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EP1092054A2 - Method for producing a non-woven fibre fabric - Google Patents

Method for producing a non-woven fibre fabric

Info

Publication number
EP1092054A2
EP1092054A2 EP99939910A EP99939910A EP1092054A2 EP 1092054 A2 EP1092054 A2 EP 1092054A2 EP 99939910 A EP99939910 A EP 99939910A EP 99939910 A EP99939910 A EP 99939910A EP 1092054 A2 EP1092054 A2 EP 1092054A2
Authority
EP
European Patent Office
Prior art keywords
fibers
perforated
openings
structures
fleece
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.)
Granted
Application number
EP99939910A
Other languages
German (de)
French (fr)
Other versions
EP1092054B1 (en
Inventor
Stefan Etzold
Joachim Bauer
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Corovin GmbH
Original Assignee
Corovin GmbH
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Corovin GmbH filed Critical Corovin GmbH
Publication of EP1092054A2 publication Critical patent/EP1092054A2/en
Application granted granted Critical
Publication of EP1092054B1 publication Critical patent/EP1092054B1/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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
    • 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
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H13/00—Other non-woven fabrics
    • 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
    • D04H3/14—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 yarns or filaments produced by welding
    • 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
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/601—Nonwoven fabric has an elastic quality
    • Y10T442/602—Nonwoven fabric comprises an elastic strand or fiber material

Definitions

  • the invention relates to a method for producing a nonwoven from fibers with a multiplicity of hole structures extending over the entire cross section of the nonwoven, and to a nonwoven produced by this method.
  • Single-layer or multi-layer nonwovens with hole structures that extend over the entire cross-section are required, for example, for coverstock materials for hygiene articles such as sanitary napkins and diapers or for other applications in the textile or technical field.
  • the perforated structures serve to allow liquid, tissue components and faeces occurring on the body to be drained as quickly as possible into the liquid-absorbing interior of diapers, feminine hygiene articles or the like.
  • the nonwovens can be single or multi-layered, wherein multi-layered nonwovens can be connected to other web-shaped media, in particular foils.
  • perforated structures can be introduced into a single- or multi-layered nonwoven in a targeted manner, with the previously known methods having in common that the perforated structures are introduced into the finished nonwoven after solidification, in particular thermal bonding.
  • perforated structures are introduced into the consolidated fleece by pressing heated stamps, between which the fleece is passed, pressed against one another such that a hole is melted into the consolidated fleece.
  • a similar method is also known from US Pat. No. 5,709,829 as a so-called hot-needle punch method.
  • the advantage of this method is that the nonwoven structure is not weakened in its cohesion by the melt edges that arise along the holes. It is disadvantageous, however, that the handle (softness) is negatively influenced by the relatively hard melting edges, insofar as a fleece obtained in this way feels relatively hard and can be perceived by users as unpleasant.
  • the perforated structures are created by (cold) punching / cutting out fibers from the consolidated nonwoven.
  • Such methods have the advantage that no hard stamping or melting edges are formed and materials obtained in this way therefore have a good grip. It is disadvantageous, however, that these methods can only be implemented at a slow speed.
  • the fibers are shortened along the holes, which leads to a lower strength of the fleece.
  • the hole structures are passed through two rollers between which the fleece is passed after the fleece has been finished is introduced, one roller having a plurality of heated needles and the other roller having openings corresponding to the needles of the first roller.
  • the needles are supposed to displace the fibers - and thereby form the hole structures - and at the same time form depressions around the hole structures and finally seal the edges of the hole structures by melting the fibers.
  • the fibers are not shortened or destroyed, but hard melt edges are created here, which negatively affect the grip.
  • the introduction of perforated structures after thermobonding the fleece is complex and expensive.
  • the object of the invention is therefore to provide a method by which the person skilled in the art is able to create a fleece with perforated structures which has a good grip, the fiber structure of which is not weakened by the introduction of the perforated structures and which does not produce waste feasible and which should be easy and inexpensive to carry out.
  • the fibers are laid down in a confused manner on a sieve web to form a fiber web, in a wide step the fiber web a hole structure generating unit is transported, in a third step the hole structures by mechanical displacement of the fibers are produced, the displacement of the fibers leaving their mechanical and chemical structure unaffected, and in a fourth step the fiber web provided with the hole structures is consolidated in a consolidation unit to form a fleece.
  • the invention is therefore based on the surprising finding that in order to produce hole structures in a nonwoven, it is sufficient to displace the fibers which cover the area of the hole to be formed and to compress it and / or the surrounding area, if necessary, without it would be necessary to destroy or reduce the fiber pile in the area of the holes to be dilated and / or its overall appearance.
  • the fibers of the fibrous web in the area of the perforated structures are optimized or deflected from their previous course before the completion of the fleece by consolidation and optionally thermal bonding, without thermal treatment or simultaneous compression being necessary.
  • Suitable fibers or filaments for producing a nonwoven according to the method according to the invention are all fibers and filaments which are suitable for the formation of nonwovens according to the different methods, in particular staple fibers, continuous filaments, bicomponent fibers and filaments. Staple fibers in particular can be particularly suitable.
  • the fibrous web can be connected to one or more further nonwovens or nonwovens and / or to another web-like medium, such as a film.
  • the risk of the fibers springing back can be countered in an advantageous manner by the fiber web being fed directly to the strengthening unit after the hole structure has been produced.
  • a consolidation unit for example a calender roll arrangement
  • the fiber web is compressed to the finished nonwoven and, according to an advantageous embodiment of the invention, is simultaneously thermobonded.
  • a very short distance will therefore be preferred.
  • the fiber web before the third step is pre-consolidated in such a way that the tensile strength of the pre-consolidated fibrous web corresponds to 0.1 to 75%, in particular up to 50%, of the tensile strength of the consolidated nonwoven.
  • the unconsolidated fibrous web is to a certain extent tacked by a few bonding points which are very far apart from one another or by the application of pressure and / or heat.
  • a certain mechanical stability of the fibrous web can be achieved, as a result of which it can be transported to the hole structure generation unit at a higher speed. The higher speed enables faster production.
  • the fibers surrounding the hole structures are fixed before the fiber web is fed to the consolidation unit.
  • This fixation is used to prevent the perforated structures from being stretched when the fibrous web, which is now provided with perforated structures, is transported further.
  • the fixation i.e. that is, the fibers can easily be stitched together in the vicinity of the perforated structures by suitable means, for example by applying heat and / or pressure to the fiber web, for example by smooth rolling.
  • the fourth method step is carried out with the hole structure generating unit directly after the third method step.
  • the hole structure generation unit would be used for solidification at the same time.
  • the hole structure generating unit has two elements faces facing each other, between which the batt is passed, the face of a first element having a plurality of spikes facing the face, and the face of a second element having openings into which the spikes of the first face can at least partially dip , the fibers of the fibrous web located below the spines being displaced non-destructively when the spikes are immersed in the openings and the perforated structures being formed.
  • the openings of the second surface communicate with a vacuum / overpressure source, such as a blower, so that fibers of the fiber web located in the region of the openings are sucked into the openings or blown out of the openings .
  • a vacuum / overpressure source such as a blower
  • Such a blower can, on the one hand, support the non-destructive displacement of the fibers to form the perforated structures by sucking in the fibers m the openings of the second surface, on the other hand, the blown fiber web provided with the perforated structures can be blown away from the second surface, so that one possibly existing adhesion of the pile of fibers to the second surface after the hole structures have been gently lifted.
  • the channels and openings of the vacuum source can be shaped and dimensioned in such a way that the fibers to be deformed or reorganized, which are sucked into the openings and channels of the vacuum source, are reliably prevented from getting caught.
  • the first element is a roller, with practical embodiments of the invention providing that the roller has a diameter of 100 to 500 mm.
  • Such a roller can be advantageous if a relatively high production speed is to be made possible.
  • the first element is a rising and falling plate.
  • a plate with which hole structures can be produced discontinuously, can be advantageous if the displacement of the fibers is to be carried out slowly and carefully.
  • the spikes of the first element are conical, or have the shape of an involute, or have an ogival cross section, the spikes practically having a height of 0.5 to 5 mm.
  • Different shapes, sizes and heights will be used for the spines, depending on the requirements of the fleece to be created, which can be a single-layer or multi-layer fleece, for example an SMS fleece, or a combination of fleece and other web-shaped media.
  • the second element is a perforated tape.
  • the fibrous web to be treated can be placed on such a perforated band and transported to the first element, where the spikes of the first element then penetrate through the fibrous web into the perforations of the perforated band.
  • the second element is a calender roll.
  • a calender roll is used as the second element at the same time.
  • a nonwoven fabric produced by a method according to the invention has hole structures with a diameter of 0.5 to 5 mm, that the bonding area is 3 to 40% of the nonwoven area and that the number of bonding points is 20 to 120 per square centimeter.
  • FIG. 1 shows a schematic representation of a plant for carrying out the method according to the invention
  • FIG. 2 shows a detailed view of a hole structure generation unit of the system from FIG. 1, FIG.
  • FIG. 3 shows a plan view of a perforated structure of a fleece produced using the method according to the invention
  • Fig. 4 shows an alternative embodiment of a
  • FIG. 1 shows a first embodiment of a system 10 for carrying out the method according to the invention.
  • a fibrous web 18 is first produced from fibers 14 and placed on a screen belt 16.
  • a fiber web 18 consisting of fibers 14 is transported further to a perforated structure generation unit 20.
  • This perforated structure generating unit 20 consists of a roller 22 which, with its outer surface 24, which forms the first surface 24 of the perforated structure generating unit 20, is arranged above a perforated belt 26 with a surface 28 directed towards the roller 22. This surface 28 forms the second surface 28 of the hole structure generation unit 20.
  • the surface 24 of the roller 22 is provided with a multiplicity of spikes 30, which can at least partially dip into holes 32 in the perforated strip 26.
  • roller 22 rotates counterclockwise;
  • this consolidation unit 38 consists of two calender rolls 40, 42. Through the calender rolls 40, 42, the fiber web 18 is solidified by thermal bonding, so that the finished fleece 44 leaves the calender rolls 40, 42.
  • FIG. 2 shows the hole structure generation unit 20 in detail on a greatly enlarged scale compared to FIG. 1.
  • a negative pressure is generated by the negative pressure / positive pressure source 34, as a result of which the filaments 14 of the fibrous web 18 located above the hole 32 of the perforated band 26 are sucked into the hole 32.
  • FIG 3 shows an example of a hole structure 36 of a fleece 44 created by the method according to the invention in detail.
  • the fleece 44 has a multiplicity of receptacles created by the calender rolls 40, 42 Thing points 48, which are evenly distributed over the entire surface of the fleece 44. Due to the corresponding size, number and distribution of the bonding points, it is possible that the hole structure 36 m is also provided with bonding points to a sufficient extent in its edge area 50, so that the hole structure 36 is stabilized by the bonding points 48.
  • the hole structure generation unit 20a has a roller 22 corresponding to the roller 22 from FIG. 1.
  • the second surface 28a is the outer surface of the calender roller 40a.
  • the surface 28a of the calender roll 40a is provided with holes 32a, which spikes 30 of the roll 22 can dip into.
  • the holes 32a are also connected to a vacuum source, not shown in detail.
  • the arrangement 10a shown in FIG. 4 makes it possible to dispense with a perforated belt 26 and to shorten the transport path from the perforated structure generation unit 20a to the consolidation unit 38a compared to the arrangement 10 shown in FIG. 1.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Treatment Of Fiber Materials (AREA)

Abstract

Disclosed is a method for producing a non-woven fibre fabric comprising a plurality of perforated structures extending along the entire cross-section of said fabric. The inventive method consists of the following steps: in a first step, the matted fibres are placed on a belt screen to form a web of fibres; in a second step, the web of fibres is conveyed to a perforated-structure manufacturing unit, in a third step, the perforated structures are manufactured by mechanically impinging upon the fibres, whereby the mechanical impingement upon said fibres does not affect the mechanical and chemical structure thereof; and in a fourth step, the web of fibres provided with said perforated structures is compacted in a compaction unit to form a non-woven fabric.

Description

Verfahren zur Herstellung eines Vlieses aus Fasern Process for producing a nonwoven from fibers
Die Erfindung betrifft ein Verfahren zur Herstellung eines Vlieses aus Fasern mit einer Vielzahl von sich über den gesamten Querschnitt des Vlieses erstreckenden Lochstrukturen, sowie ein nach diesem Verfahren hergestelltes Vlies.The invention relates to a method for producing a nonwoven from fibers with a multiplicity of hole structures extending over the entire cross section of the nonwoven, and to a nonwoven produced by this method.
Ein- oder mehrschichtige Vliese mit sich über den gesamten Querschnitt erstreckenden Lochstrukturen werden beispielsweise für Coverstock-Materialien von Hygieneartikeln wie Damenbinden und Windeln oder für andere Anwendungen im textilen oder technischen Bereich benötigt. Die Lochstrukturen dienen dazu, körperseitig auftretende Flüssigkeit, Gewebebestandteile und Kot möglichst schnell in das flüssigkeitsabsorbierende Innere von Windeln, Damenhygieneartikeln oder dergleichen ableiten zu können. Je nach Anwendungsbereich können die Vliese ein- oder mehrschichtig sein, wobei mehrschichtige Vliese mit anderen bahnförmigen Medien, insbesondere Folien, verbunden sein können.Single-layer or multi-layer nonwovens with hole structures that extend over the entire cross-section are required, for example, for coverstock materials for hygiene articles such as sanitary napkins and diapers or for other applications in the textile or technical field. The perforated structures serve to allow liquid, tissue components and faeces occurring on the body to be drained as quickly as possible into the liquid-absorbing interior of diapers, feminine hygiene articles or the like. Depending on the area of application, the nonwovens can be single or multi-layered, wherein multi-layered nonwovens can be connected to other web-shaped media, in particular foils.
Es sind mehrere Verfahren bekannt, mit denen man gezielt Lochstrukturen in ein ein- oder mehrschichtiges Vlies einbringen kann, wobei den bislang bekannten Verfahren gemeinsam ist, daß die Lochstrukturen nach Verfestigung, insbesondere Thermobondierung, des fertigen Vlieses in dieses eingebracht werden. So werden beispielsweise bei einem aus der EP 0 687 757 A2 bekannten Verfahren Lochstrukturen dadurch m das verfestigte Vlies eingebracht, daß erhitzte Stempel, zwischen denen das Vlies hmdurchgefuhrt wird, derart gegeneinander gepreßt werden, daß ein Loch in das verfestigte Vlies eingeschmolzen wird. Ein ähnliches Verfahren ist ferner aus der US 5 709 829 als sogenanntes Hot-Needle-Punchmg-Verfahren bekannt.Several methods are known by means of which perforated structures can be introduced into a single- or multi-layered nonwoven in a targeted manner, with the previously known methods having in common that the perforated structures are introduced into the finished nonwoven after solidification, in particular thermal bonding. For example, in a method known from EP 0 687 757 A2, perforated structures are introduced into the consolidated fleece by pressing heated stamps, between which the fleece is passed, pressed against one another such that a hole is melted into the consolidated fleece. A similar method is also known from US Pat. No. 5,709,829 as a so-called hot-needle punch method.
Der Vorteil bei diesem Verfahren besteht darin, daß durch die entstehenden Schmelzerander entlang der Locher die Vliesstruktur m ihrem Zusammenhalt nicht geschwächt w rd. Nachteilig ist aber, daß der Griff (Softness) durch die relativ harten Schmelzrander negativ beeinflußt wird, insofern, als daß sich ein derart gewonnenes Vlies relativ hart anfühlt und von den Anwendern als unangenehm empfunden werden kann.The advantage of this method is that the nonwoven structure is not weakened in its cohesion by the melt edges that arise along the holes. It is disadvantageous, however, that the handle (softness) is negatively influenced by the relatively hard melting edges, insofar as a fleece obtained in this way feels relatively hard and can be perceived by users as unpleasant.
Bei einem anderen bekannten Verfahren werden die Lochstrukturen durch ein (kaltes) Ausstanzen/Ausschneiden von Fasern aus dem verfestigten Vlies geschaffen. Derartige Verfahren bieten den Vorteil, daß keine harten Stanz- oder Schmelzerander entstehen und derartig gewonnene Materialien daher einen guten Griff aufweisen. Nachteilig ist jedoch, daß sich diese Verfahren nur bei einer geringen Fordergeschwindigkeit realisieren lassen. Zudem werden die Fasern entlang der Locher verkürzt, was zu einer geringeren Festigkeit des Vlieses fuhrt.In another known method, the perforated structures are created by (cold) punching / cutting out fibers from the consolidated nonwoven. Such methods have the advantage that no hard stamping or melting edges are formed and materials obtained in this way therefore have a good grip. It is disadvantageous, however, that these methods can only be implemented at a slow speed. In addition, the fibers are shortened along the holes, which leads to a lower strength of the fleece.
Bei den genannten Verfahren ist es nachteilig, daß durch das heiße bzw. kalte Ausstanzen bzw. Brennen Material unnötigerweise vernichtet wird bzw. als Abfall anfallt.In the above-mentioned processes, it is disadvantageous that the hot or cold punching or firing unnecessarily destroys material or produces waste.
Bei einem weiteren, aus der EP 0 214 608 A2 bekanntem Verfahren werden nach Fertigstellung des Vlieses die Lochstrukturen durch zwei Walzen, zwischen denen das Vlies hindurch gefuhrt wird, eingebracht, wobei eine Walze eine Vielzahl von erhitzten Nadeln und die andere Walze den Nadeln der ersten Walze entsprechende Offnungen aufweist. Die Nadeln sollen hierbei die Fasern verdrangen - und hierdurch die Lochstrukturen bilden - und gleichzeitig Vertiefungen um die Lochstrukturen herum bilden und schließlich durch Anschmelzen der Fasern die Rander der Lochstrukturen versiegeln. Bei diesem Verfahren werden die Fasern zwar nicht verkürzt oder zerstört, es entstehen jedoch auch hier harte Schmelzerander, welche den Griff negativ beeinflussen. Zudem ist ein Einbringen von Lochstrukturen nach dem Thermobondieren des Vlieses aufwendig und teuer.In a further method known from EP 0 214 608 A2, the hole structures are passed through two rollers between which the fleece is passed after the fleece has been finished is introduced, one roller having a plurality of heated needles and the other roller having openings corresponding to the needles of the first roller. The needles are supposed to displace the fibers - and thereby form the hole structures - and at the same time form depressions around the hole structures and finally seal the edges of the hole structures by melting the fibers. With this method, the fibers are not shortened or destroyed, but hard melt edges are created here, which negatively affect the grip. In addition, the introduction of perforated structures after thermobonding the fleece is complex and expensive.
Aufgabe der Erfindung ist daher, ein Verfahren zu schaffen, durch welches der Fachmann n die Lage versetzt wird, ein Vlies mit Lochstrukturen zu schaffen, welches einen guten Griff aufweist, dessen Faserverband durch das Einbringen der Lochstrukturen nicht geschwächt wird, welches ohne Anfall von Abfall durchfuhrbar und welches einfach und preiswert auszufuhren sein soll.The object of the invention is therefore to provide a method by which the person skilled in the art is able to create a fleece with perforated structures which has a good grip, the fiber structure of which is not weakened by the introduction of the perforated structures and which does not produce waste feasible and which should be easy and inexpensive to carry out.
Diese Aufgabe wird mit einem Verfahren αer eingangs genannten Art gelost, welches die Merkmale des Patentanspruchs 1 aufweist .This object is achieved with a method of the type mentioned at the outset, which has the features of patent claim 1.
Erfmdungsgemaß ist vorgesehen, daß bei einem Verfahren zur Herstellung eines Vlieses aus Fasern mit einer Vielzahl von sich über den gesamten Querschnitt des Vlieses erstreckenden Lochstrukturen in einem ersten Schritt die Fasern wirr auf einem Siebbanα zu einem Faserflor abgelegt werden, n einem weiten Schritt der Faserflor zu einer Lochstruktur- Erzeugungseinheit transportiert wird, m einem dritten Schritt die Lochstrukturen durch eine mechanische Verdrängung der Fasern erzeugt werden, wobei die Verdrängung der Fasern deren mechanische und chemische Struktur unbeeinflußt laßt, und m einem vierten Schritt der mit den Lochstrukturen versehene Faserflor m einer Verfestigungseinheit zu einem Vlies verfestigt wird.According to the invention, it is provided that in a method for producing a fleece from fibers with a multiplicity of hole structures extending over the entire cross-section of the fleece, the fibers are laid down in a confused manner on a sieve web to form a fiber web, in a wide step the fiber web a hole structure generating unit is transported, in a third step the hole structures by mechanical displacement of the fibers are produced, the displacement of the fibers leaving their mechanical and chemical structure unaffected, and in a fourth step the fiber web provided with the hole structures is consolidated in a consolidation unit to form a fleece.
Der Erfindung liegt also die überraschende Erkenntnis zugrunde, daß zur Erzeugung von Lochstrukturen m einem Vlies es ausreichend st, αie Fasern, welche den Bereich des zu bildenden Loches bedecken, zu verdrangen und m diesem und/oder dem umliegenden Bereich gegebenenfalls zu verdichten, ohne daß es notig wäre, den Faserflor im Bereich der zu Dildenden Locher und/oder sein übergeordnetes Erscheinungsbild zu zerstören oder zu schmälern. Kurz gefaßt werden also bei dem er- fmdungsgemaßen Verfahren vor der Fertigstellung des Vlieses durch Verfestigung und gegebenenfalls Thermobondierung die Fasern des Faserflors m Bereich der Lochstrukturen αmoπen- tiert oder von ihrem bisherigen Verlauf abgelenkt, ohne daß eine tnermische Behandlung oder eine gleichzeitige Verdichtung notig wäre.The invention is therefore based on the surprising finding that in order to produce hole structures in a nonwoven, it is sufficient to displace the fibers which cover the area of the hole to be formed and to compress it and / or the surrounding area, if necessary, without it would be necessary to destroy or reduce the fiber pile in the area of the holes to be dilated and / or its overall appearance. In short, in the method according to the invention, the fibers of the fibrous web in the area of the perforated structures are optimized or deflected from their previous course before the completion of the fleece by consolidation and optionally thermal bonding, without thermal treatment or simultaneous compression being necessary.
Als geeignete Fasern oder Filamente zur Erzeugung eines Vlieses gemäß des erfmdungsgemaßen Verfahren kommen alle Fasern und Filamente in Betracht, welche zur Vl esbildung nach den unterschiedlichen Verfahren geeignet sind, insbesondere kommen Stapelfasern, Endlosflla ente, Bikomponentenfasern und - filamente in Betracht. Insbesondere Stapelfasern können besonders gut geeignet sein.Suitable fibers or filaments for producing a nonwoven according to the method according to the invention are all fibers and filaments which are suitable for the formation of nonwovens according to the different methods, in particular staple fibers, continuous filaments, bicomponent fibers and filaments. Staple fibers in particular can be particularly suitable.
Von Vorteil ist hierbei insbesondere, daß kein unnötiger Abfall oder Materialschwund entsteht, daß die Fasern m Bereich der Lochstrukturen nicht verKurzt und nicht zerstört werden und daß der Griff des fertigen Vlieses dadurch ein sehr guter ist, daß keine zusätzlichen Verhärtungen im Randbereich der Lochstrukturen den Griff des fertigen Vlieses beeinträchtigen.It is particularly advantageous that there is no unnecessary waste or material shrinkage, that the fibers in the area of the perforated structures are not shortened and not destroyed, and that the handle of the finished nonwoven is therefore very good is that no additional hardening in the edge area of the hole structures impair the handle of the finished fleece.
Ein derartiger Lösungsweg ist bislang nicht eingeschlagen worden, da insbesondere bei einem aus der EP 0 214 608 A2 bekannten Verfahren davon ausgegangen wurde, daß durch den sogenannten Rückspringeffekt die Fasern dazu neigen würden, nach dem Verdrängen wieder in ihre ursprüngliche Lage zurückzukehren, wodurch die geschaffenen Lochstrukturen wieder verlorengehen würden. Überraschend hat sich jedoch gezeigt, daß dieser Rückspringeffekt durch das erfindungsgemäße Verfahren nicht mehr relevant ist.Such a solution has not been adopted so far, since it has been assumed in particular in a method known from EP 0 214 608 A2 that the so-called springback effect would tend to return the fibers to their original position after displacement, as a result of which the created ones Hole structures would be lost again. Surprisingly, however, it has been shown that this springback effect is no longer relevant due to the method according to the invention.
Vor Durchführung des dritten Verfahrensschrittes kann der Faserflor mit einem oder mehreren weiteren Vlies bzw. Vliesen und/oder mit einem anderen bahnförmigen Medium, wie einer Folie, verbunden werden.Before the third process step is carried out, the fibrous web can be connected to one or more further nonwovens or nonwovens and / or to another web-like medium, such as a film.
Zudem läßt sich in vorteilhafter Weise der Gefahr des Rück- springens der Fasern dadurch begegnen, daß der Faserflor nach Erzeugung der Lochstruktur unmittelbar der Verfestigungseinheit zugeführt wird. In einer solchen Verfestigungseinheit, beispielsweise einer Kalanderwalzenanordnung, wird der Faserflor zum fertigen Vlies verdichtet und, gemäß einer vorteilhaften Ausgestaltung der Erfindung, gleichzeitig thermobon- diert. Damit die Lochstrukturen nicht während des Transports von der Lochstruktur-Erzeugungseinheit zu der Verfestigungseinheit verlorengehen, wird man daher eine sehr kurze Wegstrecke bevorzugen.In addition, the risk of the fibers springing back can be countered in an advantageous manner by the fiber web being fed directly to the strengthening unit after the hole structure has been produced. In such a consolidation unit, for example a calender roll arrangement, the fiber web is compressed to the finished nonwoven and, according to an advantageous embodiment of the invention, is simultaneously thermobonded. In order that the perforated structures are not lost during the transport from the perforated structure generation unit to the consolidation unit, a very short distance will therefore be preferred.
In einer weiteren vorteilhaften Ausgestaltung der Erfindung ist vorgesehen, daß vor dem dritten Schritt der Faserflor vorverfestigt wird, dergestalt, daß die Zugfestigkeit des vorverfestigten Faserflors 0,1 bis 75 %, insbesondere bis 50 % der Zugfestigkeit des verfestigten Vlieses entspricht.In a further advantageous embodiment of the invention it is provided that the fiber web before the third step is pre-consolidated in such a way that the tensile strength of the pre-consolidated fibrous web corresponds to 0.1 to 75%, in particular up to 50%, of the tensile strength of the consolidated nonwoven.
Hierunter ist zu verstehen, daß der unverfestigte Faserflor durch einige wenige Bondingpunkte, welche zueinander einen sehr großen Abstand aufweisen, oder durch Aplizierung von Druck und/oder Wärme gewissermaßen geheftet werden. Dadurch läßt sich eine gewisse mechanische Stabilität des Faserflors erreichen, wodurch er mit einer höheren Geschwindigkeit zur Lochstruktur-Erzeugungseinheit transportiert werden kann. Durch die höhere Geschwindigkeit wird eine schnellere Fertigung ermöglicht.This is to be understood as meaning that the unconsolidated fibrous web is to a certain extent tacked by a few bonding points which are very far apart from one another or by the application of pressure and / or heat. As a result, a certain mechanical stability of the fibrous web can be achieved, as a result of which it can be transported to the hole structure generation unit at a higher speed. The higher speed enables faster production.
In einer vorteilhaften Ausgestaltung des Verfahrens ist vorgesehen, daß die die Lochstrukturen umgebenden Fasern vor dem Zuführen des Faserflors zur Verfestigungseinheit fixiert werden. Diese Fixierung dient dazu, daß beim Weitertransport des nun mit Lochstrukturen versehenen Faserflors die Lochstrukturen nicht gedehnt werden können. Die Fixierung, d. h., das leichte Zusammenheften der Fasern in der Umgebung der Lochstrukturen, kann durch geeignete Mittel erfolgen, beispielsweise durch Applizierung von Wärme und/oder Druck auf den Faserflor, beispielsweise durch Glattwalzen.In an advantageous embodiment of the method it is provided that the fibers surrounding the hole structures are fixed before the fiber web is fed to the consolidation unit. This fixation is used to prevent the perforated structures from being stretched when the fibrous web, which is now provided with perforated structures, is transported further. The fixation, i.e. that is, the fibers can easily be stitched together in the vicinity of the perforated structures by suitable means, for example by applying heat and / or pressure to the fiber web, for example by smooth rolling.
Desweiteren kann vorgesehen sein, daß mit der Lochstruktur- Erzeugungseinheit im direkten Anschluß an den dritten Verfahrensschritt der vierte Verfahrensschritt durchgeführt wird. In diesem Fall würde die Lochstruktur-Erzeugungseinheit gleichzeitig zum Verfestigen genutzt werden.Furthermore, it can be provided that the fourth method step is carried out with the hole structure generating unit directly after the third method step. In this case, the hole structure generation unit would be used for solidification at the same time.
In einer praktischen Ausgestaltung der Erfindung ist vorgesehen, daß die Lochstruktur-Erzeugungseinheit zwei Elemente mit zueinander hin gerichteten Flachen aufweist, zwischen denen der Faserflor hmdurchgefuhrt wird, wobei die Flache eines ersten Elements eine Vielzahl von zum Faserflor hin gerichteten Stacheln aufweist, und wobei die Flache eines zweiten Elements Offnungen aufweist, in welche die Stacheln der ersten Flache zumindest teilweise eintauchen können, wobei die unterhalb der Stacheln befindlichen Fasern des Faserflors beim Eintauchen der Stacheln in die Offnungen zerstörungsfrei verdrangt und die Lochstrukturen gebildet werden.In a practical embodiment of the invention it is provided that the hole structure generating unit has two elements faces facing each other, between which the batt is passed, the face of a first element having a plurality of spikes facing the face, and the face of a second element having openings into which the spikes of the first face can at least partially dip , the fibers of the fibrous web located below the spines being displaced non-destructively when the spikes are immersed in the openings and the perforated structures being formed.
In einer vorteilhaften Ausgestaltung der Erfindung ist vorgesehen, daß die Offnungen der zweiten Flache mit einer Unter- druck-/Uberdruckquelle, wie einem Geblase, kommunizieren, so daß im Bereich der Offnungen befindliche Fasern des Faserflors in die Offnungen eingesaugt oder aus den Offnungen ausgeblasen werden. Eine derartiges Geblase kann einerseits durch Ansaugen der Fasern m die Offnungen der zweiten Flache das zerstörungsfreie Verdrangen der Fasern zur Bildung der Lochstrukturen unterstutzen, zum anderen kann durch das Geblase der mit den Lochstrukturen versehene Faserflor von der zweiten Flache weg geblasen werden, so daß eine möglicherweise bestehende Haftung des Faserflors an der zweiten Flache nach Erzeugung der Lochstrukturen sanft aufgehoben wird.In an advantageous embodiment of the invention it is provided that the openings of the second surface communicate with a vacuum / overpressure source, such as a blower, so that fibers of the fiber web located in the region of the openings are sucked into the openings or blown out of the openings . Such a blower can, on the one hand, support the non-destructive displacement of the fibers to form the perforated structures by sucking in the fibers m the openings of the second surface, on the other hand, the blown fiber web provided with the perforated structures can be blown away from the second surface, so that one possibly existing adhesion of the pile of fibers to the second surface after the hole structures have been gently lifted.
Hierbei können die Kanäle und Offnungen der Unterdruckquelle so ausgeformt und bemessen sein, daß ein Verhaken der zu verformenden bzw. umzuorietierenden Fasern, welche m die Off- nungen und Kanäle der Unterdruckquelle eingesaugt werden, sicher ausgeschlossen ist.The channels and openings of the vacuum source can be shaped and dimensioned in such a way that the fibers to be deformed or reorganized, which are sucked into the openings and channels of the vacuum source, are reliably prevented from getting caught.
In einer weiteren vorteilhaften Ausgestaltung der Erfindung ist vorgesehen, daß das erste Element eine Walze ist, wobei in praktischen Ausgestaltungen der Erfindung vorgesehen ist, daß die Walze einen Durchmesser von 100 bis 500 mm aufweist. Eine derartige Walze kann dann vorteilhaft sein, wenn eine relativ große Produktionsgeschwindigkeit ermöglicht werden soll.In a further advantageous embodiment of the invention, it is provided that the first element is a roller, with practical embodiments of the invention providing that the roller has a diameter of 100 to 500 mm. Such a roller can be advantageous if a relatively high production speed is to be made possible.
In einer alternativen Ausgestaltung der Erfindung ist vorgesehen, daß das erste Element eine sich hebende und senkende Platte ist. Eine derartige Platte, mit der sich diskontinuierlich Lochstrukturen erzeugen lassen, kann dann vorteilhaft sein, wenn die Verdrängung der Fasern langsam und vorsichtig erfolgen soll.In an alternative embodiment of the invention it is provided that the first element is a rising and falling plate. Such a plate, with which hole structures can be produced discontinuously, can be advantageous if the displacement of the fibers is to be carried out slowly and carefully.
In praktischen Ausgestaltungen der Erfindung ist vorgesehen, daß die Stacheln des ersten Elements kegelförmig sind, oder die Form einer Evolvente aufweisen, oder einen ogivalen Querschnitt aufweisen, wobei die Stacheln praktischerweise eine Hohe von 0,5 bis 5 mm aufweisen können. Man wird für die Stacheln unterschiedliche Formen, Großen und Hohen einsetzen, j e nach Anforderung an oas zu schaffende Vlies, welches ein einschichtiges oder mehrschichtiges Vlies, beispielsweise ein SMS-Vlies, oder eine Kombination aus Vlies und anderen bahn- formigen Medien sein kann.In practical embodiments of the invention it is provided that the spikes of the first element are conical, or have the shape of an involute, or have an ogival cross section, the spikes practically having a height of 0.5 to 5 mm. Different shapes, sizes and heights will be used for the spines, depending on the requirements of the fleece to be created, which can be a single-layer or multi-layer fleece, for example an SMS fleece, or a combination of fleece and other web-shaped media.
In einer weiteren praktischen Ausgestaltung der Erfindung ist vorgesehen, daß das zweite Element ein Lochband ist. Auf ein derartiges Lochband kann der zu behandelnde Faserflor aufgegeben und zum ersten Element transportiert werden, wo dann die Stacheln des ersten Elements durch der Faserflor hindurch n die Locher des Lochbandes eintauchen. Alternativ kann vorgesehen sein, daß das zweite Element eine Kalanderwalze ist. Hierbei wird also eine Kalanderwalze gleichzeitig als zweites Element benutzt. In einer weiteren praktischen Ausgestaltung der Erfindung ist vorgesehen, daß ein nach einem erfindungsgemäßen Verfahren hergestelltes Vlies Lochstrukturen mit einem Durchmesser von 0,5 bis 5 mm aufweist, daß die Bondingfläche 3 bis 40 % der Vliesfläche beträgt und daß die Anzahl der Bondingpunkte 20 bis 120 pro Quadratzentimeter beträgt. Bei einer derart gewählten Anzahl von Bondingpunkten einerseits und einem entsprechenden Durchmesser der Lochstrukturen andererseits wird gewährleistet, daß sich eine genügend große Anzahl von Bondingpunkten im Randbereich der Lochstrukturen befindet und die Lochstruktur hierdurch festgelegt wird, so daß die verdrängten Filamente um die Lochstrukturen herum nach dem Verfestigen und Thermobondieren nicht mehr in ihre ursprüngliche Lage zurückspringen können.In a further practical embodiment of the invention it is provided that the second element is a perforated tape. The fibrous web to be treated can be placed on such a perforated band and transported to the first element, where the spikes of the first element then penetrate through the fibrous web into the perforations of the perforated band. Alternatively, it can be provided that the second element is a calender roll. Here, a calender roll is used as the second element at the same time. In a further practical embodiment of the invention it is provided that a nonwoven fabric produced by a method according to the invention has hole structures with a diameter of 0.5 to 5 mm, that the bonding area is 3 to 40% of the nonwoven area and that the number of bonding points is 20 to 120 per square centimeter. With such a selected number of bonding points on the one hand and a corresponding diameter of the hole structures on the other hand, it is ensured that there is a sufficiently large number of bonding points in the edge region of the hole structures and the hole structure is thereby fixed, so that the displaced filaments around the hole structures after solidification and thermal bonding can no longer spring back to their original position.
Weitere Vorteile und Ausgestaltungen der Erfindung werden anhand von Ausführungsbeispielen in der nachfolgenden Beschreibung und der Zeichnung, sowie in den Patentansprüchen beschrieben. In der Zeichnung zeigt:Further advantages and refinements of the invention are described on the basis of exemplary embodiments in the following description and the drawing, and in the patent claims. The drawing shows:
Fig. 1 eine schematische Darstellung einer Anlage zur Durchführung des erfindungsgemäßen Verfahrens,1 shows a schematic representation of a plant for carrying out the method according to the invention,
Fig. 2 eine Detailansicht einer Lochstrukturen- Erzeugungseinheit der Anlage aus Fig. 1,FIG. 2 shows a detailed view of a hole structure generation unit of the system from FIG. 1, FIG.
Fig. 3 eine Draufsicht auf eine Lochstruktur eines mit dem erfindungsgemäßen Verfahren erzeugten Vlieses, und Fig. 4 eine alternative Ausführungsform einer3 shows a plan view of a perforated structure of a fleece produced using the method according to the invention, and Fig. 4 shows an alternative embodiment of a
Anlage zur Durchführung des erfindungsgemäßen Verfahrens von der Seite.Plant for performing the method according to the invention from the side.
In Fig. 1 ist eine erste Ausführungsform einer Anlage 10 zur Durchführung des erfindungsgemäßen Verfahrens dargestellt. Mit einer geeigneten und nur schematisch angedeuteten Einrichtung 12 wird zunächst ein Faserflor 18 aus Fasern 14 erzeugt und auf einem Siebband 16 abgelegt. Wie mit dem Pfeil A angedeutet, wird ein aus Fasern 14 bestehender Faserflor 18 zu einer Lochstruktur-Erzeugungseinheit 20 weiter transportiert. Diese Lochstruktur-Erzeugungseinheit 20 besteht aus einer Walze 22, welche mit ihrer äußeren Fläche 24, welche die erste Fläche 24 der Lochstruktur-Erzeugungseinheit 20 bildet, über einem Lochband 26 mit einer zur Walze 22 hin gerichteten Fläche 28 angeordnet. Diese Fläche 28 bildet die zweite Fläche 28 der Lochstruktur-Erzeugungseinheit 20.1 shows a first embodiment of a system 10 for carrying out the method according to the invention. With a suitable device 12, which is only indicated schematically, a fibrous web 18 is first produced from fibers 14 and placed on a screen belt 16. As indicated by arrow A, a fiber web 18 consisting of fibers 14 is transported further to a perforated structure generation unit 20. This perforated structure generating unit 20 consists of a roller 22 which, with its outer surface 24, which forms the first surface 24 of the perforated structure generating unit 20, is arranged above a perforated belt 26 with a surface 28 directed towards the roller 22. This surface 28 forms the second surface 28 of the hole structure generation unit 20.
Die Fläche 24 der Walze 22 ist mit einer Vielzahl von Stacheln 30 versehen, welche zumindest teilweise in Löcher 32 des Lochbandes 26 eintauchen können. Wie durch den Pfeil B angedeutet, dreht sich die Walze 22 gegen den Uhrzeigersinn; entsprechend der Fördergeschwindigkeit des Lochbandes 26 tauchen die Stachel 30, von denen in Fig. 1 zur Vereinfachung nur drei dargestellt sind, kontinuierlich in die Löcher 32 ein und verdrängen an dieser Stelle die Filamente 14 des Faserflors 18 aus ihrer Lage.The surface 24 of the roller 22 is provided with a multiplicity of spikes 30, which can at least partially dip into holes 32 in the perforated strip 26. As indicated by arrow B, roller 22 rotates counterclockwise; In accordance with the conveying speed of the perforated belt 26, the spikes 30, of which only three are shown in FIG. 1 for the sake of simplicity, continuously dip into the holes 32 and at this point displace the filaments 14 of the fiber pile 18 from their position.
Unterhalb des Lochbandes 26 ist eine Unterdruck-/Über- ruckquelle angeordnet, auf welche noch näher einzugehen sein wird. Nachdem der Faserflor 18 die beiden Flächen 24, 28 durchlaufen hat, gelangt der nun mit Lochstrukturen 36 versehene Faserflor 18 weiter zu einer Verfestigungseinheit 38. Diese Verfestigungseinheit 38 besteht gemäß der Anordnung 10 aus Fig. 1 aus zwei Kalanderwalzen 40, 42. Durch die Kalanderwalzen 40, 42 wird der Faserflor 18 durch thermisches Bondieren verfestigt, so daß das fertige Vlies 44 die Kalanderwalzen 40, 42 verläßt.A vacuum / pressure source is arranged below the perforated tape 26, which will be discussed in more detail below. After the fibrous web 18 has passed through the two surfaces 24, 28, the fibrous web 18, which is now provided with perforated structures 36, continues to a consolidation unit 38. According to the arrangement 10 from FIG. 1, this consolidation unit 38 consists of two calender rolls 40, 42. Through the calender rolls 40, 42, the fiber web 18 is solidified by thermal bonding, so that the finished fleece 44 leaves the calender rolls 40, 42.
In Fig. 2 ist die Lochstruktur-Erzeugungseinheit 20 im gegenüber Fig. 1 stark vergrößerten Maßstab im Detail dargestellt. Wie durch die Pfeile C angedeutet, wird durch die Unterdruck- /Überdruckquelle 34 ein Unterdruck erzeugt, wodurch die über dem Loch 32 des Lochbandes 26 befindlichen Filamente 14 des Faserflors 18 in das Loch 32 eingesaugt werden. Hierdurch entsteht eine Art Mulde, durch welche es dem Stachel 30 der Walze 22 erleichtert wird, derart durch den Faserflor 18 in das Loch 32 einzutauchen, daß die Filamente 14 des Faserflors 18 nicht zerstört, sondern im Bereich des zu bildenden Loches 32 nur verdrängt bzw. umorientiert werden.FIG. 2 shows the hole structure generation unit 20 in detail on a greatly enlarged scale compared to FIG. 1. As indicated by the arrows C, a negative pressure is generated by the negative pressure / positive pressure source 34, as a result of which the filaments 14 of the fibrous web 18 located above the hole 32 of the perforated band 26 are sucked into the hole 32. This creates a kind of trough through which it is made easier for the spike 30 of the roller 22 to dip through the fiber web 18 into the hole 32 in such a way that the filaments 14 of the fiber web 18 are not destroyed, but rather only displaced in the region of the hole 32 to be formed to be reoriented.
Um nach der Erzeugung der Lochstruktur 36 der Faserflor 18 leichter vom Lochband 26 abziehen zu können, ist es möglich, einen Überdruck zu erzeugen, so daß die in ein Loch 32 des Lochbandes 26 hineinhängenden Filamente wieder angehoben werden, so daß die Filamente 14 beim Abziehen des Faserflors 18 vom Lochband 28 nicht gegen eine Kante 46 des Loches 32 stoßen können.In order to be able to pull off the fibrous web 18 more easily from the perforated belt 26 after the perforated structure 36 has been produced, it is possible to generate an excess pressure, so that the filaments hanging into a hole 32 in the perforated belt 26 are raised again, so that the filaments 14 are pulled off of the batt 18 from the perforated tape 28 cannot abut against an edge 46 of the hole 32.
In Fig. 3 ist beispielhaft eine Lochstruktur 36 eines durch das erfindungsgemäße Verfahren geschaffenen Vlieses 44 im Detail dargestellt. Wie zu erkennen, weist das Vlies 44 eine Vielzahl von durch die Kalanderwalzen 40, 42 geschaffene Bon- dingpunkte 48 auf, welche gleichmäßig über die gesamte Flache des Vlieses 44 verteilt sind. Durch entsprechende Große, Anzahl und Verteilung der Bondingpunkte ist es möglich, daß die Lochstruktur 36 m genügendem Maße auch in ihrem Randbereich 50 mit Bondingpunkten versehen ist, so daß die Lochstruktur 36 durch die Bondingpunkte 48 stabilisiert wird.3 shows an example of a hole structure 36 of a fleece 44 created by the method according to the invention in detail. As can be seen, the fleece 44 has a multiplicity of receptacles created by the calender rolls 40, 42 Thing points 48, which are evenly distributed over the entire surface of the fleece 44. Due to the corresponding size, number and distribution of the bonding points, it is possible that the hole structure 36 m is also provided with bonding points to a sufficient extent in its edge area 50, so that the hole structure 36 is stabilized by the bonding points 48.
In Fig. 4 ist ein Teilbereich einer zweiten Ausfuhrungsform einer Anlage 10a zur Durchfuhrung des erfmdungsgemaßen Verfahrens dargestellt. Auch hier weist die Lochstruktur- Erzeugungseinheit 20a eine Walze 22 entsprechend der Walze 22 aus Fig. 1 auf. Die zweite Flache 28a ist hier aber die Außenflache der Kalanderwalze 40a. Entsprechend ist die Flache 28a der Kalanderwalze 40a mit Lochern 32a versehen, welche Stachel 30 der Walze 22 eintauchen können. Auch die Locher 32a sind mit einer nicht naher dargestellten Unterdruckquelle verbunden.4 shows a partial area of a second embodiment of a system 10a for carrying out the method according to the invention. Here, too, the hole structure generation unit 20a has a roller 22 corresponding to the roller 22 from FIG. 1. Here, however, the second surface 28a is the outer surface of the calender roller 40a. Correspondingly, the surface 28a of the calender roll 40a is provided with holes 32a, which spikes 30 of the roll 22 can dip into. The holes 32a are also connected to a vacuum source, not shown in detail.
Durch die m Fig. 4 dargestellte Anordnung 10a ist es möglich, auf ein Lochband 26 zu verzichten und den Transportweg von der Lochstruktur-Erzeugungsemheit 20a zu der Verfesti- gungsemheit 38a gegenüber der in Fig. 1 dargestellten Anordnung 10 zu verkurzen. The arrangement 10a shown in FIG. 4 makes it possible to dispense with a perforated belt 26 and to shorten the transport path from the perforated structure generation unit 20a to the consolidation unit 38a compared to the arrangement 10 shown in FIG. 1.

Claims

P a t e n t a n s p r ü c h e Patent claims
1. Verfahren zur Herstellung eines Vlieses (44) aus Fasern (14) mit einer Vielzahl von sich über den gesamten Querschnitt des Vlieses (44) erstreckenden Lochstrukturen (36), bei dem:1. A method for producing a fleece (44) from fibers (14) with a plurality of perforated structures (36) extending over the entire cross section of the fleece (44), in which:
in einem ersten Schritt die Fasern (14) wirr auf einem Siebband (16) zu einem Faserflor (18) abgelegt werden, in einem zweiten Schritt der Faserflor (18) zu einer Lochstruktur-Erzeugungseinheit (20; 20a) transportiert wird, in einem dritten Schritt die Lochstrukturen (36) durch eine mechanische Verdrängung der Fasern (14) erzeugt werden, wobei die Verdrängung der Fasern (14) deren mechanische und chemische Struktur unbeeinflußt läßt, undin a first step the fibers (14) are deposited in a tangled manner on a wire belt (16) to form a fiber web (18), in a second step the fiber web (18) is transported to a perforated structure generation unit (20; 20a), in a third Step the hole structures (36) are generated by mechanical displacement of the fibers (14), the displacement of the fibers (14) leaving their mechanical and chemical structure unaffected, and
in einem vierten Schritt der mit den Lochstrukturen (36) versehene Faserflor (18) in einer Verfestigungseinheit (38; 38a) zu einem Vlies (44) verfestigt wird.in a fourth step, the fiber web (18) provided with the perforated structures (36) is consolidated in a consolidation unit (38; 38a) to form a fleece (44).
2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß der Faserflor (18) in der Verfestigungseinheit (38;38a) durch Verfestigung und Thermobondierung zum Vlies (44) umgewandelt wird. 2. The method according to claim 1, characterized in that the fibrous web (18) in the consolidation unit (38; 38a) is converted by bonding and thermal bonding to the nonwoven (44).
3. Verfahren nach Anspruch 2, dadurch gekennzeichnet, daß vor dem dritten Schritt der Faserflor (18) vorverfestigt wird, dergestalt, daß die Zugfestigkeit des vorverfestigten Faserflors (18) 0,1 bis 75 %, insbesondere bis 50 % der Zugfestigkeit des verfestigten Vlieses (44) entspricht.3. The method according to claim 2, characterized in that before the third step of the fibrous web (18) is pre-consolidated such that the tensile strength of the pre-consolidated fibrous web (18) 0.1 to 75%, in particular up to 50% of the tensile strength of the consolidated nonwoven (44) corresponds.
4. Verfahren nach einem der Ansprüche 1 - 3, dadurch gekennzeichnet, daß die die Lochstrukturen (36) umgebenden Fasern (14) vor dem Zuführen des Faserflors (18) zur Verfestigungseinheit (38; 38a) fixiert werden.4. The method according to any one of claims 1-3, characterized in that the fibers (14) surrounding the hole structures (36) are fixed before the supply of the fibrous web (18) to the consolidation unit (38; 38a).
5. Verfahren nach Anspruch 1 - 4, dadurch gekennzeichnet, daß der Faserflor (18) nach Erzeugung der Lochstruktur (36) unmittelbar der Verfestigungseinheit (38; 38a) zugeführt wird.5. The method according to claim 1-4, characterized in that the fibrous web (18) after generation of the perforated structure (36) is fed directly to the consolidation unit (38; 38a).
6. Verfahren nach Anspruch 5, dadurch gekennzeichnet, daß mit der Lochstruktur-Erzeugungseinheit (20; 20a) im direkten Anschluß an den dritten Verfahrensschritt der vierte Verfahrensschritt durchgeführt wird.6. The method according to claim 5, characterized in that the fourth method step is carried out with the hole structure generating unit (20; 20a) in direct connection to the third method step.
7. Verfahren nach einem der Ansprüche 1 bis 6, dadurch gekennzeichnet, daß die Lochstruktur-Erzeugungseinheit (20; 20a) zwei Elemente (22, 26; 40a) mit zueinander hin gerichteten Flächen (24, 28; 28a) aufweist, zwischen denen der Faserflor (18) hindurchgeführt wird, wobei die Fläche (24) eines ersten Elements (22) eine Vielzahl von zum Faserflor (18) hin gerichteten Stacheln (30) aufweist, und wobei die Fläche (28; 28a) eines zweiten Elements (26; 40a) Öffnungen (32, 32a) aufweist, in welche die Stacheln (30) der ersten Fläche (24) zumindest teilweise eintauchen können, wobei die unterhalb der Stacheln (30) befindlichen Fasern (14) des Faserflors (18) beim Eintauchen der Stacheln (30) in die Öffnungen (32; 32a) zerstörungsfrei verdrangt und die Lochstrukturen (36) gebildet werden.7. The method according to any one of claims 1 to 6, characterized in that the hole structure generating unit (20; 20a) has two elements (22, 26; 40a) with mutually facing surfaces (24, 28; 28a), between which the Fiber web (18) is passed through, the surface (24) of a first element (22) having a plurality of spikes (30) directed towards the fiber web (18), and the surface (28; 28a) of a second element (26; 40a) has openings (32, 32a) into which the spikes (30) of the first surface (24) can at least partially dip, the fibers (14) of the fibrous web (18) located below the spikes (30) when the spikes are immersed (30) into the openings (32; 32a) is displaced non-destructively and the hole structures (36) are formed.
8. Verfahren nach Anspruch 7, dadurch gekennzeichnet, daß die Offnungen (32; 32a) der zweiten Flache (28; 28a) mit einer Unterdruckquelle (34), wie einem Geblase, kommunizieren, so daß im Bereich der Offnungen (32; 32a) befindliche Fasern (14) des Faserflors (18) in die Offnungen (32; 32a) eingesaugt werden.8. The method according to claim 7, characterized in that the openings (32; 32a) of the second surface (28; 28a) communicate with a vacuum source (34), such as a blower, so that in the region of the openings (32; 32a) located fibers (14) of the fiber pile (18) are sucked into the openings (32; 32a).
9. Verfahren nach Anspruch 7, dadurch gekennzeichnet, daß die Offnungen (32; 32a) der zweiten Flache (28; 28a) mit einer Uberdruc quelle (34), wie einem Geblase, kommunizieren, so daß im Bereich der Offnungen (32; 32a) befindliche Fasern (14) des Faserflors (18) aus den Offnungen (32; 32a) ausgeblasen werden.9. The method according to claim 7, characterized in that the openings (32; 32a) of the second surface (28; 28a) with an overpressure source (34), such as a blower, communicate, so that in the region of the openings (32; 32a ) fibers (14) of the fibrous web (18) are blown out of the openings (32; 32a).
10. Verfahren nach Anspruch 7 bis 9, dadurch gekennzeichnet, daß das erste Element (22) eine Walze (22) ist.10. The method according to claim 7 to 9, characterized in that the first element (22) is a roller (22).
11. Verfahren nach Anspruch 10, dadurch gekennzeichnet, daß die Walze (22) einen Durchmesser von 100 bis 500 mm aufweist.11. The method according to claim 10, characterized in that the roller (22) has a diameter of 100 to 500 mm.
12. Verfahren nach Anspruch 7 und 8, dadurch gekennzeichnet, daß das erste Element (22) eine sich hebende und senkende Platte ist.12. The method according to claim 7 and 8, characterized in that the first element (22) is a rising and falling plate.
13. Verfahren nach einem der Ansprüche 7 bis 12, dadurch ge- kennzeichnet, daß die Stacheln (30) des ersten Elements (22) kegelförmig sind. 13. The method according to any one of claims 7 to 12, characterized in that the spikes (30) of the first element (22) are conical.
14. Verfahren nach einem der Ansprüche 7 bis 12, dadurch gekennzeichnet, daß die Stacheln (30) die Form einer Evolvente aufweisen.14. The method according to any one of claims 7 to 12, characterized in that the spikes (30) have the shape of an involute.
15. Verfahren nach einem der Ansprüche 7 bis 12, dadurch gekennzeiohnet, daß die Stacheln (30) jeweils einen ogivalen Querschnitt aufweisen.15. The method according to any one of claims 7 to 12, characterized gekennzeiohnet that the spikes (30) each have an ogival cross section.
16. Verfahren nach einem der Ansprüche 7 bis 15, dadurch ge- kennzeichnet, daß die Stacheln eine Höhe von 0,5 bis 5 mm aufweisen.16. The method according to any one of claims 7 to 15, characterized in that the spines have a height of 0.5 to 5 mm.
17. Verfahren nach einem der Ansprüche 7 bis 16, dadurch gekennzeichnet, daß das zweite Element (26) ein Lochband (26) ist.17. The method according to any one of claims 7 to 16, characterized in that the second element (26) is a perforated tape (26).
18. Verfahren nach einem der Ansprüche 7 bis 16, dadurch gekennzeichnet, daß das zweite Element (40a) eine Kalanderwalze18. The method according to any one of claims 7 to 16, characterized in that the second element (40a) is a calender roll
(40a) ist.(40a) is.
19. Nach einem Verfahren gemäß einem der Ansprüche 1 bis 18 hergestelltes Vlies (44), dadurch gekennzeichnet, daß die19. A fleece (44) produced by a method according to one of claims 1 to 18, characterized in that the
Lochstrukturen (36) einen Durchmesser von 0,5 bis 5 mm aufweisen.Hole structures (36) have a diameter of 0.5 to 5 mm.
20. Vlies nach Anspruch 19, dadurch gekennzeichnet, daß die20. Nonwoven according to claim 19, characterized in that the
Bondingfläche 3 bis 40 % der Vliesfläche beträgt.Bonding area is 3 to 40% of the nonwoven area.
21. Vlies nach Anspruch 19 oder 20, dadurch gekennzeichnet, daß die Anzahl der Bondingpunkte (48) 20 bis 120 pro Quadratzentimeter beträgt. 21. Nonwoven according to claim 19 or 20, characterized in that the number of bonding points (48) is 20 to 120 per square centimeter.
22. Vlies nach einem der Ansprüche 19 bis 21, dadurch gekennzeichnet, daß die Form der Lochstrukturen (36) von einer Kreisform abweicht.22. Fleece according to one of claims 19 to 21, characterized in that the shape of the hole structures (36) deviates from a circular shape.
23. Vlies nach einem der Ansprüche 19 bis 22, dadurch gekennzeichn , daß der Abstand einzelner Lochstrukturen (36) zueinander unregelmäßig ist.23. Fleece according to one of claims 19 to 22, characterized in that the distance between individual hole structures (36) is irregular to one another.
24. Nach einem Verfahren gemäß einem der Ansprüche 1 bis 23 hergestelltes Vlies (44), dadurch gekennzeichnet, daß der Faserflor (18) vor dem Erzeugen der Lochstrukturen (36) mit wenigstens einem weiteren bahnför igen Medium verbunden wird.24. Nonwoven fabric (44) produced by a method according to one of claims 1 to 23, characterized in that the fibrous web (18) is connected to at least one further web-shaped medium before the perforated structures (36) are produced.
BERICHTIGTES BLATT (REGEL 91) ISA/EP CORRECTED SHEET (RULE 91) ISA / EP
EP99939910A 1998-06-20 1999-06-18 Method for producing a non-woven fibre fabric Expired - Lifetime EP1092054B1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE19827567 1998-06-20
DE19827567A DE19827567A1 (en) 1998-06-20 1998-06-20 Prodn of perforated nonwoven fabrics for sanitary articles
PCT/DE1999/001793 WO1999067454A2 (en) 1998-06-20 1999-06-18 Method for producing a non-woven fibre fabric

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EP1092054A2 true EP1092054A2 (en) 2001-04-18
EP1092054B1 EP1092054B1 (en) 2002-11-13

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US (1) US6750166B1 (en)
EP (1) EP1092054B1 (en)
AU (1) AU5406599A (en)
DE (2) DE19827567A1 (en)
WO (1) WO1999067454A2 (en)

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Also Published As

Publication number Publication date
DE59903412D1 (en) 2002-12-19
DE19827567A1 (en) 1999-12-23
WO1999067454A2 (en) 1999-12-29
AU5406599A (en) 2000-01-10
US6750166B1 (en) 2004-06-15
WO1999067454A3 (en) 2000-03-09
EP1092054B1 (en) 2002-11-13

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