EP1192306B1 - Method for producing a nonwoven material, installation therefor and resulting nonwoven - Google Patents

Method for producing a nonwoven material, installation therefor and resulting nonwoven

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Publication number
EP1192306B1
EP1192306B1 EP00931356A EP00931356A EP1192306B1 EP 1192306 B1 EP1192306 B1 EP 1192306B1 EP 00931356 A EP00931356 A EP 00931356A EP 00931356 A EP00931356 A EP 00931356A EP 1192306 B1 EP1192306 B1 EP 1192306B1
Authority
EP
European Patent Office
Prior art keywords
web
spunbond
fibres
sheet
filaments
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 - Lifetime
Application number
EP00931356A
Other languages
German (de)
French (fr)
Other versions
EP1192306A1 (en
Inventor
André Vuillaume
Frédéric NOELLE
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.)
Rieter Perfojet SAS
Original Assignee
Rieter Perfojet SAS
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Filing date
Publication date
Application filed by Rieter Perfojet SAS filed Critical Rieter Perfojet SAS
Publication of EP1192306A1 publication Critical patent/EP1192306A1/en
Application granted granted Critical
Publication of EP1192306B1 publication Critical patent/EP1192306B1/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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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
    • D04H1/42—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 characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/425—Cellulose series
    • D04H1/4258—Regenerated cellulose series
    • 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
    • D04H1/42—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 characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4374—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 characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece using different kinds of webs, e.g. by layering webs
    • 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
    • D04H1/44—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/492—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet
    • 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
    • D04H1/44—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/498—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres entanglement of layered webs
    • 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
    • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
    • D04H1/74—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being orientated, e.g. in parallel (anisotropic fleeces)
    • 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
    • D04H18/00—Needling machines
    • D04H18/04—Needling machines with water jets
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/005—Synthetic yarns or filaments
    • D04H3/007—Addition polymers
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/10—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically
    • D04H3/11—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically by fluid jet
    • 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
    • D04H5/00—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
    • D04H5/02—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by mechanical methods, e.g. needling
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H5/00—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
    • D04H5/02—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by mechanical methods, e.g. needling
    • D04H5/03—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by mechanical methods, e.g. needling by fluid jet
    • 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
    • D04H5/00—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
    • D04H5/08—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of fibres or yarns

Definitions

  • the present invention relates to an improvement made to the technology making it possible to produce such spunbond nonwoven webs and relates more specifically to a method, an installation and a new type of product obtained by the use of these means, a product having the appearance and properties such as touch, mechanical characteristics, flexibility, close to a conventional textile, including fabric.
  • the web is consolidated, for example by performing a calibration or calendering, preferably hot, so that the elementary filaments are bonded to each other.
  • Such treatments are frequently used when it is desired to produce complexes consisting of a superposition of discontinuous fibrous webs optionally comprising an internal reinforcement, such as a fabric, knitted fabric, unidirectional or bidirectional web consisting of one or more sets of yarns. parallel or not.
  • pressing is carried out by compaction of the assembly consisting of the superposition of the layer or layers of discontinuous fibers which cover or imprison between them the "spunbond" tablecloth produced.
  • Such compaction which can be achieved by any suitable means, such as in particular by means of a pressure roller, can in no way be likened to a calendering operation since it is made cold.
  • a single staple fiber veil can be associated with the web to the "spunbond" type web, said staple fiber web being able to be delivered upstream of the "spunbond” formation zone and being brought on the conveyor belt on which are deposited the filaments from the "spunbond” installation, filaments which are therefore distributed on the surface of this web, or, delivered downstream of the continuous filament web formation zone.
  • the spunbond-type sheet is covered on both sides by a veil of staple fibers, produced one upstream of the formation zone of the "spunbond” veil, the other in downstream, the web of continuous filaments being thus trapped sandwiched between the two layers of staple fibers.
  • the complex thus formed of three layers is, after compacting by pressing, transferred, always continuously, on a binding treatment line by means of water jets, jets which act successively against the surfaces of said complexes.
  • a binding treatment line by means of water jets, jets which act successively against the surfaces of said complexes.
  • the invention also relates to an installation for the continuous implementation of the aforementioned method.
  • such an installation comprises, between the water jetting means and the drying means, a set of textile producing jets reorienting the fibers.
  • the article obtained is characterized in that the continuous filaments which compose it are associated with discontinuous fibers, fibers which cover the web based on continuous filaments and penetrate inside this layer. last by binding around said filaments.
  • Such a product retains all the mechanical strength characteristics of conventional spunbond webs whose cohesion is given by a calendering treatment, the product obtained also having the appearance and properties such as touch, flexibility comparable to a conventional textile.
  • the staple fibers which are associated with the spunbond web can be of any type, natural or chemical, hydrophobic or hydrophilic, and this, depending on the applications for which the product is intended, the length of said fibers being between 5 mm and 60 mm and their titre between 0.8 dtex and 6.6 dtex.
  • basis weight of the staple fiber fleece (s) which are associated with the spunbond web may vary according to the applications, but will advantageously be between 10 g / m 2 and 50 g / m 2, a tablecloth having a lower grammage at 10 g / m2 not allowing to obtain a proper binding of the spunbond web, while a web greater than 50 g / m2 reduces the economic interest of the process.
  • the invention therefore relates to a method and an installation which makes it possible to continuously produce a new type of "spunbond" plies consisting of continuous synthetic filaments, plies which not only retain the properties of mechanical strength ( elongation, tensile strength, tearing resistance ...), equivalent to conventional "hot” calendered “spunbond” plies, which, moreover, have the appearance, feel and flexibility of a conventional textile such as than a fabric.
  • a spunbond-type nonwoven web is produced according to the conventional technique of extruding a molten organic polymer through a die (2). piercing holes so as to form a bundle or curtain of filaments (3).
  • the extruded filaments (3) After cooling, to obtain the at least superficial solidification of the extruded filaments (3), they are oriented and stretched by means of one or more devices (4) with fluid jets at the exit of which they are distributed on a receiving surface in the form of a web (S).
  • the "spunbond" web (S) is not received directly on the surface of a conveyor belt (5) subjected to a suction source, but on a web (V1) of fibers discontinuous - natural and / or artificial and / or synthetic - produced immediately upstream of the spunbond plant (1).
  • This web (V1) is for example made by means of a conventional assembly (6) consisting of a card associated possibly with a spreader spreader assembly, the web (V1) produced being delivered to the conveyor belt (5).
  • the two textile layers (V1) and (S) superimposed then pass, still being maintained on the conveyor belt (5), on a first assembly (8), consisting for example of two cylinders to ensure compaction.
  • a second assembly (9), such as a card or other equivalent installation is delivered to the surface of the spunbond web (S), a second web (V2) of staple fibers, the three textile layers superposed elementary elements (V1, S and V2) being compacted again by pressing between two cylinders (8).
  • the compacted assembly is then brought to a treatment line, illustrated in more detail in FIG. 2, designated by the general reference (10) making it possible to subject said complex to a binding treatment by means of jet jets. water, acting successively against both surfaces of said complex.
  • a treatment line illustrated in more detail in FIG. 2, designated by the general reference (10) making it possible to subject said complex to a binding treatment by means of jet jets. water, acting successively against both surfaces of said complex.
  • such a treatment unit (10) consists of a hydraulic binding unit of the " Jetlace 2000 " type marketed by the Applicant and implementing the teachings of FR-A-2 730 246 (US Pat. A-5,718,022), and FR-A-2,734,285 (US-A-5,768,756) in the name of the Applicant.
  • Such a binding unit consists essentially of a conveyor (11) on which the fibrous structure constituted by the three superimposed layers (V1, S and V2) is transferred.
  • the structure is compacted between the conveyor (11) and a first suction cylinder (12), preferably coated with a microperforated envelope, the holes of which are arranged randomly as described in FIG. French Patent 2,734,285.
  • this cylinder may be coated with a wire mesh.
  • the complex web (V1 / S / V2), designated in the rest of the description by the reference (N), can receiving a first wetting treatment, by means of a ramp (13), shown in dashed lines in Figure 2, and which delivers a water curtain which passes through the conveyor belt (11) and the superimposed sheets.
  • the compacted complex supported by the suction drum (12), is then subjected to the action of jets of water coming from an injector (14), the jets thus acting against the surface constituted by the fibrous web (V1) and causing the fibers that constitute the veil inside the complex.
  • the ramp or injector (14) arranged parallel to a generatrix of the cylinder (12), is a conventional ramp which makes it possible to create jets or water needles having a diameter of 100 to 170 microns, the jets being spaced from each other between 0.5 and 2.2 mm, the supply pressure itself between 50 and 150 bar depending on the grammage of the complex.
  • the treated complex is brought to the surface of a second cylinder (15) identical to the preceding suction cylinder, associated with one or two series of injectors (16, 17) delivering jets of water which therefore act on the face of the web (N) constituted by the web (V2).
  • the ramps (16, 17) create jets or water needles having a diameter of 100 to 170 microns, said jets being spaced as previously from each other between 0.5 and 2.4 mm, and the supply pressure being between 50 bars and 400 bars.
  • the action of the injectors (16, 17) thus makes it possible to drive the fibers of the web V1 into the thickness of the web (N), said fibers surrounding the continuous filaments and binding thereto.
  • the bonded spun web designated by reference (18) can be directly fed to the drying assembly (19) by passing it over a conventional heating drum (26) before being received.
  • a third hydraulic bonding treatment can be achieved by means of a third suction drum (20) associated with a nozzle ramp (21), whose jets act against the face which was constituted by the veil (V1).
  • Such a treatment consists, as is more particularly apparent from FIG. 2, in transferring the bonded "spun" sheet (18) to an assembly produced for example in accordance with the teachings of patent EP 059 608.
  • such an assembly is constituted by a conveyor belt (22), of the "Fourdrinier” type, used in the paper industry.
  • the bound spun (18) held on this fabric is subjected to the action of a series of water jets obtained via a ramp (23) projecting a curtain of water against the internal surface of a perforated rotary cylinder (24), these jets reorienting the fibers.
  • a suction assembly (25) for the removal of water is of course provided below the conveyor (22).
  • This example uses the realization of a complex in which the "spunbond" web is trapped between two staple fiber webs.
  • V1 a fiber web (V1) weighing 30 g / m 2 and made of 100% viscose fibers of 1.7 dtex and 38 mm in length is produced.
  • This veil is produced at a speed of 100 m / minute.
  • the web (V1) is transferred to the receiving belt (5) of the installation (1) for producing a web (S) of the "spunbond" type.
  • the "spunbond" sheet produced is obtained from polypropylene and is distributed over the web (V1) so as to form a web consisting of filaments having a title of 1.7 dtex, weighing 40 g / m 2 .
  • the two superimposed layers (V1) and (S) are compressed by means of a pressure roller (8) and a second fiber web (V2) reproduced in a manner similar to the web (V1), weighing 30 g / m 2 , is delivered to the surface of the "spunbond" (S), the superposed layers then being subjected to a new compaction also by means of a pressure roller.
  • the complex formed is fed to a treatment line comprising a hydraulic binding unit (10) of the "Jetlace 2000" type marketed by the Applicant.
  • Such an installation essentially comprises a conveyor belt (11), and three jet treatment units comprising suction cylinders (12, 15, 20) having a diameter of 516 mm and coated with a microperforated envelope whose holes are distributed in a manner as described in French Pat. No. 2,634,285.
  • suction drums (12,15,20) To these suction drums (12,15,20) are associated ramps injectors (14, 16, 17, 21) which act against the surfaces of the complex (N) constituted by the superposition of the web (V1) of the spunbond (S) and the web (V2).
  • the ramps (14,16,17,21) all produce 1,666 jets per meter and are adjusted in the following manner.
  • Downstream of the last hydraulic binding system (20) is a textile assembly consisting of a conveyor belt (22) made of a polyester fabric, associated with a textilisation assembly itself, comprising a rotary perforated drum (24). inside which is disposed an injector (23) supplied with water at 150 bar.
  • This injector (23) produces jets of water of 130 microns in diameter which reorient the fibers. Water from the injector (23) is recovered by means of the suction assembly (25) disposed below the conveyor (22).
  • This sheet is perfectly bonded and has great flexibility, touch, appearance and mechanical characteristics comparable to a traditional textile equivalent weight obtained with fibers of the same nature.
  • This example illustrates the implementation of the method according to the invention for producing a structure composed of a "spunbond” type sheet associated with a single fibrous sheet which, in this embodiment, is formed upstream of the formation zone of the "spunbond” tablecloth.
  • the procedure is as follows.
  • V1 a web of fibers (V1) weighing 20 g / m 2 and made of 100% viscose fibers of 1.7 dtex and 38 mm in length is made.
  • This veil is produced at a speed of 150 m / min.
  • the web (V1) is transferred to the receiving mat (5) of the spunbond unit.
  • a spunbond web (S) made of polypropylene filaments is deposited on the web (V1).
  • This spunbond web of 25 g / m 2 consists of 2 dtex filaments.
  • the two superimposed layers (V1) and (S) are compressed by means of a pressure roller (8) thus forming a complex of 45 g / m 2 which is transferred continuously to a hydraulic bonding unit (10) of the "Jetlace” type. 2000 "marketed by the Applicant.
  • This installation comprises a conveyor belt (11) and two water jet treatment units consisting of suction cylinders (12) and (15) followed by a final conveyor (22) on which is arranged a patterning / textilisation device.
  • the two cylinders (12) and (15) are covered with a microperforated envelope whose holes are arranged in a random manner as described in French Patent 2,634,285.
  • the injectors produce all 1666 water jets of 120 microns per meter and the water pressure in these injectors is respectively 60, 80 and 110 bar.
  • the textilisation of the bound complex on the preceding cylinders is carried out by a perforated drum (23) as described in the preceding example, the injector of which is supplied with a water pressure of 80 bar.
  • the final product of 45 g / m 2 has excellent mechanical properties, superior to those of a spunlace veil made of fibers of the same kind.
  • the appearance and flexibility of the veil are also remarkable, far superior to those of a spunbond polypropylene or polyester equivalent weight bonded by calendering.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Manufacturing Of Multi-Layer Textile Fabrics (AREA)

Abstract

This invention concerns a method and an installation for producing a spunbonded fabric, characterized in that it consists in: producing a spunbonded lap (5) against the surface of which is delivered at least a web (V1 and/or V2) of discontinuous fibers, obtained by carding. The formed complex is compacted by pressing and is continuously transferred onto a line (10) for water jet binding treatment, driving the fibers in the direction of thickness, the fibers which are bound together like a splice between and around the continuous filaments while remaining visible at the surface. After drying, the final product is obtained.

Description

Domaine TechniqueTechnical area

Depuis des décennies, il a été proposé de remplacer des nappes textiles traditionnelles (tissus, tricots) par des structures dites « non-tissés » qui, d'une manière générale, peuvent être classées en trois grandes catégories, résultant de leur processus même de fabrication, à savoir :

  • _ les non-tissés dits par « voie humide » produits selon une technologie proche de la fabrication du papier ;
  • _ les non-tissés dits par « voie sèche » constitués de fibres discontinues, naturelles ou chimiques, obtenues par cardage, nappage ou tout autre matériel de préparation textile ;
  • _ les non-tissés dits par « voie fondue » constitués de filaments chimiques continus et couramment désignés sous le nom générique de « spunbond ».
For decades, it has been proposed to replace traditional textile fabrics (fabrics, knits) with so-called "non-woven" structures which, in general, can be classified in three broad categories, resulting from their very process of manufacture, namely:
  • nonwovens called "wet" produced by a technology close to the manufacture of paper;
  • "non-woven" so-called "dry process" consisting of staple fibers, natural or chemical, obtained by carding, glazing or any other textile preparation material;
  • _ nonwovens called "melted" consist of continuous chemical filaments and commonly referred to under the generic name of "spunbond".

La présente invention concerne un perfectionnement apporté à la technologie permettant de réaliser de telles nappes non tissées de type « spunbond » et concerne plus spécifiquement un procédé, une installation et un nouveau type de produit obtenu par la mise en oeuvre de ces moyens, produit ayant l'aspect et les propriétés tels que toucher, caractéristiques mécaniques, souplesse, proches d'un textile conventionnel, tissu notamment.The present invention relates to an improvement made to the technology making it possible to produce such spunbond nonwoven webs and relates more specifically to a method, an installation and a new type of product obtained by the use of these means, a product having the appearance and properties such as touch, mechanical characteristics, flexibility, close to a conventional textile, including fabric.

Techniques antérieuresPrevious techniques

La production de nappes non-tissés de type « spunbond » remonte à des décennies comme cela ressort notamment des brevets GB-A-932 482, US-A-3 286 896 qui sont parmi les documents les plus anciens la décrivant.The production of spunbond-type nonwoven webs goes back decades, as can be seen in particular from patents GB-A-932 482 and US-A-3,286,896, which are among the oldest documents describing it.

D'une manière générale, une telle technique consiste :

  • _ à extruder un polymère organique fondu, voire même dissout, à travers une filière percée de trous, de manière à former un faisceau ou rideau de filaments ;
  • _ puis, à orienter les filaments extrudés par étirage au moyen d'un ou plusieurs dispositifs à jets de fluide, notamment à air comprimé,
  • _ et enfin, à recevoir le faisceau de filaments sous la forme d'une nappe sur un tapis transporteur mobile, en général soumis à une source d'aspiration, et dont la vitesse est réglée en fonction des caractéristiques que l'on souhaite obtenir, grammage notamment.
In general, such a technique consists of:
  • extruding a molten organic polymer, or even dissolved, through a die pierced with holes, so as to form a bundle or curtain of filaments;
  • and then, directing the extruded filaments by stretching by means of one or more fluid jet devices, in particular with compressed air,
  • and finally, receiving the bundle of filaments in the form of a sheet on a moving conveyor belt, generally subjected to a suction source, and whose speed is adjusted according to the characteristics that it is desired to obtain, grammage in particular.

Après réalisation, et en général en continu, la nappe est consolidée, par exemple en effectuant un calibrage ou un calandrage, de préférence à chaud, de sorte que les filaments élémentaires soient liés les uns aux autres.After completion, and generally continuously, the web is consolidated, for example by performing a calibration or calendering, preferably hot, so that the elementary filaments are bonded to each other.

Par suite, de tels non-tissés « spunbond », qui présentent de très bonnes caractéristiques mécaniques équivalentes à des tissus conventionnels, ont trouvé un large développement dans de nombreux secteurs techniques, par exemple en vue de les utiliser comme substrats d'enduction, éléments de renfort de complexes employés notamment pour réaliser des stratifiés, des produits techniques tels que revêtements d'étanchéité, comme couches anti-contaminantes dans le domaine des travaux publics, pour de nombreuses applications en tant que géotextiles....As a result, such "spunbond" nonwovens, which have very good mechanical properties equivalent to conventional fabrics, have found a wide development in many technical sectors, for example in order to use them as coating substrates, elements reinforcement of complexes used especially for making laminates, technical products such as waterproofing coatings, as anti-contaminating layers in the field of public works, for many applications as geotextiles ....

En revanche, leur utilisation dans le domaine des applications textiles conventionnelles, tel qu'habillement, vêtements à jeter, matériaux d'essuyage, ameublement, textiles d'intérieur..., ne s'est pas développée, car une liaison par calandrage, qui entraîne une thermofusion partielle des fibres, sans détériorer les caractéristiques mécaniques du produit, détruit en revanche la souplesse, le toucher et l'aspect textile.On the other hand, their use in the field of conventional textile applications, such as clothing, disposable garments, wiping materials, furniture, interior textiles, has not developed, because a connection by calendering, which causes a partial thermofusion of the fibers, without deteriorating the mechanical characteristics of the product, destroys on the other hand the suppleness, the touch and the textile aspect.

Dans le cadre de la consolidation des nappes « spunbond », outre un traitement par calibrage ou calandrage tel que précité, il a également été envisagé de faire subir à de telles nappes un traitement d'aiguilletage, soit conventionnel au moyen d'aiguilles à barbes, soit par jets de fluide.In the context of the consolidation of "spunbond" sheets, in addition to a treatment by calibration or calendering as mentioned above, it has also been envisaged to subject such sheets to a needle-punching treatment, which is conventional using barbed needles. or by jets of fluid.

De tels traitements sont fréquemment utilisés lorsque l'on souhaite réaliser des complexes constitués d'une superposition de nappes fibreuses discontinues comportant éventuellement un renfort interne, tel qu'un tissu, tricot, nappe unidirectionnelle ou bidirectionnelle constituée d'une ou plusieurs séries de fils parallèles ou non.Such treatments are frequently used when it is desired to produce complexes consisting of a superposition of discontinuous fibrous webs optionally comprising an internal reinforcement, such as a fabric, knitted fabric, unidirectional or bidirectional web consisting of one or more sets of yarns. parallel or not.

En revanche, du moins à la connaissance du Demandeur, ces techniques d'aiguilletage n'ont jamais été proposées en vue de résoudre le problème de la consolidation d'une nappe « spunbond » en tant que telle, tout en communiquant à une telle nappe les caractéristiques de souplesse, toucher... des textiles conventionnelsOn the other hand, at least to the knowledge of the Applicant, these needling techniques have never been proposed in order to solve the problem of the consolidation of a "spunbond" sheet as such, while communicating with such a tablecloth. the features of flexibility, touch ... conventional textiles

En effet, si un traitement d'aiguilletage par aiguilles à barbes était appliqué à une nappe « spunbond » seule, cela peut entraîner une rupture des filaments continus qui constituent une telle nappe et, en conséquence, cela peut détériorer les caractéristiques mécaniques qui sont l'un des principaux avantages de tels matériaux.Indeed, if a needling treatment with barbs was applied to a "spunbond" only, this can cause a rupture of the continuous filaments which constitute such a sheet and, consequently, it can deteriorate the mechanical characteristics which are the same. one of the main advantages of such materials.

Concernant l'utilisation d'un traitement conventionnel de liage par jets de fluide, eau notamment, une telle technologie n'est pas adaptée. En effet, il est bien connu que dans de telles nappes spunbond constituées de filaments continus, ceux-ci sont difficiles à déplacer les uns par rapport aux autres. En conséquence, il est pratiquement impossible d'envisager d'obtenir avec une telle technologie une nappe « spunbond » ayant une cohésion comparable à celle que l'on obtient par calandrage, et ce, sans affecter les propriétés mécaniques du matériau.Regarding the use of a conventional treatment of binding by jets of fluid, especially water, such technology is not suitable. Indeed, it is well known that in such spunbond webs consisting of continuous filaments, they are difficult to move relative to each other. Consequently, it is practically impossible to envisage obtaining with such a technology a "spunbond" sheet having a cohesion comparable to that obtained by calendering, and without affecting the mechanical properties of the material.

Le US-A-03 8320 décrit un procédé pour la réalisation d'un matériau absorbant non-tissé qui consiste, en continu :

  • a) à réaliser une nappe de type « spunbond » (14), le faisceau de filaments continus extrudé et étiré étant réceptionné sur un tapis transporteur (12) mobile,
  • a') à faire passer la nappe de type « spunbond » entre deux rouleaux de consolidation (15, 16) afin de lier la nappe fibreuse,
  • b) à délivrer, contre au moins une face de la nappe « spunbond » (14) ainsi formée, une couche fibreuse préformée (19, 22) constituée par un mélange de fibres et de pulpe de bois obtenue par voie humide ou autre technique utilisée dans le domaine papetier et celui des non-tissés,
  • c) à faire passer le complexe ainsi formé entre les cylindres (17) et (18),
  • d) à transférer, toujours en continu, ledit complexe sur une ligne (26) de traitement de liage au moyen de jets d'eau,
  • e) à procéder à un traitement de séchage, puis à réceptionner le produit fini.
US-A-03 8320 discloses a method for producing a nonwoven absorbent material which consists, continuously:
  • a) producing a "spunbond" type ply (14), the extruded and drawn continuous filament bundle being received on a moving conveyor belt (12),
  • a ') passing the "spunbond" type web between two consolidation rolls (15, 16) to bind the fibrous web,
  • b) delivering, on at least one side of the "spunbond" web (14) thus formed, a preformed fibrous layer (19, 22) constituted by a mixture of fibers and wet-laid wood pulp or other technique used in the paper and non-woven sectors,
  • c) passing the complex thus formed between the cylinders (17) and (18),
  • d) transferring, continuously, said complex on a binding treatment line (26) by means of water jets,
  • e) carry out a drying treatment and then receive the finished product.

L'objet de la revendication 1 se distingue de l'état de la technique le plus proche en ce que

  • I) la nappe de type « spunbond » est non liée,
  • II) un voile (V1 et/ou V2) obtenu par cardage et de grammage compris entre 10 g/m2 et 50 g/m2 est délivré sur au moins une face de la nappe « spunbond »,
  • III) le complexe ainsi formé est compacté par pressage à froid.
The subject matter of claim 1 differs from the closest state of the art in that
  • I) the "spunbond" type web is unbound,
  • II) a web (V1 and / or V2) obtained by carding and with a grammage of between 10 g / m 2 and 50 g / m 2 is delivered on at least one face of the "spunbond" web,
  • III) the complex thus formed is compacted by cold pressing.

Exposé de l'inventionPresentation of the invention

Or on a trouvé, et c'est ce qui fait l'objet de la présente invention, un procédé perfectionné qui permet de réaliser de telles nappes non tissées de type « spunbond », parfaitement liées, présentant des caractéristiques mécaniques élevées (résistance à la traction, à la déchirure...) équivalentes à des nappes « spunbond » consolidées par calandrage à chaud, et qui, par ailleurs, présentent l'aspect, le toucher et la souplesse d'un textile conventionnel, tel qu'un tissu.Now it has been found, and this is the object of the present invention, an improved process which makes it possible to produce such spunbond-type nonwoven webs, which are perfectly bonded, having high mechanical characteristics (resistance to traction, tearing ...) equivalent to "spunbond" plies consolidated by hot calendering, and which, moreover, have the appearance, feel and flexibility of a conventional textile, such as a fabric.

D'une manière générale, le procédé selon l'invention permettant d'obtenir un non-tissé de type « spunbond » ayant l'aspect et les propriétés d'un textile conventionnel, consiste, en continu :

  • _ à réaliser une nappe de type « spunbond », le faisceau de filaments continus extrudé et étiré étant réceptionné sur un tapis transporteur mobile sous la forme d'une nappe non liée ;
  • _ à délivrer, contre au moins une face de la nappe « spunbond » ainsi formée, un voile de fibres discontinues - naturelles et/ou artificielles et/ou synthétiques -, obtenu par cardage et de grammage compris entre 10g/m2 et 50g/m2;
  • _ à compacter par pressage à froid le complexe ainsi formé ;
  • _ à transférer, toujours en continu, ledit complexe sur une ligne de traitement de liage au moyen de jets d'eau, agissant contre la ou les surfaces du complexe constitué de fibres discontinues, entraînant lesdites fibres dans le sens de l'épaisseur, fibres qui se lient à la façon d'une épissure entre et autour des filaments continus tout en restant visibles en surface ;
  • _ à procéder à un traitement de séchage ;
  • _ puis à réceptionner le produit fini.
In general, the method according to the invention making it possible to obtain a "spunbond" type nonwoven having the appearance and properties of a conventional textile, consists, continuously:
  • making a "spunbond" type web, the extruded and drawn continuous filament bundle being received on a moving conveyor belt in the form of an unbonded web;
  • _ to deliver, against at least one side of the "spunbond" thus formed, a veil of staple fibers - natural and / or artificial and / or synthetic - obtained by carding and weighing between 10g / m 2 and 50g / m 2 ;
  • compressing the complex thus formed by cold pressing;
  • continuously transferring said complex to a binder treatment line by means of water jets acting against the one or more surfaces of the discontinuous fiber complex, causing said fibers in the direction of thickness, fibers which bind like a splice between and around the continuous filaments while remaining visible on the surface;
  • to carry out a drying treatment;
  • _ then to receive the finished product.

Il convient de noter que, conformément à l'invention, avant d'effectuer l'opération de liage hydraulique, on procède à un compactage par pressage de l'ensemble constitué par la superposition de la ou des couches de fibres discontinues qui recouvrent ou emprisonnent entre elles la nappe « spunbond » produite.It should be noted that, in accordance with the invention, before carrying out the hydraulic binding operation, pressing is carried out by compaction of the assembly consisting of the superposition of the layer or layers of discontinuous fibers which cover or imprison between them the "spunbond" tablecloth produced.

Un tel compactage, qui peut être réalisé par tout moyen approprié, tel que notamment au moyen d'un rouleau presseur, ne peut en aucun cas être assimilé à une opération de calandrage étant donné qu'il est réalisé à froid.Such compaction, which can be achieved by any suitable means, such as in particular by means of a pressure roller, can in no way be likened to a calendering operation since it is made cold.

Conformément à l'invention, un seul voile de fibres discontinues peut être associé au voile à la nappe de type « spunbond », ledit voile de fibres discontinues pouvant être délivré soit en amont de la zone de formation du voile « spunbond » et étant amené sur le tapis transporteur sur lequel sont déposés les filaments provenant de l'installation « spunbond », filaments qui se répartissent donc à la surface de ce voile, soit, délivré en aval de la zone de formation du voile de filaments continus.According to the invention, a single staple fiber veil can be associated with the web to the "spunbond" type web, said staple fiber web being able to be delivered upstream of the "spunbond" formation zone and being brought on the conveyor belt on which are deposited the filaments from the "spunbond" installation, filaments which are therefore distributed on the surface of this web, or, delivered downstream of the continuous filament web formation zone.

Selon une forme de réalisation proprement dite, la nappe de type « spunbond » est recouverte sur ses deux faces par un voile de fibres discontinues, produits l'un en amont de la zone de formation du voile « spunbond », l'autre en aval, la nappe de filaments continus se trouvant donc emprisonnée en sandwich entre les deux couches de fibres discontinues.According to one embodiment itself, the spunbond-type sheet is covered on both sides by a veil of staple fibers, produced one upstream of the formation zone of the "spunbond" veil, the other in downstream, the web of continuous filaments being thus trapped sandwiched between the two layers of staple fibers.

Dans un tel cas, le complexe ainsi constitué de trois couches, est, après compactage par pressage, transféré, toujours en continu, sur une ligne de traitement de liage au moyen de jets d'eau, jets qui agissent successivement contre les surfaces desdits complexes en entraînant les fibres discontinues dans le sens de l'épaisseur, fibres qui se lient à la façon d'une épissure entre et autour des filaments continus tout en restant visibles sur les deux faces extérieures.In such a case, the complex thus formed of three layers is, after compacting by pressing, transferred, always continuously, on a binding treatment line by means of water jets, jets which act successively against the surfaces of said complexes. by driving the staple fibers in the direction of the thickness, fibers which bond in the manner of a splice between and around the continuous filaments while remaining visible on the two outer faces.

Par ailleurs, après l'opération de liage par jets d'eau et avant séchage, il est possible d'effectuer un traitement complémentaire de « textilisation » (réalisé par exemple conformément aux enseignements du brevet EP-059 608), consistant à transférer le complexe lié sur un convoyeur constitué par une toile grossière et à soumettre la nappe à l'action de jets d'eau obtenus par l'intermédiaire d'un ensemble comprenant essentiellement un tambour perforé rotatif, à l'intérieur duquel est disposé un injecteur alimenté en eau sous pression, cet ensemble produisant des jets réorientant les fibres, un ensemble d'aspiration pour l'élimination de l'eau étant prévu en dessous du convoyeur.Furthermore, after the water jet binding operation and before drying, it is possible to carry out a complementary treatment of "textilisation" (carried out for example in accordance with the teachings of patent EP-059 608), consisting in transferring the bonded complex on a conveyor constituted by a coarse fabric and subjecting the sheet to the action of water jets obtained via an assembly essentially comprising a rotary perforated drum, inside which is disposed a fuel injector in water under pressure, this assembly producing jets reorienting the fibers, a suction assembly for the removal of water being provided below the conveyor.

L'invention concerne également une installation permettant la mise en oeuvre en continu du procédé précité.The invention also relates to an installation for the continuous implementation of the aforementioned method.

D'une manière générale, une telle installation comporte, disposés en ligne :

  • _ un ensemble de formation, sur un tapis transporteur, d'une nappe de filaments continus de type « spunbond » ;
  • _ au moins une carde permettant de délivrer contre au moins une face de la nappe « spunbond » produite un voile de fibres discontinues et de grammage compris entre 10g/m2 et 50g/m2 ;
  • _ des moyens de pressage du complexe formé suivis d'une zone de traitement au moyen de jets de fluide, agissant au moins contre la surface recouverte de fibres discontinues et entraînant lesdites fibres dans le sens de l'épaisseur, fibres qui se lient à la façon d'une épissure entre et autour des filaments continus, tout en restant visibles en surface ;
  • _ des moyens de séchage et de réception du complexe lié.
In general, such an installation comprises, arranged online:
  • a formation assembly, on a conveyor belt, of a web of continuous filaments of "spunbond"type;
  • at least one card for delivering, against at least one side of the spunbond web, a staple fiber web having a basis weight of between 10 g / m 2 and 50 g / m 2 ;
  • means for pressing the complex formed followed by a treatment zone by means of fluid jets, acting at least against the surface covered with discontinuous fibers and driving said fibers in the direction of the thickness, fibers which bind to the way of a splice between and around the continuous filaments, while remaining visible on the surface;
  • means for drying and receiving the bound complex.

Eventuellement, une telle installation comporte, entre les moyens de liage par jets d'eau et les moyens de séchage, un ensemble de textilisation produisant des jets réorientant les fibres.Optionally, such an installation comprises, between the water jetting means and the drying means, a set of textile producing jets reorienting the fibers.

Par rapport aux nappes « spunbond » produites antérieurement, l'article obtenu se caractérise en ce que les filaments continus qui le composent sont associés à des fibres discontinues, fibres qui recouvrent la nappe à base de filaments continus et pénètrent à l'intérieur de cette dernière en se liant autour desdits filaments.Compared with the "spunbond" sheets produced previously, the article obtained is characterized in that the continuous filaments which compose it are associated with discontinuous fibers, fibers which cover the web based on continuous filaments and penetrate inside this layer. last by binding around said filaments.

Un tel produit conserve toutes les caractéristiques mécaniques de résistance des nappes spunbond conventionnelles dont la cohésion est donnée par un traitement de calandrage, le produit obtenu ayant également l'aspect et les propriétés tels que toucher, souplesse comparables à un textile conventionnel.Such a product retains all the mechanical strength characteristics of conventional spunbond webs whose cohesion is given by a calendering treatment, the product obtained also having the appearance and properties such as touch, flexibility comparable to a conventional textile.

Il convient de noter que les fibres discontinues qui sont associées à la nappe spunbond, peuvent être de tout type, naturelles ou chimiques, hydrophobes ou hydrophiles et ce, en fonction des applications auxquelles le produit est destiné, la longueur desdites fibres étant comprise entre 5 mm et 60 mm et leur titre compris entre 0,8 dtex et 6,6 dtex.It should be noted that the staple fibers which are associated with the spunbond web, can be of any type, natural or chemical, hydrophobic or hydrophilic, and this, depending on the applications for which the product is intended, the length of said fibers being between 5 mm and 60 mm and their titre between 0.8 dtex and 6.6 dtex.

Concernant le grammage du ou des voile(s) de fibres discontinues qui sont associés à la nappe spunbond, il pourra varier en fonction des applications, mais sera avantageusement compris entre 10 g/m2 et 50 g/m2, une nappe ayant un grammage inférieur à 10 g/m2 ne permettant pas d'obtenir un liage correct de la nappe spunbond, alors qu'une nappe supérieure à 50 g/m2 réduit l'intérêt économique du procédé.As regards the basis weight of the staple fiber fleece (s) which are associated with the spunbond web, it may vary according to the applications, but will advantageously be between 10 g / m 2 and 50 g / m 2, a tablecloth having a lower grammage at 10 g / m2 not allowing to obtain a proper binding of the spunbond web, while a web greater than 50 g / m2 reduces the economic interest of the process.

Description sommaire des dessinsBrief description of the drawings

L'invention et les avantages qu'elle apporte sera cependant mieux comprise grâce à la description qui suit et qui est illustrée par les figures annexées dans lesquelles :

  • _ la figure 1 illustre, vu de côté, l'ensemble d'une ligne de production permettant la mise en oeuvre du procédé conforme à l'invention ;
  • _ la figure 2 est également une vue de côté, montrant plus en détail la
  • manière dont est réalisée l'opération de liage au moyen de jets d'eau et le
  • traitement complémentaire éventuel de textilisation.
The invention and the advantages that it brings will however be better understood thanks to the description which follows and which is illustrated by the appended figures in which:
  • FIG. 1 illustrates, from the side, the whole of a production line allowing the implementation of the process according to the invention;
  • FIG. 2 is also a side view, showing in more detail the
  • the manner in which the binding operation is carried out by means of jets of water and the
  • possible additional processing of textilisation.

Manière de réaliser l'inventionWay of realizing the invention

En se reportant aux figures annexées, l'invention concerne donc un procédé et une installation qui permet de réaliser, en continu, un nouveau type de nappes « spunbond » constituées de filaments synthétiques continus, nappes qui non seulement conservent les propriétés de résistance mécanique (allongement, résistance à la traction, à la déchirure...), équivalentes à des nappes « spunbond » conventionnelles consolidées par calandrage à chaud et qui, par ailleurs, présentent l'aspect, le toucher et la souplesse d'un textile conventionnel tel qu'un tissu.With reference to the appended figures, the invention therefore relates to a method and an installation which makes it possible to continuously produce a new type of "spunbond" plies consisting of continuous synthetic filaments, plies which not only retain the properties of mechanical strength ( elongation, tensile strength, tearing resistance ...), equivalent to conventional "hot" calendered "spunbond" plies, which, moreover, have the appearance, feel and flexibility of a conventional textile such as than a fabric.

Conformément à l'invention, sur une installation destinée par la référence générale (1), on réalise une nappe non-tissé de type « spunbond » selon la technique classique qui consiste à extruder un polymère organique fondu, à travers une filière (2) percée de trous de manière à former un faisceau ou rideau de filaments (3).According to the invention, on an installation intended by the general reference (1), a spunbond-type nonwoven web is produced according to the conventional technique of extruding a molten organic polymer through a die (2). piercing holes so as to form a bundle or curtain of filaments (3).

Après refroidissement, permettant d'obtenir la solidification au moins superficielle des filaments extrudés (3), ceux-ci sont orientés et étirés au moyen d'un ou plusieurs dispositifs (4) à jets de fluide à la sortie du ou desquels ils sont répartis sur une surface réceptrice sous la forme d'une nappe (S).After cooling, to obtain the at least superficial solidification of the extruded filaments (3), they are oriented and stretched by means of one or more devices (4) with fluid jets at the exit of which they are distributed on a receiving surface in the form of a web (S).

Conformément à l'invention, pour consolider la nappe « spunbond » (S) ainsi formée et donner de la cohésion à cette nappe et des caractéristiques mécaniques élevées de résistance à la traction et à la déchirure tout en lui conférant un aspect, un toucher et la souplesse d'un textile conventionnel, la nappe « spunbond » (S) est réceptionnée non pas directement à la surface d'un tapis transporteur (5) soumis à une source d'aspiration, mais, sur un voile (V1) de fibres discontinues - naturelles et/ou artificielles et/ou synthétiques - produit immédiatement en amont de l'installation « spunbond» (1).According to the invention, to consolidate the "spunbond" sheet (S) thus formed and give cohesion to this sheet and high mechanical characteristics of tensile strength and tear while giving it an appearance, a touch and the flexibility of a conventional textile, the "spunbond" web (S) is not received directly on the surface of a conveyor belt (5) subjected to a suction source, but on a web (V1) of fibers discontinuous - natural and / or artificial and / or synthetic - produced immediately upstream of the spunbond plant (1).

Ce voile (V1) est par exemple réalisé par l'intermédiaire d'un ensemble (6) conventionnel constitué d'une carde associée éventuellement à un ensemble étaleur nappeur, le voile (V1) produit étant délivré au tapis transporteur (5) de l'installation « spunbond » (1) par un ensemble d'alimentation constitué également par un tapis transporteur (7).This web (V1) is for example made by means of a conventional assembly (6) consisting of a card associated possibly with a spreader spreader assembly, the web (V1) produced being delivered to the conveyor belt (5). the installation "spunbond" (1) by a feeding assembly also constituted by a conveyor belt (7).

Les deux couches textiles (V1) et (S) superposées passent ensuite, toujours en étant maintenues sur le tapis transporteur (5), sur un premier ensemble (8), constitué par exemple par deux cylindres permettant d'assurer un compactage.The two textile layers (V1) and (S) superimposed then pass, still being maintained on the conveyor belt (5), on a first assembly (8), consisting for example of two cylinders to ensure compaction.

Par l'intermédiaire d'un second ensemble (9), tel qu'une carde ou autre installation équivalente, on délivre à la surface de la nappe spunbond (S), un second voile (V2) de fibres discontinues, les trois couches textiles élémentaires superposées (V1, S et V2) étant à nouveau compactées par pressage entre deux cylindres (8).Via a second assembly (9), such as a card or other equivalent installation, is delivered to the surface of the spunbond web (S), a second web (V2) of staple fibers, the three textile layers superposed elementary elements (V1, S and V2) being compacted again by pressing between two cylinders (8).

Toujours en continu, l'ensemble compacté est alors amené sur une ligne de traitement, illustré plus en détail par la figure 2, désigné par la référence générale (10) permettant de soumettre ledit complexe à un traitement de liage au moyen de jets d'eau, agissant successivement contre les deux surfaces dudit complexe.Still continuously, the compacted assembly is then brought to a treatment line, illustrated in more detail in FIG. 2, designated by the general reference (10) making it possible to subject said complex to a binding treatment by means of jet jets. water, acting successively against both surfaces of said complex.

Dans la forme de réalisation décrite, un tel ensemble de traitement (10) est constitué par une unité de liage hydraulique du type « Jetlace 2000 » commercialisée par le Demandeur et mettant en oeuvre les enseignements du FR-A-2 730 246 (US-A-5 718 022), et FR-A-2 734 285 (US-A-5 768 756) au nom du Demandeur.In the embodiment described, such a treatment unit (10) consists of a hydraulic binding unit of the " Jetlace 2000 " type marketed by the Applicant and implementing the teachings of FR-A-2 730 246 (US Pat. A-5,718,022), and FR-A-2,734,285 (US-A-5,768,756) in the name of the Applicant.

Une telle unité de liage se compose essentiellement d'un convoyeur (11) sur lequel la structure fibreuse constituée par les trois couches superposées (V1,S et V2) est transférée.Such a binding unit consists essentially of a conveyor (11) on which the fibrous structure constituted by the three superimposed layers (V1, S and V2) is transferred.

Ainsi que cela ressort plus particulièrement de la figure 2, la structure est compactée entre le convoyeur (11) et un premier cylindre aspirant (12), revêtu préférentiellement d'une enveloppe microperforée, dont les trous sont disposés de manière aléatoire tel que décrit dans le brevet français 2 734 285.As is more particularly apparent from FIG. 2, the structure is compacted between the conveyor (11) and a first suction cylinder (12), preferably coated with a microperforated envelope, the holes of which are arranged randomly as described in FIG. French Patent 2,734,285.

Dans une autre forme de réalisation, ce cylindre peut être revêtu d'une toile métallique.In another embodiment, this cylinder may be coated with a wire mesh.

Eventuellement au niveau de la zone de compactage entre la surface du convoyeur (11) et celle du cylindre (12), la nappe complexe (V1/S/V2), désignée dans la suite de la description par la référence (N), peut recevoir un premier traitement de mouillage, au moyen d'une rampe (13), illustrée en pointillés à la figure 2, et qui délivre un rideau d'eau qui traverse le tapis transporteur (11) ainsi que les nappes superposées.Possibly at the level of the compacting zone between the surface of the conveyor (11) and that of the cylinder (12), the complex web (V1 / S / V2), designated in the rest of the description by the reference (N), can receiving a first wetting treatment, by means of a ramp (13), shown in dashed lines in Figure 2, and which delivers a water curtain which passes through the conveyor belt (11) and the superimposed sheets.

Une telle opération de mouillage n'est cependant pas indispensable.Such a wetting operation is however not essential.

Le complexe compacté, supporté par le tambour aspirant (12), est alors soumis à l'action de jets d'eau provenant d'un injecteur (14), les jets agissant donc contre la surface constituée par le voile fibreux (V1) et entraînant les fibres qui constituent ce voile à l'intérieur du complexe.The compacted complex, supported by the suction drum (12), is then subjected to the action of jets of water coming from an injector (14), the jets thus acting against the surface constituted by the fibrous web (V1) and causing the fibers that constitute the veil inside the complex.

La rampe ou injecteur (14) disposée parallèlement à une génératrice du cylindre (12), est une rampe conventionnelle qui permet de créer des jets ou aiguilles d'eau ayant un diamètre de 100 à 170 microns, les jets étant espacés les uns des autres d'une valeur comprise entre 0,5 et 2,2 mm, la pression d'alimentation elle-même comprise entre 50 et 150 bars en fonction du grammage du complexe.The ramp or injector (14) arranged parallel to a generatrix of the cylinder (12), is a conventional ramp which makes it possible to create jets or water needles having a diameter of 100 to 170 microns, the jets being spaced from each other between 0.5 and 2.2 mm, the supply pressure itself between 50 and 150 bar depending on the grammage of the complex.

Eventuellement, il peut être envisagé de réaliser un second traitement par jets sur ce premier cylindre (12) au moyen d'un deuxième injecteur.Optionally, it may be envisaged to perform a second jet treatment on the first cylinder (12) by means of a second injector.

A la sortie de ce cylindre (12), le complexe traité est amené à la surface d'un second cylindre (15), identique au précédent cylindre aspirant, associé à une ou deux séries d'injecteurs (16,17) délivrant des jets d'eau qui agissent donc sur la face de la nappe (N) constituée par le voile (V2).At the outlet of this cylinder (12), the treated complex is brought to the surface of a second cylinder (15) identical to the preceding suction cylinder, associated with one or two series of injectors (16, 17) delivering jets of water which therefore act on the face of the web (N) constituted by the web (V2).

Lors de ce second traitement de consolidation, les rampes (16,17) créent des jets ou aiguilles d'eau ayant un diamètre de 100 à 170 microns, lesdits jets étant espacés comme précédemment les uns des autres entre 0,5 et 2,4 mm, et la pression d'alimentation étant comprise entre 50 bars et 400 bars.During this second consolidation treatment, the ramps (16, 17) create jets or water needles having a diameter of 100 to 170 microns, said jets being spaced as previously from each other between 0.5 and 2.4 mm, and the supply pressure being between 50 bars and 400 bars.

L'action des injecteurs (16,17) permet donc d'entraîner les fibres du voile V1 dans l'épaisseur de la nappe (N), lesdites fibres entourant les filaments continus et se liant à ces derniers.The action of the injectors (16, 17) thus makes it possible to drive the fibers of the web V1 into the thickness of the web (N), said fibers surrounding the continuous filaments and binding thereto.

A la sortie de cet ensemble, la nappe spun liée, désignée par la référence (18) peut être directement amenée à l'ensemble de séchage (19) par passage sur un tambour chauffant conventionnel (26) avant d'être réceptionné.At the outlet of this assembly, the bonded spun web designated by reference (18) can be directly fed to the drying assembly (19) by passing it over a conventional heating drum (26) before being received.

Eventuellement, et ainsi que cela ressort des figures annexées, un troisième traitement de liage hydraulique peut être réalisé par l'intermédiaire d'un troisième tambour aspirant (20) associé à une rampe d'injecteurs (21), dont les jets agissent contre la face qui était constituée par le voile (V1).Optionally, and as is apparent from the appended figures, a third hydraulic bonding treatment can be achieved by means of a third suction drum (20) associated with a nozzle ramp (21), whose jets act against the face which was constituted by the veil (V1).

Après ce dernier traitement, un traitement complémentaire de textilisation peut éventuellement être effectué. Un tel traitement consiste, comme cela ressort plus particulièrement de la figure 2, à transférer la nappe « spun » liée (18) sur un ensemble réalisé par exemple conformément aux enseignements du brevet EP 059 608.After this last treatment, a complementary processing of textilisation can possibly be carried out. Such a treatment consists, as is more particularly apparent from FIG. 2, in transferring the bonded "spun" sheet (18) to an assembly produced for example in accordance with the teachings of patent EP 059 608.

D'une manière générale, un tel ensemble est constitué par une toile transporteuse (22), du type « Fourdrinier», utilisée dans le domaine papetier. Le spun lié (18) maintenu sur cette toile, est soumis à l'action d'une série de jets d'eau obtenus par l'intermédiaire d'une rampe (23) projetant un rideau d'eau contre la surface interne d'un cylindre rotatif perforé (24), ces jets réorientant les fibres.In general, such an assembly is constituted by a conveyor belt (22), of the "Fourdrinier" type, used in the paper industry. The bound spun (18) held on this fabric is subjected to the action of a series of water jets obtained via a ramp (23) projecting a curtain of water against the internal surface of a perforated rotary cylinder (24), these jets reorienting the fibers.

Un ensemble d'aspiration (25) pour l'élimination de l'eau est bien entendu prévu en dessous du convoyeur (22).A suction assembly (25) for the removal of water is of course provided below the conveyor (22).

Grâce à une telle installation, il est possible soit de réaliser des complexes dans lesquels le voile non tissé de type « spunbond » est associé à deux voiles constitués de fibres discontinues, l'ensemble des moyens décrits précédemment étant mis en oeuvre, soit de réaliser des articles dans lesquels le voile de type « spunbond » est associé à un seul voile de fibres discontinues pouvant être distribué soit en amont soit en aval de la zone de formation du voile « spunbond ».Thanks to such an installation, it is possible either to make complexes in which the spunbond nonwoven web is associated with two webs made of staple fibers, all the means described above being used, or to realize articles in which the "spunbond" type web is associated with a single staple fiber web capable of being distributed either upstream or downstream of the "spunbond" web formation zone.

Exemple 1Example 1

Cet exemple utilise la réalisation d'un complexe dans lequel la nappe « spunbond » est emprisonné entre deux voiles de fibres discontinues.This example uses the realization of a complex in which the "spunbond" web is trapped between two staple fiber webs.

Un tel produit est réalisé conformément à l'invention de la manière suivante :Such a product is produced in accordance with the invention as follows:

Au moyen d'une carde (6) conventionnelle, on réalise un voile de fibres (V1) pesant 30 g/m2 et composé de 100 % de fibres de viscose de 1,7 dtex et 38 mm de longueur.By means of a conventional card (6), a fiber web (V1) weighing 30 g / m 2 and made of 100% viscose fibers of 1.7 dtex and 38 mm in length is produced.

Ce voile est produit à une vitesse de 100 m/minute.This veil is produced at a speed of 100 m / minute.

En sortie de carde (6), le voile (V1) est transféré sur le tapis récepteur (5) de l'installation (1) de réalisation d'une nappe (S) de type « spunbond ».At the card outlet (6), the web (V1) is transferred to the receiving belt (5) of the installation (1) for producing a web (S) of the "spunbond" type.

La nappe « spunbond » produite est obtenue à partir de polypropylène et est répartie sur le voile (V1) de manière à former une nappe constituée de filaments ayant un titre de 1,7 dtex, pesant 40 g/m2.The "spunbond" sheet produced is obtained from polypropylene and is distributed over the web (V1) so as to form a web consisting of filaments having a title of 1.7 dtex, weighing 40 g / m 2 .

Les deux couches superposées (V1) et (S) sont comprimées au moyen d'un cylindre presseur (8) et un second voile de fibres (V2) reproduit d'une manière similaire au voile (V1), pesant 30 g/m2, est délivré à la surface de la nappe « spunbond » (S), les couches superposées étant alors soumises à un nouveau compactage également au moyen d'un cylindre presseur.The two superimposed layers (V1) and (S) are compressed by means of a pressure roller (8) and a second fiber web (V2) reproduced in a manner similar to the web (V1), weighing 30 g / m 2 , is delivered to the surface of the "spunbond" (S), the superposed layers then being subjected to a new compaction also by means of a pressure roller.

En continu, le complexe formé est amené sur une ligne de traitement comportant une unité de liage hydraulique (10) de type «Jetlace 2000 », commercialisé par le Demandeur.Continuously, the complex formed is fed to a treatment line comprising a hydraulic binding unit (10) of the "Jetlace 2000" type marketed by the Applicant.

Une telle installation comporte essentiellement un tapis transporteur (11), et trois ensembles de traitement par jets comprenant des cylindres aspirants (12,15,20) ayant un diamètre de 516 mm et revêtus d'une enveloppe microperforée dont les trous sont répartis de manière aléatoire tel que décrit dans le brevet français 2 634 285. A ces tambours aspirants (12,15,20) sont associées des rampes d'injecteurs (14,16,17,21) qui agissent contre les surfaces du complexe (N) constitué par la superposition du voile (V1) du spunbond (S) et du voile (V2).Such an installation essentially comprises a conveyor belt (11), and three jet treatment units comprising suction cylinders (12, 15, 20) having a diameter of 516 mm and coated with a microperforated envelope whose holes are distributed in a manner as described in French Pat. No. 2,634,285. To these suction drums (12,15,20) are associated ramps injectors (14, 16, 17, 21) which act against the surfaces of the complex (N) constituted by the superposition of the web (V1) of the spunbond (S) and the web (V2).

La disposition de ces injecteurs est telle que l'on agit successivement contre les faces opposées du complexe (N).The arrangement of these injectors is such that one acts successively against the opposite faces of the complex (N).

Les rampes (14,16,17,21) produisent toutes 1666 jets au mètre et sont réglées de la manière suivante. Rampes Diamètre du jet en microns (µm) Vitesse des jets m/seconde Pression d'alimentation Vitesse en m/min des cylindres 14 : jets contre V1 120 µm 144 m/seconde 100 bars 12 : 102m/minute 16 : jets contre V2 120 µm 170 m/seconde 150 bars 15 : 103 m/minute 17 : jets contre V2 120 µm 220 m/seconde 250 bars 15 : 104 m/minute 21 : jets contre V1 120 µm 220 m/seconde 250 bars 20 : 105m/minute The ramps (14,16,17,21) all produce 1,666 jets per meter and are adjusted in the following manner. ramps Jet diameter in microns (μm) Jet speed m / second Feed pressure Speed in m / min of the cylinders 14: throws against V1 120 μm 144 m / second 100 bars 12: 102m / minute 16: throws against V2 120 μm 170 m / second 150 bars 15: 103 m / minute 17: throws against V2 120 μm 220 m / second 250 bars 15: 104 m / minute 21: throws against V1 120 μm 220 m / second 250 bars 20: 105m / minute

En aval du dernier système de liage hydraulique (20), est disposé un ensemble de textilisation constitué par un tapis transporteur (22) réalisé dans une toile en polyester, associée à un ensemble de textilisation proprement dit comportant un tambour perforé rotatif (24) à l'intérieur duquel est disposé un injecteur (23) alimenté avec de l'eau à 150 bars.Downstream of the last hydraulic binding system (20) is a textile assembly consisting of a conveyor belt (22) made of a polyester fabric, associated with a textilisation assembly itself, comprising a rotary perforated drum (24). inside which is disposed an injector (23) supplied with water at 150 bar.

Cet injecteur (23) produit des jets d'eau de 130 µm de diamètre qui réorientent les fibres. L'eau provenant de l'injecteur (23) est récupérée au moyen de l'ensemble d'aspiration (25) disposé en dessous du convoyeur (22).This injector (23) produces jets of water of 130 microns in diameter which reorient the fibers. Water from the injector (23) is recovered by means of the suction assembly (25) disposed below the conveyor (22).

En procédant dans les conditions précitées, on obtient en sortie de l'installation, une nappe conforme à l'invention qui, après séchage sur un tambour chauffant, pèse 95 g/m2.By proceeding under the above conditions, at the outlet of the installation, a web according to the invention is obtained which, after drying on a heating drum, weighs 95 g / m 2 .

Cette nappe est parfaitement liée et présente une grande souplesse, un toucher, un aspect et des caractéristiques mécaniques comparables à un textile traditionnel de grammage équivalent obtenu avec des fibres de même nature.This sheet is perfectly bonded and has great flexibility, touch, appearance and mechanical characteristics comparable to a traditional textile equivalent weight obtained with fibers of the same nature.

Exemple 2Example 2

Cet exemple illustre la mise en oeuvre du procédé conforme à l'invention pour la réalisation d'une structure composée d'une nappe de type « spunbond » associé à une seule nappe fibreuse qui, dans cette forme de réalisation, est formée en amont de la zone de formation de la nappe « spunbond ».This example illustrates the implementation of the method according to the invention for producing a structure composed of a "spunbond" type sheet associated with a single fibrous sheet which, in this embodiment, is formed upstream of the formation zone of the "spunbond" tablecloth.

Conformément à l'invention, on procède de la manière suivante.According to the invention, the procedure is as follows.

Au moyen d'une carde conventionnelle (6), on réalise un voile de fibres (V1) pesant 20 g/m2 et composé de 100 % de fibres de viscose de 1.7 dtex et 38 mm de longueur.By means of a conventional card (6), a web of fibers (V1) weighing 20 g / m 2 and made of 100% viscose fibers of 1.7 dtex and 38 mm in length is made.

Ce voile est produit à une vitesse de 150 m/min.This veil is produced at a speed of 150 m / min.

En sortie de carde (6), le voile (V1) est transféré sur le tapis récepteur (5) de l'unité spunbond.At the card outlet (6), the web (V1) is transferred to the receiving mat (5) of the spunbond unit.

Une nappe spunbond (S) constituée de filaments de polypropylène est déposée sur le voile (V1).A spunbond web (S) made of polypropylene filaments is deposited on the web (V1).

Cette nappe spunbond de 25 g/m2 est constituée de filaments de 2 dtex.This spunbond web of 25 g / m 2 consists of 2 dtex filaments.

Les deux couches superposées (V1) et (S) sont comprimées au moyen d'un rouleau presseur (8) formant ainsi un complexe de 45 g/m2 qui est transféré en continu sur une unité de liage hydraulique (10) de type « Jetlace 2000 » commercialisé par le Demandeur.The two superimposed layers (V1) and (S) are compressed by means of a pressure roller (8) thus forming a complex of 45 g / m 2 which is transferred continuously to a hydraulic bonding unit (10) of the "Jetlace" type. 2000 "marketed by the Applicant.

Cette installation comporte un tapis transporteur (11) et deux ensembles de traitement par jets d'eau constitués de cylindres aspirants (12) et (15) suivis d'un convoyeur final (22) sur lequel est disposé un dispositif de patterning/textilisation.This installation comprises a conveyor belt (11) and two water jet treatment units consisting of suction cylinders (12) and (15) followed by a final conveyor (22) on which is arranged a patterning / textilisation device.

Les deux cylindres (12) et (15) sont recouverts d'une enveloppe microperforée dont les trous sont disposés de manière aléatoire tel que décrit dans le brevet français 2 634 285.The two cylinders (12) and (15) are covered with a microperforated envelope whose holes are arranged in a random manner as described in French Patent 2,634,285.

A ces cylindres, sont associées des rampes d'injecteurs (14) (16) (17).To these cylinders are associated injector ramps (14) (16) (17).

La disposition de ces injecteurs est telle que l'on agit successivement sur les deux faces du complexe.The arrangement of these injectors is such that one acts successively on both sides of the complex.

Les injecteurs produisent tous les 1666 jets d'eau de 120 microns par mètre et la pression d'eau dans ces injecteurs est respectivement de 60, 80 et 110 bars.The injectors produce all 1666 water jets of 120 microns per meter and the water pressure in these injectors is respectively 60, 80 and 110 bar.

La textilisation du complexe lié sur les cylindres précédents est réalisée par un tambour perforé (23) tel que décrit dans l'exemple précédent dont l'injecteur est alimenté à une pression d'eau de 80 bars.The textilisation of the bound complex on the preceding cylinders is carried out by a perforated drum (23) as described in the preceding example, the injector of which is supplied with a water pressure of 80 bar.

Après séchage, le produit final de 45 g/m2 possède d'excellentes caractéristiques mécaniques, supérieures à celles d'un voile spunlace constitué de fibres de même nature.After drying, the final product of 45 g / m 2 has excellent mechanical properties, superior to those of a spunlace veil made of fibers of the same kind.

L'aspect et la souplesse du voile sont également remarquables, très supérieurs à celles d'un spunbond en polypropylène ou polyester de grammage équivalent lié par calandrage.The appearance and flexibility of the veil are also remarkable, far superior to those of a spunbond polypropylene or polyester equivalent weight bonded by calendering.

Claims (6)

  1. Process for the production of a nonwoven of "spunbond" type having mechanical properties equivalent to spunbond webs consolidated by hot calendering and having the appearance, the handle and the pliancy of a conventional textile, which consists in continuously:
    - producing a web (S) of "spunbond" type, the bundle of continuous filaments, which is extruded and drawn, being collected in the form of a non-bonded web on a moving conveyor belt;
    - delivering, against at least one face of the "spunbond" web thus formed, a sheet (V1 and/or V2) consisting of natural and/or artificial and/or synthetic, discontinuous fibres, obtained by carding and having a weight of between 10 g/m2 and 50 g/m2;
    - compacting the complex thus formed by cold pressing it;
    - transferring, still continuously, said complex onto a treatment line (10) for bonding it by means of water jets which act against the surface or surfaces of the complex consisting of discontinuous fibres and entrain said fibres in the thickness direction, which fibres bond together in the manner of a splice between and around the continuous filaments, while still remaining visible on the surface;
    - carrying out a drying treatment;
    - and then collecting the finished product.
  2. Process according to Claim 1, characterized in that the web (5) of "spunbond" type is covered on both its faces with a sheet (V1/V2) of discontinuous fibres, one lap (V1) being produced directly upstream of the zone in which the "spunbond" web is formed and being taken onto the conveyor belt (11) on which the filaments coming from the "spunbond" plant are deposited, said filaments therefore being distributed over the surface of this sheet (V1), the second lap (V2) being delivered downstream of the zone in which the web of continuous filaments is formed, which web is thus sandwiched between the two fibrous layers (V1, V2).
  3. Process according to either of Claims 1 and 2, characterized in that, after the water-jet bonding operation and before drying, a complementary "textiling" treatment is carried out which consists in transferring the bonded complex onto a coarse fabric (22) and in subjecting the web to the action of water jets which are obtained by means of a unit essentially comprising a perforated rotary drum (24) inside which an injector (23) fed with pressurized water is placed, this unit producing jets which reorient the fibres, a suction unit (25) for removing the water being provided beneath the conveyor.
  4. Plant for producing a nonwoven of "spunbond" type, comprising, arranged in line:
    - a unit (1) for forming, on a conveyor belt (5), a web (S) of continuous filaments of "spunbond" type;
    - at least one carding machine (6 and/or 9) for delivering, against at least one face of the "spunbond" web produced, a sheet (V1 and/or V2) of discontinuous fibres and having a weight of between 10 g/m2 and 50 g/m2;
    - means for cold pressing the complex formed, followed by a zone (10) for treatment by means of fluid jets, which act at least against the surface covered with discontinuous fibres and entrain said fibres in the thickness direction, which fibres bond together in the manner of a splice between and around the continuous filaments, while still being visible on the surface;
    - means for drying and collecting the bonded web, characterized in that it includes, between the water-jet bonding means (10) and the drying means, a textiling unit delivering a coarse fabric (22) which is intended to support the bonded complex and is associated with a perforated rotary drum inside which an injector (23) fed with pressurized water is placed, this unit producing jets which reorient the fibres, a suction unit (25) for removing the water being placed beneath the conveyor.
  5. Plant according to Claim 4, characterized in that it includes, upstream and downstream of the zone in which the "spunbond" web is formed, means (6, 9) for producing a sheet of fibres, the sheet (V1) produced upstream being delivered onto the conveyor belt (5) of the "spunbond" line, the bundle of filaments, which is extruded and drawn, being collected directly on said sheet, the second sheet (V2) being placed downstream of the zone in which the "spunbond" web is formed and being delivered onto the surface of the latter.
  6. Nonwoven obtained by implementing the process according to one of Claims 1 to 3, characterized in that it is composed of a web produced from continuous filaments combined with a carded sheet of discontinuous fibres having a weight of between 10 g/m2 and 50 g/m2, a length of between 5 mm and 60 mm and a linear density of between 0.8 dtex and 6.6 dtex, which fibres cover at least one face of the continuous-filament-based web and penetrate the interior of the latter, by becoming bonded around said filaments.
EP00931356A 1999-06-10 2000-05-26 Method for producing a nonwoven material, installation therefor and resulting nonwoven Expired - Lifetime EP1192306B1 (en)

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FR9907602A FR2794776B1 (en) 1999-06-10 1999-06-10 PROCESS FOR THE PRODUCTION OF A NONWOVEN MATERIAL, INSTALLATION FOR ITS IMPLEMENTATION AND NONWOVEN THUS OBTAINED
FR9907602 1999-06-10
PCT/FR2000/001428 WO2000077286A1 (en) 1999-06-10 2000-05-26 Method for producing a nonwoven material, installation therefor and resulting nonwoven

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EP1192306B1 true EP1192306B1 (en) 2006-08-16

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EP (1) EP1192306B1 (en)
JP (1) JP4546010B2 (en)
CN (1) CN1355864A (en)
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DE (1) DE60030120T2 (en)
DK (1) DK1192306T3 (en)
ES (1) ES2270833T3 (en)
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IL (1) IL146867A0 (en)
PL (1) PL352192A1 (en)
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WO2000077286A1 (en) 2000-12-21
FR2794776B1 (en) 2001-10-05
US20020157766A1 (en) 2002-10-31
FR2794776A1 (en) 2000-12-15
TR200103471T2 (en) 2002-07-22
DE60030120T2 (en) 2007-02-15
IL146867A0 (en) 2002-08-14
ES2270833T3 (en) 2007-04-16
JP4546010B2 (en) 2010-09-15
DK1192306T3 (en) 2006-12-11
ATE336611T1 (en) 2006-09-15
PL352192A1 (en) 2003-08-11
EP1192306A1 (en) 2002-04-03
DE60030120D1 (en) 2006-09-28
JP2003502515A (en) 2003-01-21
CN1355864A (en) 2002-06-26

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