or by 39 fixing wires of a metal or synthetic resin at a pre determined interval to give s~its, snd woven or nonwoven 41 abrics. These perfo~ated pl~tes can be used indiv-42 idually, but in order to increase the mechanical s~reng~h, 43 it is preferable to use two or mor~ perforated plates 44 in layers. In ~hls case9 it is desirable to use ~ thin 1 perforated plate ~ith small h~les as an upper layer 2 and a thick perforated pl~te with large holes as a 3 lower layer. ~Ioreover, the foregoing woven fabric or 4 nonwoven fabric can be wound round ~he perfora~ed plate S a~ an upper layer. The shape, size and distribution 6 density of the holes of these perforated plates can ` 7 optionally be determined to ~ome extent depending upon 8 the property of the nonwoven fabric to be prepared and 9 generally it is desirabLe to use a pl:mched perfora~ed lp pla~e sr woven net of ~ metal or syn~hetic resin with a 11 network size o 5 to 200 meshes, preferably Io to 40 12 meshes. The collecting plate and press plate have gen-13 erally the shape of a belt or ring~ preferably a shape 14 su~ported by a roll or drum or ~ hollow-cylindrical sha~e.~
16 Examples of the shapes of collecting plate 3 17 and press plate 4 ~or forming fiber collecting sect~ ~ 6 1~ are shown in Fig. 3 to Fig. 7. Fig. 3 shows fiber 19 collecting Section 6 formed by t~e flat part of belt-like or ring-like collecting plate 3 and press plate 4 21 wound partly round hollow-cylindrical drum 41 having many 22 holes on ~he side wall. In this case, drum or roll 31 23~ for holding collecting pl~te 3 is preferably a hollow 24 cylinder having many holes on the side wall, but if the diameter thereof ~s smalL, provision o~ these holes is 26 not always nece~sary. Thi~ drum or roll 31 can be omitted 27 depending on the method of holding collecting plate 3, 28 for example, where collecting plate 3 is wound round 29 other rolls in the form o an endless belt, Fig. 4 shows a case where the relation of collecting plate 3 31 and press plate 4 is reversed to that o Fig. 3. Fig.
32 S shows a case wherein collecting plate 3 and press 33 plate 4 are respec~ively wound abou~ hollow-cylindrical 34 druMs 31 and 41 each having a numb~r of holes. Fig. 6 show~ a case where collec~ing plate 3 and press pla~e 4 36 are both hollow and cylindrical. Fig. 7 shows a case 37 where collecting plate 3 ls hollow and cylindrical and 38 press plate 4 is an annular perforated plate 41 wound 39 rou~d hollow-cy~indrical drums 41 and 41'. ~n these cases, the shape of the surface of collec~ing pla~e 3 41 and press plate 4 is ordinarily linear in the cross 42 section containing normal Y-Y' of collecting plate 3 43 and axes 32 and 42 of ~he drum~ roll~ collecting plate 44 or press plate, but may be va~ied as shown ~n Fig0 8.
7~L3 ,, g 1 Mo~eover~ the movement directions of collecting plate 3 2 and press plate 4 are preferably the same, at least, at 3 points A and A' shown in Fig~ 1 and Fig. 2 However, 4 this is not necessarily essentia~, but it is sufficient that the vectors of the moving directions of these plates . 6 c~incide at points A and A' only. For example, the 7 relative relationship of the moving directions of collect-8 ing plate 3 and press plate 4 as shown in Fig 1 can be 9 -designe~ as shown in Fig. 9. If the moving directions of both the plates are set.as described above (Fig. 9 11 and the blowing angle of the fiber stream is adjusted 12 ~o 0 degrees, a nonwoven fabric wherein fibers are greatly 13 entangled is obtained, This embodiment is thus desirable.
14 According to the present invention9 in a fiber collecting section wherein a collecting plate having a 16 number of holes and a press plate having ~ number of 17 holes are placed so as to form a valley-like portion, 18 a fiber stream containing fine fibers is blown against -19 th`e collecting plate at a high speed in such a ~anner that the central surface of the fiber stream is applied 21 to a fiber blow portion and the fibers are thus collected~
22 as described above. Therefore, the gas can readily be 23 exhausted through the holes of press plate 4 and collect-24 ing plate 3 ~nd a uniform nonwoven fabric can be pro~uced without scattering fibers even if there i~ provided no 26 suction apparatus. That is, as shown in Fig~ 10, the 27 gas in fiber stream 6 is readily exhausted through per-28 forated pistes at both sides of point P. Consequently~ ;
29 the turbulence of the gas current on the collecting plate is decreased and, in particular, there is iittle 31 gas.current passing over the surface of the nonwoven 32 abric, so that the fibers are not scattered and even 33 if partly scattered~ they are collected by collecting 34 plate 3 and press plate 4~ In the case of the present 35 invention, in particular~ there are no fibers adhered -36 on the parts o collectLng plate 3 ~nd press plate 4 37 ~rom which the gas of flber stream 7 is exhausted, and, 38 according~y, the gas can be exhausted without any dis-39 turbance. In the case of the second die 2' when using 40 two dies as shown in Fig. 16 or in the case of using a 41 nonwoven fabric or woven fabric as the collecting ~2 plate and press plate as shown in Fig. 19~ the g~s is 43 hard to pass through the woven or nonwoven fabric having 44 a fine network even if the hardness depends somewhat on the mesh size of the network~ but the 46 scattered fibers can be collected7 ~ 3 1 more readily as compared with the prior art method, on 2 ~ the colLecting plate and press plate. Thus the advan~ages 3 of ~he present invention can sufficiently be realized in 4 these cases.
On the other hand, when using a fla~ or cylin-6 drical ~ollecting plate having a number of holes only as<
7 in the.priOr art me~hod, a fiber stream o thermoplastic resin is blown against point P on the collecting pla~e g` and the fibers are collected at or near point P as shown in Fig~ 11, so the holes on the area of s~de X of point P
11 on the collecting plate ~in the moving direction o the 12 collecting plate) are closed and9 on the area of side X
13 of point P on the colleoting plate (in the opposite 14 direction to the moving direction of the collecting plate), the gas is exhausted through the holes of the 16 collec~ing plate. On the area of side X of point P on 17 collecting plate 3, the gas does not pass th~ ugh the 18 holes of collecting plate 3, but 10ws toward side X
lg of point P on the surface of the collected ~ibers ~in the moving .direction~, thus causing ~ lowered collecting 21 efficiency of fibers and a ~catter of the collected fibers.
22 It is further found that in the prior art method, the 23 balance of the gas current is lost at both the sides of - 24 point P on~the collecting plate~ which af~ects sometimes 2~ the fiber s~ream and causes a diffieulty in obtaining a 26 uniform nonwoven fabric 27 According to the process of the presen~ invention, 28 the gas can readily be exhausted th~ ugh the holes of the 29 collecting plate and press plat~ and, consequently~ there 30 occurs scarcely a turbulenee of gas current at both the 31 sides of point P as set forth above, whereby the above 32 described disadvantages of ~he prior art can be o~ercome~
~3 The other feature of the present invention consists in 34 that a nonwoven abric with a uniform thickness can be obtained~ if nec~ssary, by pressing the colleeted fibers 36 to a pr~determ~ned thickness by a collecting plate and 3~ pre~s plate) and, in addition~ a nonwoven abrlc com-38 prising fibers in the vertlcaL direction to the surf~ce 39 of the nonwoven fabric can be obtained by selecting suitably a position against which a fiber stream ~s 4~ blown, as set forth above.
42 The present invention will now be illustrated-43 in greatex detail by examples.
44 Flg. lZ ~o Fig. 20 s~ow examples of apparatus ~7~3 1 suitable for carrying out the process of the present 2 invention, ~he main parts ~hereof o~ly being shown with 3 details omitted.
4 Referring to Fig. 12, a system for spinning comprises extruder 1~ hopper ~1 of extruder 1, motor 12, 6 power transmit~ing mechanism 13, die 2, spinning holes 21, 7 gas exhaust hole~ 22 and gas feed inle~ 23. Gas feed 8 inlet 23 is connected with a préssure gas feeding 9 apparatus (not shown) . 3 is a collectir~g plate, i. e .
lQ net or perforated plate made of a metal such as stainless 11 steel or synthetic resin such as fluorine resin~ poly-12 amide or polyester and having a network size of 5 to 13 200 meshes, preferably 10 to 40 meshes. 31 is a hollow-14 cylindrical drum for holding collecting plate 39 having a diameter of about 1 m and a number of holeson the side 16 thereof (not the bottoms thereof) as shown in Fig. 13 and 17 Fig. 14. Collecting plate 3 is provided on the side 18 surface. The two ends of the hollow cylindrical drum 19 are preferably supported to be rotatable by such a met~od as having openings (not shown, e.g.-method of using 21 spokes for a wheel, method of holding the inner wall of 22 a drum by roils, etc.)7 but it is not always to provide 23 openings on~the two ends. Driving of drum 31 is carried ~4 out by a known method selec~ed from a method compris~ng connecting central axle 32 with a motor and ~ method 26 comprising dri~ing through the inner wall or outer 27 circumerence of the drum. The shape of hole 33 on ~he 28 side of d~um 31 is not particularly limited as long as 29 the exh~ust of gas is not hindered. For example, any 30 circular or sli~-like forms can be used3 but~ in parti- -31 cular, the so-called circular tapered hole wherein the 32 outer diame~er at opening portion 35 is largsr than the 33 inner diameter at opening port~on 34i as shown, in plan 34 and cross section, in Fig. 13 and Fig. 14,is a preferred example. ~he size of the hole in the side wall of d~um 31 36 can optionally be determined depending on the relation wi~h 37 structure of collecting plate 39 but, in general, it is 38 in a range of 1 to 50 m~ preferably 5 to 20 mm~ In 39 this igure,-colfecting plate 3 is held by holding drum 329 but as occasio~ demands, the side w~ll itself of the 41 ho~ding drum can be used as such a collecting plate. 4 ~
42 is a press plate, i~e. annular net or perforated plate 43 made of a met~l such as st~inless steel or a synthetic 44 resin such as polyester, polyamide or fluorine resin, ~ `
wh,ich is wound round hollow-~ylindrical dru~n 41 or 2 holding drum 41' having a number of holes in the side 3 wall and a diame~er of about 20 cm A flber stre~m 4 consisting of fibers spun ~rom spiming holes 21 of die 2 and a-gas blown at a high speed from gas exhaust hole . 6 22 is blown agains~ point P (which is a point in the 7 cross section~ but which is correctly a line parallel 8 to central axis 32 on rollecting plate 3) on the surface g of col~ecting plate 3 to collect fibers, pxessed to a predetermined.thickness by collecting pl~te 3 and 11 press plate 4 to form nonwoven fabric 5 and then taken up 12 by roll 8 through rolls 71 and 71' to give a product.
13 9 is 8 sprayer for feeding water drops to cool the 14 collecting plate . In this example, furthermore9 a
15 suctio~ apparatus for exhausting the gas can i necessary
16 be provided in hollow-cylindrical drums 31 and 41.
17 Fig. 15 shows a modification of the system -
18 of Fig. 12. Press plate 4 is an annular net or perforated l9 plate made of a metal such as stainless steel or a synthetic resin such as polyester9 polyamide or fluorine 21 resin, which is movably held by rolls 41~ 41' and 41" .
22 In this case, roll 41 is a roll coated with a synthetic - 23 rubber having a diameter of about 3 cm, the interval 24 between roll 41~ and roll 419' is about 15 cm and press pl~te 3 in fiber collecting section 6 i5 a substantially 26 perforated plate, wherein the advantages of the pxesent 27 lnven ion can similarly be maintained 28 Fig. 16 and Fig. 17 show other embodl~ents.
29 Fig. 16 shows a case where a laminated article consisting of the same resin or different resins is produced using 31 tw~ spinning dies. Fig. 17 shows a ease where using 3~2 collecting plate 3 and press plate 4 having the same 33 shape, fiber stream 7 is blown into the space between 34 the~e plates.
Fig. 18 shows cross sectlonal views of the 36 nonwoven fabrics obtained by blowing fiber stream 7 into 37 the space between collec~ing plate 3 and press plate 4 38 by t~e method of Fig. 17 or other methods according to 39 the invention.
Fig. 19 shows a case where a fiber stream is 41 blown against one woven or nonwoven fabr~c to produce 8 42 ~aminated nonwoven fabric. In this case, as the woven 43 fabric there are used woven fabrics of synthetic fibers 44 such as polyolefins, polyamides, polyester3 polyurethane.s~
.
7~3 1 polyacrylonitriles and the like and natural fibers such 2 as cotton, hempg silk and the like. The nonwoven 3 fabric can be prepared by the process of the present 4 .invention, but it is preferable to use nonwoven fabrics cQnsisting o relatively thick fibers such as prepared by 6 other known methods, since according to the present 7 process, there is only obtained a nonwoven fabric con-8 sisting of fine fibers~
9 As fibers to be blown against.such a woven or nonwoven fabric~ the abové described synthetic fibers 11 can be used, and, in particul~r, polyamides, polyesters 12 and polyurethanes are preferably used. When the nonwoven 13 fabric obtained in this way is divided into two or more 14 sheets at the center, a raised and laminated nonwoven fabric is obtained as shown in Fig. 20 (b)o For ~he 16 purpose of improving the adhesiveness between the woven 17 or nonwoven fabr;c and thenonwoven fabric to be laminated 18 thereon, in addition, the surface of the woven fabric
22 In this case, roll 41 is a roll coated with a synthetic - 23 rubber having a diameter of about 3 cm, the interval 24 between roll 41~ and roll 419' is about 15 cm and press pl~te 3 in fiber collecting section 6 i5 a substantially 26 perforated plate, wherein the advantages of the pxesent 27 lnven ion can similarly be maintained 28 Fig. 16 and Fig. 17 show other embodl~ents.
29 Fig. 16 shows a case where a laminated article consisting of the same resin or different resins is produced using 31 tw~ spinning dies. Fig. 17 shows a ease where using 3~2 collecting plate 3 and press plate 4 having the same 33 shape, fiber stream 7 is blown into the space between 34 the~e plates.
Fig. 18 shows cross sectlonal views of the 36 nonwoven fabrics obtained by blowing fiber stream 7 into 37 the space between collec~ing plate 3 and press plate 4 38 by t~e method of Fig. 17 or other methods according to 39 the invention.
Fig. 19 shows a case where a fiber stream is 41 blown against one woven or nonwoven fabr~c to produce 8 42 ~aminated nonwoven fabric. In this case, as the woven 43 fabric there are used woven fabrics of synthetic fibers 44 such as polyolefins, polyamides, polyester3 polyurethane.s~
.
7~3 1 polyacrylonitriles and the like and natural fibers such 2 as cotton, hempg silk and the like. The nonwoven 3 fabric can be prepared by the process of the present 4 .invention, but it is preferable to use nonwoven fabrics cQnsisting o relatively thick fibers such as prepared by 6 other known methods, since according to the present 7 process, there is only obtained a nonwoven fabric con-8 sisting of fine fibers~
9 As fibers to be blown against.such a woven or nonwoven fabric~ the abové described synthetic fibers 11 can be used, and, in particul~r, polyamides, polyesters 12 and polyurethanes are preferably used. When the nonwoven 13 fabric obtained in this way is divided into two or more 14 sheets at the center, a raised and laminated nonwoven fabric is obtained as shown in Fig. 20 (b)o For ~he 16 purpose of improving the adhesiveness between the woven 17 or nonwoven fabr;c and thenonwoven fabric to be laminated 18 thereon, in addition, the surface of the woven fabric
19 or nonwo~en fabric can be heated or coated with solvents or adhesives
Claims (16)
PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A process for the production of a non-woven fabric comprising spinning continuously a molten thermoplastic resin from a plurality of spinning holes provided in a spinning apparatus thereby to spin fibers, while simultaneously jetting a gas at high speed from gas discharging holes provided adjacent to the spinning holes to stretch the spun fibers of the thermoplastic resin, there-by forming a fiber stream consisting of the fibers and the gas, then directing said stream into a fiber collecting zone formed by two porous moving members having a gap there between said porous members having a large number of pores of 5 to 200 mesh size therein, said members being arranged to come into contact with each other via the fibers to provide a contact region, said members having an angle of divergence of 0-90 , said gap between the two members increasing as the distance increases from said contact region in the opposite direction to the movement of said members, and blowing said fiber stream in said fiber collecting zone in such a manner that the central plane of said fiber stream is directed within said fiber collecting zone on at least one said porous member at a distance from said contact region equal to less than within 5 times the width of the fiber stream on said porous member, the angle at which the fiber stream is blown being 0-90 , the fibers being collected on said porous member or members, whereby little gas flow passes over the surface of the resulting non-woven fabric, and compressing said resulting non-woven fabric between said porous members to provide a non-woven fabric of uniform thickness.
2. The process as claimed in claim 1, wherein said porous members respectively comprise a collecting plate and a press plate.
3. The process as claimed in claim 2, wherein at least one of the collecting plate and press plate is a hollow cylinder.
4. The process as claimed in claim 2, wherein at least one of the collecting plate and press plate is a belt-like or annular thin plate.
5. The process as claimed in claim 2 wherein at least one of the collect-ing plate and press plate is a net or porous or perforated plate made of a metal or synthetic resin, and is in contact with the surface of a hollow cylinder having a number of holes therein.
6. The process according to claim 5 wherein said net or porous plate is a woven net or punched porous plate made of metal or a synthetic resin having pores of 10 to 40 mesh.
7. The process as claimed in claim 6, wherein at least one of the collect ing plate and press plate is in contact with the surface of a hollow cylinder having holes through the side wall.
8. A process according to claim 7 wherein said through holes have a diameter of 1 to 50 mm.
9. A process according to claim 1 wherein the distance between the site on a porous member at which the central plane of the fiber stream is blown and said contact region is within 3 times the width of the fiber stream on the surface of said porous member.
10. A process according to claim 1 wherein at least one of said porous members is covered with a woven or non-woven fabric and blowing of the fiber stream onto the surface of said woven or non-woven fabric.
11. The process as claimed in claim 10, wherein the woven or non-woven fabric to be wound is heated.
12. The process as claimed in claim 10, wherein an adhesive is coated onto the surface of the woven or non-woven fabric.
13. The process according to claim 1 wherein said members move continuously in the same direction.
14. The process according to claim 1 wherein the angle of blow is 0-60°.
15. The process according to claim 1 wherein the angle of blow is substantially 0° and both members are porous.
16. The process according to claim 15 wherein the fibers in the resulting non-woven fabric are substantially perpendicular to the surface thereof.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP50,745/78 | 1978-05-01 | ||
| JP53050745A JPS6056825B2 (en) | 1978-05-01 | 1978-05-01 | Manufacturing method of nonwoven fabric |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1147113A true CA1147113A (en) | 1983-05-31 |
Family
ID=12867369
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000326588A Expired CA1147113A (en) | 1978-05-01 | 1979-04-30 | Process for the production of a nonwoven fabric |
Country Status (7)
| Country | Link |
|---|---|
| US (1) | US4375446A (en) |
| JP (1) | JPS6056825B2 (en) |
| BE (1) | BE875978A (en) |
| CA (1) | CA1147113A (en) |
| DE (1) | DE2948820T1 (en) |
| GB (1) | GB2045300B (en) |
| WO (1) | WO1979001014A1 (en) |
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| US6057024A (en) * | 1997-10-31 | 2000-05-02 | Kimberly-Clark Worldwide, Inc. | Composite elastic material with ribbon-shaped filaments |
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- 1978-05-01 JP JP53050745A patent/JPS6056825B2/en not_active Expired
-
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- 1979-04-30 CA CA000326588A patent/CA1147113A/en not_active Expired
- 1979-05-01 WO PCT/JP1979/000108 patent/WO1979001014A1/en not_active Application Discontinuation
- 1979-05-01 GB GB7943312A patent/GB2045300B/en not_active Expired
- 1979-05-01 US US06/167,637 patent/US4375446A/en not_active Expired - Lifetime
- 1979-05-01 DE DE792948820T patent/DE2948820T1/en active Granted
- 1979-05-02 BE BE0/194939A patent/BE875978A/en not_active IP Right Cessation
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6057024A (en) * | 1997-10-31 | 2000-05-02 | Kimberly-Clark Worldwide, Inc. | Composite elastic material with ribbon-shaped filaments |
Also Published As
| Publication number | Publication date |
|---|---|
| JPS6056825B2 (en) | 1985-12-12 |
| DE2948820T1 (en) | 1980-12-11 |
| JPS54147273A (en) | 1979-11-17 |
| DE2948820C2 (en) | 1991-03-14 |
| US4375446A (en) | 1983-03-01 |
| WO1979001014A1 (en) | 1979-11-29 |
| BE875978A (en) | 1979-11-05 |
| GB2045300A (en) | 1980-10-29 |
| GB2045300B (en) | 1982-11-17 |
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| MKEX | Expiry |