EP2630287B1 - Method and apparatus for producing a composite nonwoven - Google Patents
Method and apparatus for producing a composite nonwoven Download PDFInfo
- Publication number
- EP2630287B1 EP2630287B1 EP11781766.8A EP11781766A EP2630287B1 EP 2630287 B1 EP2630287 B1 EP 2630287B1 EP 11781766 A EP11781766 A EP 11781766A EP 2630287 B1 EP2630287 B1 EP 2630287B1
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- EP
- European Patent Office
- Prior art keywords
- installation
- woven
- belt
- composite
- layer
- 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.)
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Classifications
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/559—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 the fibres being within layered webs
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01G—PRELIMINARY TREATMENT OF FIBRES, e.g. FOR SPINNING
- D01G15/00—Carding machines or accessories; Card clothing; Burr-crushing or removing arrangements associated with carding or other preliminary-treatment machines
- D01G15/02—Carding machines
- D01G15/12—Details
- D01G15/46—Doffing or like arrangements for removing fibres from carding elements; Web-dividing apparatus; Condensers
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01G—PRELIMINARY TREATMENT OF FIBRES, e.g. FOR SPINNING
- D01G15/00—Carding machines or accessories; Card clothing; Burr-crushing or removing arrangements associated with carding or other preliminary-treatment machines
- D01G15/02—Carding machines
- D01G15/04—Carding machines with worker and stripper or like rollers operating in association with a main cylinder
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/56—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in association with fibre formation, e.g. immediately following extrusion of staple fibres
Definitions
- the invention relates to a method for producing a composite nonwoven fabric in a continuous process sequence and to an apparatus for carrying out the method.
- the US 5,806,154 A shows such a method in addition to device, wherein a carded and already laid in multiple layers fiber web is passed over a suction roll and here covered with a nonwoven layer of synthetic fibers, which is formed by melt blowing a plurality of a polymer melt of extruded synthetic fibers. The nonwoven fibrous web is then fed to a winder.
- EP 0 501 842 A1 and EP 0 543 863 A1 disclose similar methods and devices.
- composite nonwovens For the production of composite nonwovens, it is generally known that the properties of the composite nonwoven fabric are essentially determined by the interaction of several different types of nonwoven layers. For example, in the case of the composite nonwovens used for noise insulation, it has been found that, in particular, the differences in the material density of the nonwoven layers cause sound waves to be compensated for and to be little reflected. Such composite nonwovens, which are used for insulation and noise reduction, have a relatively low basis weight, so that special demands are made on their production.
- a sound absorbing thin film laminate which consists of a foam or a nonwoven fabric and associated meltblown fibers.
- the foam or the non-woven fabric is drawn off in the form of a web from a first roll, then sprayed with a contact adhesive and dried with an infrared radiator and then combined with a second web of meltblown fibers. Both webs are then guided together by squeezing rollers and interconnected. Possibly.
- another cover layer of a nonwoven web may be applied to the thin film laminate.
- This nonwoven facing layer may consist of a meltblown web which is provisionally bonded by ultrasound.
- the thin-film laminate is then cut into blanks and fed to a molding press.
- a first nonwoven layer of microfibers is made by meltblowing, forming a second, carded nonwoven layer and then attaching it under the first layer.
- the two layers are entangled by fluid jets and connected and then dried.
- the second carded nonwoven layer is preferably pre-needled.
- a third nonwoven layer can be added.
- a meltblown microfiber layer may be directly applied and formed on a second carded layer.
- a further object of the invention is to guide a batt produced by a carding device with the highest possible belt speed to a composite web. Further, an object of the invention is the formation of a multi-layer acoustic insulating nonwoven member.
- a composite nonwoven fabric is formed from a batt produced by a carding device and a nonwoven layer produced by a meltblown process. During meltblowing, the fibers are produced with the lowest possible air pressure and the greatest possible distance from the batt. However, this does not produce fine fibers. Therefore, the known method and device are essentially suitable only for the production of composite webs with relatively high basis weights.
- the claimed technique has the advantage that even very loose and lightweight laid batts can be safely combined with a nonwoven layer made by meltblowing.
- a turbulence and change of the batt caused by the fiber flow of the meltblowing is avoided by guiding the batt into a holding zone, eg a suction zone, so that the batt on the depositing belt receives a fixation, eg generated by the suction flow.
- the synthetic fibers produced by meltblowing are in the range the holding or suction zone deposited to a nonwoven layer directly on the batt and in this case connected with this to a compound.
- the resulting excess blown air can also be advantageously absorbed and removed via a suction zone.
- the nonwoven fibrous web can be led out of the suction zone and directed to a web laying device.
- the fleece-laying device then combines several layers of the fiber pile or compound into the composite fleece.
- the development of the invention is particularly advantageous in which the batt inside the suction zone passes through several successive suction regions with separately adjustable suction ,
- the batt inside the suction zone passes through several successive suction regions with separately adjustable suction .
- different pressure settings also allow the immediate deposition of the synthetic fibers to be influenced in order to create certain structures within the nonwoven layers.
- the batt can be formed from fibers and fiber mixtures of synthetic or natural fibers.
- the fibers or fiber mixtures are formed to form the batt with a weight fraction in the range between 10% and 100% of synthetic fibers.
- the method variant is preferably used, in which the fiber material of the synthetic fibers and the polymer melt for extruding the synthetic fibers are formed from an identical base material. This considerably improves the recycling of such composite nonwovens.
- the nonwoven layer on the surface of the batt is preferably laid with fine fibers to obtain the properties advantageous for the soundproofing.
- the variant of the method is preferably used, in which the synthetic fibers are placed on the fiber web during melt blowing with a fine fiber cross section in the range of 0.2 microns to 3 microns to the nonwoven layer.
- the composite fleece can also be produced advantageously with coarser synthetic fibers.
- the performance of the carding device is exploited in particular with the variant of the method in which the batt is continuously guided after removal until it is deposited at a belt speed in the range from 50 m / min to 200 m / min.
- a belt speed in the range from 50 m / min to 200 m / min.
- essentially the capacity of the fleece-laying device is decisive for the limitation of the belt speed.
- a further process variant is proposed in which a plurality of batts are taken parallel next to each other from the carding device and are pooled together after the meltblowing and laying down of the synthetic fibers, wherein the nonwoven layer forms an intermediate layer between the batts.
- Such double batt layers are particularly suitable for protecting the intermediate nonwoven layer of the synthetic fibers from further treatment.
- the structure and distribution of the synthetic fibers within the nonwoven layer remain unchanged and can thus already adjusted in the manufacturing process to the required specific properties.
- the process variant is particularly advantageous, in which the composite nonwoven is solidified by a thermal treatment in a belt dryer, wherein the composite nonwoven is guided during solidification through a calibration zone, in which Relative to a guide band adjustable calibration belt acts on a free top of the composite web.
- a specific thickness on the composite nonwoven it is also possible to set a specific thickness on the composite nonwoven.
- the melting of the synthetic fibers within the nonwoven layers can be advantageously avoided such that the fiber material of the synthetic fibers has a slightly higher melting point than the synthetic fibers of the batt. This can be advantageously achieved by additives even with the same base polymer.
- the composite nonwoven in a storage device to a winding or alternatively to is stored in a stack.
- the storage device additionally has a cutting device in order to cut each of the composite nonwoven into individual nonwoven pieces, which are then stacked on top of each other.
- the device according to the invention preferably has a carding device, a pickup device, a transport device and a web laying device, wherein a station for producing a nonwoven layer made of synthetic fibers is provided between the pickup device and the web laying device.
- the station is designed as a melt blowing device, which is associated with a holding, in particular suction device.
- the suction device is preferably arranged below a storage belt of the transport device, so that the guided on the storage belt batt is held fixed on a suction effect on the storage belt.
- the suction device for the suction of the storage belt is formed according to an advantageous development of the device according to the invention by a plurality of suction chambers, which are connected to a vacuum source, the suction chambers are assigned to set an individual negative pressure separate control means.
- the suction chambers are assigned to set an individual negative pressure separate control means.
- the development of the device according to the invention is preferably used, in which the melt blowing device has a movable spinning head, which between a Operating position above the storage belt and a rest position laterally next to the storage belt is feasible.
- the melt blowing device has a movable spinning head, which between a Operating position above the storage belt and a rest position laterally next to the storage belt is feasible.
- the device according to the invention is specially developed in such a way that the pickup device has two separate pickup locations, which cooperate with two band arrangements of the transport device for receiving and removing a plurality of bobbins.
- the variant of the device is used in which one of the band arrangements cooperates with the depositing belt and the second belt arrangement is arranged with a transport section parallel to the depositing belt above the spinning head.
- the second band arrangement has a second depositing band and that the second depositing band is assigned a second spinner head of the melt blowing device.
- the second band arrangement has a second depositing band and that the second depositing band is assigned a second spinner head of the melt blowing device.
- the further treatment of the composite web takes place within the device by means of a conveyor belt device which connects the web laying device with a solidification device and a storage device.
- the composite fleece can thus be stored to form a roll or stack.
- the device has a belt dryer with a guide belt and a calibration belt arranged above the guide belt, wherein the calibration belt is designed to be height-adjustable relative to the guide belt.
- the calibration belt is designed to be height-adjustable relative to the guide belt.
- the invention relates to a method and an apparatus for producing a composite nonwoven fabric (36) and to a sound-absorbing nonwoven element produced therefrom.
- FIGS. 1 and 2 a first embodiment of the device according to the invention for carrying out the method according to the invention is shown.
- FIG. 1 a partial view of the front half of the machine and in FIG. 2 a partial view of the rear half of the machine shown.
- the device according to the invention has in the front half of the machine according to FIG. 1 a carding device (1).
- the carding device (1) cooperates at one end with a feed device (2) and at the opposite end with a pickup device (7).
- a pre-drum (4) and a main drum (5) are arranged, on whose circumference a plurality of carding elements (6) act.
- a plurality of feed system (3) are provided for receiving a fiber stream continuously provided by the feed device (2) and leading to the pre-drum (4).
- the fibers are carded and removed via the in the main drum (5) associated with the pickup device (7) as a batt.
- the pickup device (7) is formed in this embodiment by a picking roller system (8) which interacts directly with a conveyor belt (10.1) of a transport device (9).
- the transport device (9) is formed in this embodiment by a first conveyor belt (10.1), a storage belt (11) and a second conveyor belt (10.2), which cooperate together to continuously receive a batt (32) from the carding device (1) and evacuate.
- the storage belt (11) is associated with a melt blowing device (12) on an upper side and a holding device (17) on an underside.
- a nonwoven layer (35) of meltblown synthetic fibers (33) is applied to the surface of the fibrous web (32) by the meltblowing device (12), e.g. with a compressed gas stream.
- the composite of batt (32) and nonwoven layer (35) is referred to below as compound.
- the holding device (17) can act on the fiber web (32) and / or on a compressed gas stream of the melt blowing device (12). It can e.g. Hold the batt (32) on the storage belt (11) and stabilize it against the impinging compressed gas flow with the meltblown fibers (33). It can also act as a leader on the pressure gas flow and the fiber flow. It can e.g. the compressed gas stream after the delivery of the fibers (33) to the batt (32) derived controlled.
- the holding device (17) may e.g. be designed as a suction device.
- the storage belt (11) is gas-permeable and is guided over a total of three suction chambers (18.1, 18.2 and 18.3) of the suction device (17).
- the suction chambers (18.1, 18.2 and 18.3) of the suction device (17) via separate suction lines (19.1, 19.2 and 19.3) independently of each other with a vacuum source (not shown here) and via associated control means (20.1, 20.2, 20.3) independently of each other in their suction power adjustable.
- the melt blowing device (12) has a spinner head (13), which is coupled by a melt line (34) to an extruder (14).
- the spinning head (13) also has a connection to a pressurized gas supply (15), eg compressed air supply, via a control valve (16) with a compressed air source (not shown here) is connected.
- the spinner head (13) has on its underside a melt-blowing nozzle which extends substantially over the entire width of the depositing belt (11).
- the width of the melt-blowing nozzle of the spinning head (13) is identical to the working width of the carding device (1).
- the working widths of the carding device (1) may be in the range of 2 m to 4 m and above. Accordingly, the width of the meltblowing die is also in the range of 2 m to 4 m.
- the spinning head (13) and the extruder (14) are held in this embodiment on a movable support (21) through which the spinner head (13) between an operating position and a rest position is guided back and forth.
- a cross section of the melt blowing device (12) is shown in FIG Figure 3.1 in the operating position and in Figure 3.2 shown in the rest position. In so far, in addition to the Figures 3.1 and 3.2 Referenced.
- the spinning head (13) of the melt blowing device (12) is located directly above the depositing belt (11), which is sucked on its underside by the suction chamber (18.2).
- the suction chamber (18.2) is connected via the suction line (19.2) and a control means (20.2) with a vacuum source, not shown here.
- the carrier (21) of the spinning head (13) and the extruder (14) is designed to be movable and can be moved back and forth, for example via a rail system or a roller system transversely to the storage belt (11). In this case, the connections to the spinning head (13) remain unchanged. Thus, the spinning head (13) via the melt line (34) to the extruder (14).
- a connection to a pressure source is provided via the compressed air supply (15) and the control valve (16).
- the carrier (21) can be moved so that the spinning head (13) is obtained in a rest position laterally next to the storage belt (11). In this position, maintenance work and piecing processes can be carried out at the start of the process without a fiber web (32) being guided on the depositing belt (11).
- a nonwoven laying device (22) is arranged next to the melt blowing device (12), wherein between the melt blowing device (12) and the nonwoven laying device (22) the conveyor belt (10.2) of the transport device (9) is held.
- the fleece laying device (22) has depositing means (not shown here) in order to apply the fleece (32) or compound in continuous and, for example, uniform reciprocating motion over the conveyor belt (10.2) to a conveyor belt of a conveyor belt device (23) in multiple layers and with a selectable one Deposit layer number and form a composite fleece (36).
- the basis weight of the multilayer composite nonwoven fabric (36) can be controlled or regulated as required and continuously or locally changed in the transverse and / or longitudinal direction (so-called profiling).
- the conveyor belt device (23) is accordingly operated at a lower belt speed depending on the number of layers and on the delivery width.
- the conveying direction of the conveyor belt device (23) is thus aligned transversely to the transport direction of the transport device (9).
- the following devices of the device according to the invention form a second machine longitudinal side on which the devices are arranged one behind the other for further treatment of a composite nonwoven fabric.
- the solidification device (24) is formed by a belt dryer (25) which has a guide belt (26) and a calibration belt (27) arranged above the guide belt in a calibration zone.
- the calibration belt (27) is designed to be height-adjustable relative to the position of the guide belt (26) so that a composite web (36) guided on the guide belt (26) can be solidified with a specific material thickness.
- the solidification takes place here via a heat treatment and is referred to in the art as thermobonding. In this case, a stable cohesion of all fibers is produced by melting the fiber material of some fibers within the composite web.
- the multilayer composite nonwoven fabric (36) laid by the nonwoven laying device (22) is continuously fed to the solidification device (24) by the conveyor belt device (23).
- the storage device (28) On the outlet side of the solidification device (24), the storage device (28) is provided, which is formed in this embodiment by a winding station (29).
- the winding station (29) generates a nonwoven roll (30) from the continuously supplied composite nonwoven (36).
- FIG. 1 and 2 illustrated device of the invention is particularly suitable to carry out the process for producing a composite nonwoven fabric (36), which is used as insulating or Dämmmaterial.
- composite nonwovens usually have a relatively low basis weight and a relatively loose structure contained within the composite nonwoven Fibers.
- a continuous fiber stream of fibers or fiber mixtures of the carding device (1) abandoned.
- the fibers (31) are fed via the feed device (2) and carded within the carding device (1) via one or more drum systems and removed as a batt (32).
- the batt (32) is taken up by the transport device (9) and continuously discharged.
- the conveyor belts (10.1) and (10.2) of the transport device (9) are operated at a belt speed in the range of 50 m / min to 200 m / min.
- the belt speed is determined by the carding device (1) or the fleece laying device (22).
- the batt (32) is transferred from the first conveyor belt (10.1) to the delivery belt (11) such that the batt (32) leads to the meltblowing device (12) in which a nonwoven layer is formed on the surface of the batt (32) (35) made of synthetic fibers (33) laid and the compound is formed.
- the fibrous web (32) is guided on the depositing belt (11) through a holding zone, for example a suction zone.
- the suction zone is formed in this embodiment by the three suction chambers (18.1, 18.2 and 18.3) in the suction zone, the underside of the storage belt (11), which is gas-permeable and, for example, may be a mesh belt or fabric tape, sucked.
- a holding force is generated on the batt (32), so that in the deposition zone of the synthetic fibers (33), the structure of the batt (32) is maintained despite the air flows generated during meltblowing.
- meltblowing a polymer melt is melted via an extruder (14) and fed to a spinning head (13).
- a meltblowing die On the underside of the spinning head (13) there is provided a meltblowing die through which a plurality of synthetic fibers (33) are extruded and fed through a pressurized gas also supplied in the spinning head (13), e.g. Compressed air, withdrawn and blown in the direction of the storage belt (11).
- the melt-blowing nozzle, the melt throughput and the compressed air setting are hereby preferably chosen such that relatively fine synthetic fibers (33) are produced.
- the synthetic fibers (33) preferably have a fine fiber cross section in the range of 0.5 ⁇ m to 3 ⁇ m to form the nonwoven layer (35) on the surface of the batt (32).
- the synthetic fibers (33) are preferably deposited on the fibrous web (32) in the middle region of the suction zone, so that the separately adjustable suction capacities of the suction chambers (18.1 to 18.3) in an inlet region, in an abutment region and in an outlet region of the fibrous web (32).
- the separately adjustable suction capacities of the suction chambers (18.1 to 18.3) in an inlet region, in an abutment region and in an outlet region of the fibrous web (32).
- a sufficient holding force can be generated on the fiber web (32) when the fibrous web (32) enters.
- the deposits of the synthetic fibers (33) can be influenced by different suction powers.
- the blown air generated by melt blowing can be incorporated into the deposition process of the synthetic fibers by the suction chamber ambient air. This allows additional effects and structures to be produced in the nonwoven layer.
- the batt (32) with the nonwoven layer (35), ie the compound, through the conveyor belt (10.2) of the batt (22) is supplied.
- the fleece laying device (22) is the Fibrous web (32) with the nonwoven layer (35) laid in multiple layers to the desired composite nonwoven fabric (36).
- the composite nonwoven (36) has, for example, at least two superimposed layers of the batt (32) or a plurality of double layers of the batt (32) or compounds.
- the composite web (36) is continuously removed by the conveyor belt device (23) and fed to the solidification device (24).
- the belt speed of the conveyor belt device (23) is dependent on the number of layers and the laying width of the fleece laying device (22).
- the composite fleece (36) is thermally consolidated, where in particular in a calibration zone on the interaction of the guide belt (26) and the Kalibrierbandes (27), the material thickness of the composite web (36) is determined.
- the composite nonwoven fabric (36) is wound up into the nonwoven roll (30).
- the method and apparatus shown are used to form the batt (32) preferably 100% synthetic fibers.
- the fiber material of the synthetic fibers and the polymer melt for extruding the synthetic fibers (33) are formed from an identical base material.
- a base material for example, a polyester or a polypropylene would be suitable.
- the specific properties of the fiber material of the synthetic fibers and the fiber material of the synthetic fibers (33) are matched to one another such that essentially only the synthetic fibers in the batt (32) are melted for solidification during the thermobonding.
- the fiber material of the synthetic fibers which may also be formed as a biofibers, with a something lower melting point compared to the synthetic fibers.
- a second carding device with a pickup device is arranged between the meltblowing device (12) and the web laying device (22) in order to produce a second web.
- the second batt would be laid on the batt so that the batt layer is sandwiched between a lower and upper batt layer.
- one or both batt made of a fiber blend of synthetic fibers and natural fibers.
- at least 10% of the fibers are formed by synthetic fibers.
- FIG. 4 a further embodiment of the device according to the invention for carrying out the method according to the invention schematically shown in a partial view.
- the embodiment is essentially identical to the aforementioned embodiment according to FIG. 1 and 2 , so that at this point only the differences will be explained and otherwise reference is made to the above description.
- the pickup device (7) forms two pickup points (37.1) and (37.2).
- a picking roller system (8) is provided in each case for picking up a respective fiber web (32.1) and (32.2) and feeding it to the transport device (9).
- the transport device (9) has in this embodiment, a lower band assembly (38.1) and an upper band assembly (38.2).
- Under the band arrangement (38.1) is identical to the embodiment according to FIG. 1 and 2 educated.
- the upper band arrangement (38.2) has a transport section (10.3), which is guided parallel to the depositing belt (11) above the spinning head (13).
- the upper band arrangement (38.2) can in this case be formed in several parts by a plurality of conveyor belts or also in one piece by a circulating conveyor belt.
- both belt assemblies (38.1) and (38.2) of the transport device (9) are brought together in such a way that the two fiber webs (32.1) and (32.2) are combined in a sandwich and between them Include nonwoven layer (35).
- the multilayer nonwoven fabric or multilayer compound thus formed is fed to the nonwoven laying device (22) and laid down in several layers to form the composite nonwoven fabric (36).
- the suction zone is formed in this embodiment only by a suction chamber (18) of the suction device (17).
- the suction chamber (18) preferably extends in the longitudinal direction of the storage belt (11) such that immediately before or at the inlet of the batt (32) in the deposition zone of the meltblowing device (12) a holding force on the batt (32) by the suction of the suction chamber (18) is produced.
- FIG. 5 a further embodiment shown schematically in a partial view, which is substantially identical to the embodiment in FIG. 4 is.
- the band arrangements (38.1) and (38.2) are identical, so that the band arrangement (38.1) has a lower depositing band (11.1) and the band arrangement (38.2) has an upper depositing band (11.2).
- Each of the storage belts (11.1) and (11.2) is assigned in each case a suction chamber (18.1) and (18.2) which independently of one another convey the respective storage belts (11.1) and (11.2).
- a respective spinning head (13.1) and (13.2) of the melt blowing device (12) is arranged above the storage belts (11.1) and (11.2).
- the spinning heads (13.1) and (13.2) are coupled together with an extruder (14).
- each of the batt (32.1) and (32.2) each generates a nonwoven layer (35.1) and (35.2).
- the nonwoven layers (35.1) and (35.2) can be identical or different in structure and construction.
- the two batts (32.1) and (32.2) are brought together with the nonwoven layers (35.1) and (35.2) laid on the surfaces and fed as a multi-layer nonwoven or multi-layer compound to the nonwoven laying device (22).
- the method shown and the apparatus shown can be expanded flexibly to produce single-layer or multi-ply batt for the production of composite nonwovens.
- three fiber piles could simultaneously be produced by three separate pickup locations, which are combined via three conveyor belt systems to form a multi-layer nonwoven or multi-layer compound and fed to a fleece laying device.
- two meltblowing devices could be arranged, which are associated with the conveyor belt systems, so that two of the three fiber webs are covered with a nonwoven layer of synthetic fibers prior to the joining.
- multilayer nonwovens can advantageously be produced which contain synthetic fibers of two different polymers.
- meltblowing devices could also be assigned one after the other to a conveyor belt system in order to deposit two nonwoven layers on a batt.
- FIG. 1 and 2 illustrated means for producing the composite nonwoven fabric are exemplary.
- the method according to the invention and the device according to the invention are also suitable for the production of composite tiles, in which the solidification is produced by chemical means or by mechanical means, such as needle punching.
- the composite nonwoven fabric can also be cut into individual nonwoven pieces for storage and then stacked to form a stack.
- the winding station could be replaced by a stacking station.
- the holding device (17) may be formed and arranged in another way, e.g. as electrostatic or mechanical holding device which holds the batt (32) with electrostatic forces, hooks or needles or the like.
- the storage belt (11, 11.1, 11.2) On the storage belt (11, 11.1, 11.2) and stabilized against blowing.
- the storage belt (11, 11.1, 11.2) can in turn be gas-permeable.
- On a suction device can be omitted in these cases.
- a suction device may alternatively be present, but designed to be weaker.
- the further treatment is designed as a fleece laying device (22), for example as a crosslapper, in particular as a leveler, which screens or deposits the supplied single-layer or multilayer compound on the discharge belt (23) in a zigzag shape and with shingled layer formation.
- a fleece laying device (22) may be designed as a feeder, Camel-back-Leger or the like.
- the single-layer or multi-layer compound can be cut before the tray in a further variation and subdivided into pieces, the pieces being laid one on top of the other and possibly aligned one above the other to form a multilayer composite nonwoven (36).
- the fleece laying device (22) is designed for this purpose in a correspondingly modified manner.
- the mono- or multi-layer compound is fed to a nonwoven laying device (22) as soon as it is formed.
- an intermediate step between the compound formation and a nonwoven laying device (22) can be inserted.
- the single-layer or multi-layered compound are taken up and temporarily stored, whereby it is supplied to a nonwoven laying device (22) or another further processing process at a later point in time.
- said compound may e.g. stabilized and wound up in a suitable manner.
- a multilayer composite fleece (36) with an outer and / or inner fleece layer (35, 35.1, 35.2) has particular advantages for the sound insulation.
- the exemplary embodiments shown for multilayer or sandwich formation of the composite nonwoven (36) are particularly advantageous for this purpose.
- a composite nonwoven fabric can also be produced in one layer in the aforementioned manner and used for insulation purposes.
Description
Die Erfindung betrifft ein Verfahren zur Herstellung eines Verbundvlieses in einer kontinuierlichen Prozessfolge sowie eine Vorrichtung zur Durchführung des Verfahrens.The invention relates to a method for producing a composite nonwoven fabric in a continuous process sequence and to an apparatus for carrying out the method.
Die
Die
Zur Herstellung von Verbundvliesen ist es allgemein bekannt, dass die Eigenschaften des Verbundvlieses im Wesentlichen durch das Zusammenwirken mehrerer verschiedenartiger Vlieslagen bestimmt sind. So hat sich beispielsweise bei den Verbundvliesen, die zur Geräuschdämmung verwendet werden, herausgestellt, dass insbesondere die Materialdichtenunterschiede der Vlieslagen dazu führen, dass Schallwellen kompensiert und wenig reflektiert werden. Derartige Verbundvliese, die zur Isolation und zur Geräuschdämmung verwendet werden, weisen ein relativ geringes Flächengewicht auf, so dass an deren Herstellung besondere Anforderungen gestellt sind.For the production of composite nonwovens, it is generally known that the properties of the composite nonwoven fabric are essentially determined by the interaction of several different types of nonwoven layers. For example, in the case of the composite nonwovens used for noise insulation, it has been found that, in particular, the differences in the material density of the nonwoven layers cause sound waves to be compensated for and to be little reflected. Such composite nonwovens, which are used for insulation and noise reduction, have a relatively low basis weight, so that special demands are made on their production.
Aus der
Aus der
Die
Es ist Aufgabe der vorliegenden Erfindung, eine bessere Herstelltechnik für Verbundvliese aufzuzeigen.It is an object of the present invention to provide a better production technique for composite nonwovens.
Ein weiteres Ziel der Erfindung liegt darin, ein durch eine Kardiereinrichtung erzeugtes Faserflor mit möglichst hoher Bandgeschwindigkeit zu einem Verbundvlies zu führen. Ferner ist ein Ziel der Erfindung die Bildung eines mehrlagigen schalldämmenden Vlieselements.A further object of the invention is to guide a batt produced by a carding device with the highest possible belt speed to a composite web. Further, an object of the invention is the formation of a multi-layer acoustic insulating nonwoven member.
Die Aufgabe wird durch die selbstständigen Verfahrens- und Vorrichtungsansprüche gelöst.The problem is solved by the independent process and device claims.
Vorteilhafte Weiterbildungen der Erfindung sind durch die Merkmale und Merkmalskombinationen der jeweiligen Unteransprüche definiert.Advantageous developments of the invention are defined by the features and feature combinations of the respective subclaims.
Bei der
Die beanspruchte Technik hat den Vorteil, dass selbst sehr lockere und leichte gelegte Faserflore sicher mit einer durch Schmelzblasen hergestellten Vlieslage kombiniert werden können. Eine durch den Faserstrom des Schmelzblasens verursachte Verwirbelung und Veränderung des Faserflors wird dadurch vermieden, dass der Faserflor in eine Haltezone, z.B. eine Saugzone, geführt wird, so dass der Faserflor an dem Ablageband eine z.B. über den Saugstrom erzeugte Fixierung erhält. Die beim Schmelzblasen erzeugten Synthetikfasern werden im Bereich der Halte- oder Saugzone zu einer Vlieslage unmittelbar auf dem Faserflor abgelegt und hierbei mit diesem zu einem Compound verbunden. Die dabei auftretende überschüssige Blasluft lässt sich ebenfalls vorteilhaft über eine Saugzone aufnehmen und abführen. Um die als Decklage erzeugte Vlieslage in einer Struktur von mehreren Faserfloren einbetten zu können, kann der Faserflor mit Vlieslage aus der Saugzone herausgeführt und zu einer Vlieslegeeinrichtung geleitet werden. Die Vlieslegereinrichtung kombiniert dann mehrere Lagen des Faserflors bzw. Compounds zu dem Verbundvlies.The claimed technique has the advantage that even very loose and lightweight laid batts can be safely combined with a nonwoven layer made by meltblowing. A turbulence and change of the batt caused by the fiber flow of the meltblowing is avoided by guiding the batt into a holding zone, eg a suction zone, so that the batt on the depositing belt receives a fixation, eg generated by the suction flow. The synthetic fibers produced by meltblowing are in the range the holding or suction zone deposited to a nonwoven layer directly on the batt and in this case connected with this to a compound. The resulting excess blown air can also be advantageously absorbed and removed via a suction zone. In order to be able to embed the nonwoven layer produced as a cover layer in a structure of several fibrous webs, the nonwoven fibrous web can be led out of the suction zone and directed to a web laying device. The fleece-laying device then combines several layers of the fiber pile or compound into the composite fleece.
Um ein sicheres Einlaufen des Faserflors in den Legebereich der Schmelzblaseinrichtung zu erhalten und um den mit der Vlieslage kombinierten Faserflor aus dem Legebereich herauszuführen, ist die Weiterbildung der Erfindung besonders vorteilhaft, bei welcher das Faserflor innerhalb der Saugzone mehrere hintereinander liegende Saugbereiche mit separat einstellbaren Saugleistungen durchläuft. Damit können jeweils auf den Zustand des Faserflors angepasste Druckverhältnisse an dem Ablageband erzeugt werden, um einerseits eine aus der Umgebung erzeugten Saugstrom zu minimieren und andererseits die durch das Schmelzblasen erzeugte Blasluft sicher aufzunehmen. Zudem lässt sich durch unterschiedliche Druckeinstellungen darüber hinaus die unmittelbare Ablage der Synthetikfasern beeinflussen, um bestimmte Strukturen innerhalb der Vlieslagen zu erzeugen.In order to obtain a safe shrinkage of the batt in the laying area of the meltblown device and to lead out the laying area combined with the batt layer from the laying area, the development of the invention is particularly advantageous in which the batt inside the suction zone passes through several successive suction regions with separately adjustable suction , Thus, in each case adapted to the state of the batt printed pressure conditions can be generated on the storage belt, on the one hand to minimize a suction generated from the environment suction and on the other hand to safely receive the blown air generated by the melt blowing. In addition, different pressure settings also allow the immediate deposition of the synthetic fibers to be influenced in order to create certain structures within the nonwoven layers.
Grundsätzlich lässt sich der Faserflor aus Fasern und Fasergemischen synthetischer oder natürlicher Fasern bilden. Für die Bindung und Verfestigung hat sich jedoch als besonders vorteilhaft herausgestellt, wenn die Fasern oder Fasergemische zur Bildung des Faserflors mit einem Gewichtsanteil im Bereich zwischen 10 % und 100 % aus synthetischen Fasern gebildet sind.In principle, the batt can be formed from fibers and fiber mixtures of synthetic or natural fibers. For binding and solidification, however, it has proven to be particularly advantageous if the fibers or fiber mixtures are formed to form the batt with a weight fraction in the range between 10% and 100% of synthetic fibers.
Hierbei ist die Verfahrensvariante bevorzugt verwendet, bei welcher das Fasermaterial der synthetischen Fasern und die Polymerschmelze zum Extrudieren der Synthetikfasern aus einem identischen Grundwerkstoff gebildet sind. Damit lässt sich das Recyceln derartiger Verbundvliese erheblich verbessern.Here, the method variant is preferably used, in which the fiber material of the synthetic fibers and the polymer melt for extruding the synthetic fibers are formed from an identical base material. This considerably improves the recycling of such composite nonwovens.
Die Vlieslage an der Oberfläche des Faserflors wird bevorzugt mit feinen Fasern gelegt, um die für die Schalldämmung vorteilhaften Eigenschaften zu erhalten. Insoweit ist die Verfahrensvariante bevorzugt verwendet, bei welcher die Synthetikfasern beim Schmelzblasen mit einem feinen Faserquerschnitt im Bereich von 0,2 µm bis 3 µm zu der Vlieslage auf dem Faserflor gelegt werden. Je nach Anwendung lässt sich das Verbundvlies jedoch auch mit gröberen Synthetikfasern vorteilhaft herstellen.The nonwoven layer on the surface of the batt is preferably laid with fine fibers to obtain the properties advantageous for the soundproofing. In that regard, the variant of the method is preferably used, in which the synthetic fibers are placed on the fiber web during melt blowing with a fine fiber cross section in the range of 0.2 microns to 3 microns to the nonwoven layer. Depending on the application, however, the composite fleece can also be produced advantageously with coarser synthetic fibers.
Die Leistungsfähigkeit der Kardiereinrichtung wird insbesondere mit der Verfahrensvariante ausgeschöpft, bei welcher das Faserflor nach dem Abnehmen bis zum Ablegen kontinuierlich mit einer Bandgeschwindigkeit im Bereich von 50 m/min bis 200 m/min geführt wird. Dabei ist im Wesentlichen die Kapazität der Vlieslegereinrichtung maßgeblich für die Begrenzung der Bandgeschwindigkeit.The performance of the carding device is exploited in particular with the variant of the method in which the batt is continuously guided after removal until it is deposited at a belt speed in the range from 50 m / min to 200 m / min. In this case, essentially the capacity of the fleece-laying device is decisive for the limitation of the belt speed.
Um verschiedene Typen von Verbundvliesen herstellen zu können, wird eine weitere Verfahrensvariante vorgeschlagen, bei welcher mehrere Faserflore parallel nebeneinander von der Kardiereinrichtung abgenommen werden und nach dem Schmelzblasen und Ablegen der Synthetikfasern sandwichartig zusammengelegt werden, wobei die Vlieslage zwischen den Faserfloren eine Zwischenlage bildet. Derartige doppelte Faserflorlagen sind insbesondere geeignet, um die als Zwischenlage erhaltene Vlieslage der Synthetikfasern gegenüber den weiteren Behandlungen zu schützen. Die Struktur und Verteilung der Synthetikfasern innerhalb der Vlieslage bleiben unverändert und können somit bereits im Herstellungsprozess auf die erforderlichen spezifischen Eigenschaften eingestellt werden.In order to be able to produce different types of composite nonwovens, a further process variant is proposed in which a plurality of batts are taken parallel next to each other from the carding device and are pooled together after the meltblowing and laying down of the synthetic fibers, wherein the nonwoven layer forms an intermediate layer between the batts. Such double batt layers are particularly suitable for protecting the intermediate nonwoven layer of the synthetic fibers from further treatment. The structure and distribution of the synthetic fibers within the nonwoven layer remain unchanged and can thus already adjusted in the manufacturing process to the required specific properties.
Grundsätzlich besteht jedoch auch die Möglichkeit, beide Faserflore parallel mit jeweils einer Vlieslage zu belegen, die zu einem Mehrschichtvlies zusammengeführt werden.In principle, however, it is also possible to occupy both batts in parallel, each with a nonwoven layer, which are combined to form a multi-layer nonwoven.
Um den Zusammenhalt der in mehreren Lagen aufeinander gelegten Faserflore zu gewährleisten, wird des Weiteren vorgeschlagen, das durch die Vlieslegereinrichtung gelegte Verbundvlies kontinuierlich einer Verfestigungseinrichtung zuzuführen und zu verfestigen. Die Verfestigung kann hierbei mechanisch, chemisch oder thermisch erfolgen.In order to ensure the cohesion of the overlaid in several layers of batt, it is further proposed to continuously feed the composite laid by the nonwoven fabric composite web to a solidification device and solidify. The solidification can be done mechanically, chemically or thermally.
Um die jeweiligen Vlieslagen innerhalb des Verbundvlieses aus den Synthetikfasern möglichst vollständig zu erhalten, ist die Verfahrensvariante besonders vorteilhaft, bei welcher das Verbundvlies durch eine thermische Behandlung in einem Bandtrockner verfestigt wird, wobei das Verbundvlies während der Verfestigung durch eine Kalibrierzone geführt wird, in welcher ein relativ zu einem Führungsband verstellbares Kalibrierband auf eine freie Oberseite des Verbundvlieses einwirkt. Neben der Verfestigung lässt sich auch eine bestimmte Dicke an dem Verbundvlies einstellen. Das Aufschmelzen der Synthetikfasern innerhalb der Vlieslagen lässt sich dabei vorteilhaft derart vermeiden, dass das Fasermaterial der Synthetikfasern gegenüber den synthetischen Fasern des Faserflors einen leicht höheren Schmelzpunkt aufweist. Dies lässt sich vorteilhaft auch bei gleichem Grundpolymer durch Additive erreichen.In order to obtain the respective nonwoven layers within the composite nonwoven fabric from the synthetic fibers as completely as possible, the process variant is particularly advantageous, in which the composite nonwoven is solidified by a thermal treatment in a belt dryer, wherein the composite nonwoven is guided during solidification through a calibration zone, in which Relative to a guide band adjustable calibration belt acts on a free top of the composite web. In addition to solidification, it is also possible to set a specific thickness on the composite nonwoven. The melting of the synthetic fibers within the nonwoven layers can be advantageously avoided such that the fiber material of the synthetic fibers has a slightly higher melting point than the synthetic fibers of the batt. This can be advantageously achieved by additives even with the same base polymer.
Für die Weiterverarbeitung derartiger Verbundvliese ist des Weiteren vorgesehen, dass das Verbundvlies in einer Speichereinrichtung zu einem Wickel oder alternativ zu einem Stapel aufgespeichert wird. Bei einer Stapelbildung weist die Speichereinrichtung zusätzlich eine Schneideinrichtung auf, um jeweils das Verbundvlies in einzelne Vliesstücke zu zerschneiden, die dann aufeinander liegend gestapelt werden.For the further processing of such composite nonwovens is further provided that the composite nonwoven in a storage device to a winding or alternatively to is stored in a stack. In a stack formation, the storage device additionally has a cutting device in order to cut each of the composite nonwoven into individual nonwoven pieces, which are then stacked on top of each other.
Zur Durchführung des beanspruchten Verfahrens ist die erfindungsgemäße Vorrichtung vorgesehen. Diese weist bevorzugt eine Kardiereinrichtung, eine Abnehmereinrichtung, eine Transporteinrichtung und eine Vlieslegeeinrichtung auf, wobei zwischen der Abnehmereinrichtung und der Vlieslegeeinrichtung eine Station zur Erzeugung einer Vlieslage aus Synthetikfasern vorgesehen ist. Zur Lösung der erfindungsgemäßen Aufgabe ist die Station als eine Schmelzblaseinrichtung ausgebildet, der eine Halte-, insbesondere Saugeinrichtung zugeordnet ist. Die Saugeinrichtung ist bevorzugt unterhalb eines Ablagebandes der Transporteinrichtung angeordnet, so dass der auf dem Ablageband geführte Faserflor über eine Saugwirkung fixiert an dem Ablageband gehalten wird.To carry out the claimed method, the device according to the invention is provided. This preferably has a carding device, a pickup device, a transport device and a web laying device, wherein a station for producing a nonwoven layer made of synthetic fibers is provided between the pickup device and the web laying device. To achieve the object of the invention, the station is designed as a melt blowing device, which is associated with a holding, in particular suction device. The suction device is preferably arranged below a storage belt of the transport device, so that the guided on the storage belt batt is held fixed on a suction effect on the storage belt.
Die Saugeinrichtung zur Besaugung des Ablagebandes wird dabei gemäß einer vorteilhaften Weiterbildung der erfindungsgemäßen Vorrichtung durch mehrere Saugkammern gebildet, die an eine Unterdruckquelle angeschlossen sind, wobei den Saugkammern zur Einstellung eines individuellen Unterdrucks separate Steuermittel zugeordnet sind. Damit lässt sich sowohl die Lage des Faserflors als auch die Ablage der Synthetikfasern in die Vlieslage hinein beeinflussen.The suction device for the suction of the storage belt is formed according to an advantageous development of the device according to the invention by a plurality of suction chambers, which are connected to a vacuum source, the suction chambers are assigned to set an individual negative pressure separate control means. Thus, both the position of the batt and the storage of synthetic fibers in the nonwoven layer can be influenced.
Um bei der Herstellung des Verbundvlieses möglichst wenig Abfallmaterial zu produzieren, ist die Weiterbildung der erfindungsgemäßen Vorrichtung bevorzugt verwendet, bei welcher die Schmelzblaseinrichtung einen beweglichen Spinnkopf aufweist, welcher zwischen einer Betriebsposition oberhalb des Ablagebandes und einer Ruheposition seitlich neben dem Ablageband führbar ist. Damit lassen sich ein Anspinnen und Anfahren der Schmelzblaseinrichtung außerhalb der Betriebsposition durchführen, so dass der in der Betriebsposition gehaltene Spinnkopf ausschließlich zur Herstellung des Verbundvlieses nutzbar ist.In order to produce as little waste material as possible in the production of the composite nonwoven fabric, the development of the device according to the invention is preferably used, in which the melt blowing device has a movable spinning head, which between a Operating position above the storage belt and a rest position laterally next to the storage belt is feasible. In this way, piecing and starting of the melt blowing device can be carried out outside the operating position, so that the spinning head held in the operating position can be used exclusively for producing the composite nonwoven.
Um Kombinationen von Faserfloren herstellen zu können, ist die erfindungsgemäße Vorrichtung speziell derart weitergebildet, dass die Abnehmereinrichtung zwei separate Abnehmerstellen aufweist, die mit zwei Bandanordnungen der Transporteinrichtung zur Aufnahme und Abfuhr mehrerer Faserflore zusammenwirkt. Zur Herstellung einer sandwichartigen Faserflorkombination mit zwischenliegender Vlieslage wird die Variante der Vorrichtung verwendet, bei welcher eines der Bandanordnungen mit dem Ablageband zusammenwirkt und die zweite Bandanordnung mit einem Transportabschnitt parallel zu dem Ablageband oberhalb des Spinnkopfes angeordnet ist. Damit können die von der Kalibriereinrichtung abgenommenen Faserflore ohne Auslenkung in einer Ebene geführt werden.In order to be able to produce combinations of fiber webs, the device according to the invention is specially developed in such a way that the pickup device has two separate pickup locations, which cooperate with two band arrangements of the transport device for receiving and removing a plurality of bobbins. To produce a sandwich-type fibrous pad combination with an intermediate nonwoven layer, the variant of the device is used in which one of the band arrangements cooperates with the depositing belt and the second belt arrangement is arranged with a transport section parallel to the depositing belt above the spinning head. Thus, the removed from the calibration fiber baffles can be performed without deflection in a plane.
Alternativ besteht jedoch auch die Möglichkeit, dass die zweite Bandanordnung ein zweites Ablageband aufweist und dass dem zweiten Ablageband ein zweiter Spinnkopf der Schmelzblaseinrichtung zugeordnet ist. Somit können mehrere Faserflore mit kombinierter Vlieslage erzeugt werden.Alternatively, however, there is also the possibility that the second band arrangement has a second depositing band and that the second depositing band is assigned a second spinner head of the melt blowing device. Thus, several batt with combined nonwoven layer can be produced.
Die Weiterbehandlung des Verbundvlieses erfolgt innerhalb der Vorrichtung durch eine Förderbandeinrichtung, die die Vlieslegereinrichtung mit einer Verfestigungseinrichtung und einer Speichereinrichtung verbindet. Innerhalb der Speichereinrichtung lässt sich so das Verbundvlies zu einem Wickel oder Stapel speichern.The further treatment of the composite web takes place within the device by means of a conveyor belt device which connects the web laying device with a solidification device and a storage device. Within the storage device, the composite fleece can thus be stored to form a roll or stack.
Zur Verfestigung wird vorgeschlagen, dass die Vorrichtung einen Bandtrockner mit einem Führungsband und einem oberhalb des Führungsbandes angeordneten Kalibrierbandes aufweist, wobei das Kalibrierband relativ zum Führungsband höhenverstellbar ausgebildet ist. Somit können neben den Verfestigungen auch gezielte Materialstärken an dem Verbundvlies erzeugt werden.For solidification, it is proposed that the device has a belt dryer with a guide belt and a calibration belt arranged above the guide belt, wherein the calibration belt is designed to be height-adjustable relative to the guide belt. Thus, in addition to the solidifications, it is also possible to produce targeted material thicknesses on the composite nonwoven.
Das erfindungsgemäße Verfahren wird nachfolgend anhand einiger Ausführungsbeispiele der erfindungsgemäßen Vorrichtung zur Herstellung eines Verbundvlieses unter Bezug auf die beigefügten Figuren näher erläutert.The method according to the invention will be explained in more detail below with reference to some embodiments of the device according to the invention for producing a composite non-woven with reference to the accompanying figures.
Es stellen dar:
Figur 1- schematisch eine erste Teilansicht eines ersten Ausführungsbeispiels einer erfindungsgemäßen Vorrichtung,
Figur 2- schematisch eine zweite Teilansicht des Ausführungsbeispiels aus
Figur 1 , Figur 3- schematisch eine Querschnittsansicht der Schmelzblaseinrichtung des Ausführungsbeispiels aus
Figur 1 in mehreren Betriebspositionen, Figur 4- schematisch eine Teilansicht eines weiteren Ausführungsbeispiels der erfindungsgemäßen Vorrichtung und
Figur 5- schematisch eine Teilansicht eines weiteren Ausführungsbeispiels der erfindungsgemäßen Vorrichtung.
- FIG. 1
- FIG. 2 schematically a first partial view of a first embodiment of a device according to the invention, FIG.
- FIG. 2
- schematically a second partial view of the embodiment of
FIG. 1 . - FIG. 3
- schematically a cross-sectional view of the melt blowing device of the embodiment of
FIG. 1 in several operating positions, - FIG. 4
- schematically a partial view of another embodiment of the device according to the invention and
- FIG. 5
- schematically a partial view of another embodiment of the device according to the invention.
Die Erfindung betrifft ein Verfahren und eine Vorrichtung zur Herstellung eines Verbundvlieses (36) und ein hieraus hergestelltes schallabsorbierendes Vlieselement.The invention relates to a method and an apparatus for producing a composite nonwoven fabric (36) and to a sound-absorbing nonwoven element produced therefrom.
In den
Die erfindungsgemäße Vorrichtung weist in der vorderen Maschinenhälfte gemäß
An dieser Stelle sei ausdrücklich erwähnt, dass der Aufbau und die Anzahl der in der Kardiereinrichtung verwendeten Trommeln und Kardierelemente beispielhaft sind. Grundsätzlich sind auch Kardiereinrichtungen mit nur einer Trommel einsetzbar.It should be expressly mentioned at this point that the construction and the number of drums and carding elements used in the carding device are exemplary. In principle, carding devices with only one drum can be used.
Die Abnehmereinrichtung (7) ist in diesem Ausführungsbeispiel durch ein Abnehmerwalzensystem (8) gebildet, das unmittelbar mit einem Transportband (10.1) einer Transporteinrichtung (9) zusammenwirkt. Die Transporteinrichtung (9) ist in diesem Ausführungsbeispiel durch ein erstes Transportband (10.1), eine Ablageband (11) und ein zweites Transportband (10.2) gebildet, die gemeinsam zusammenwirken, um einen Faserflor (32) kontinuierlich von der Kardiereinrichtung (1) aufzunehmen und abzutransportieren.The pickup device (7) is formed in this embodiment by a picking roller system (8) which interacts directly with a conveyor belt (10.1) of a transport device (9). The transport device (9) is formed in this embodiment by a first conveyor belt (10.1), a storage belt (11) and a second conveyor belt (10.2), which cooperate together to continuously receive a batt (32) from the carding device (1) and evacuate.
Dem Ablageband (11) ist auf einer Oberseite eine Schmelzblaseinrichtung (12) und an einer Unterseite eine Halteeinrichtung (17) zugeordnet. Mit der Schmelzblaseinrichtung (12) wird an der Oberfläche des Faserflors (32) eine Vlieslage (35) aus schmelzgeblasenen Synthetikfasern (33) aufgebracht, z.B. mit einem Druckgasstrom. Der Verbund von Faserflor (32) und Vlieslage (35) wird nachfolgend als Compound bezeichnet.The storage belt (11) is associated with a melt blowing device (12) on an upper side and a holding device (17) on an underside. A nonwoven layer (35) of meltblown synthetic fibers (33) is applied to the surface of the fibrous web (32) by the meltblowing device (12), e.g. with a compressed gas stream. The composite of batt (32) and nonwoven layer (35) is referred to below as compound.
Die Halteeinrichtung (17) kann auf den Faserflor (32) und/oder auf einen Druckgasstrom der Schmelzblaseinrichtung (12) einwirken. Sie kann z.B. den Faserflor (32) auf dem Ablageband (11) halten und gegenüber dem auftreffenden Druckgasstrom mit den schmelzgeblasenen Fasern (33) stabilisieren. Sie kann auch auf den Druckgasstrom und den Faserstrom führend einwirken. Sie kann z.B. den Druckgasstrom nach der Abgabe der Fasern (33) an den Faserflor (32) kontrolliert ableiten. Die Halteeinrichtung (17) kann z.B. als Saugeinrichtung ausgebildet sein.The holding device (17) can act on the fiber web (32) and / or on a compressed gas stream of the melt blowing device (12). It can e.g. Hold the batt (32) on the storage belt (11) and stabilize it against the impinging compressed gas flow with the meltblown fibers (33). It can also act as a leader on the pressure gas flow and the fiber flow. It can e.g. the compressed gas stream after the delivery of the fibers (33) to the batt (32) derived controlled. The holding device (17) may e.g. be designed as a suction device.
Das Ablageband (11) ist gasdurchlässig ausgebildet und wird über insgesamt drei Saugkammern (18.1, 18.2 und 18.3) der Saugeinrichtung (17) geführt. Die Saugkammern (18.1, 18.2 und 18.3) der Saugeinrichtung (17) sind über separate Saugleitungen (19.1, 19.2 und 19.3) unabhängig voneinander mit einer Unterdruckquelle (hier nicht dargestellt) verbunden und über zugeordnete Steuermittel (20.1, 20.2, 20.3) unabhängig voneinander in ihrer Saugleistung einstellbar.The storage belt (11) is gas-permeable and is guided over a total of three suction chambers (18.1, 18.2 and 18.3) of the suction device (17). The suction chambers (18.1, 18.2 and 18.3) of the suction device (17) via separate suction lines (19.1, 19.2 and 19.3) independently of each other with a vacuum source (not shown here) and via associated control means (20.1, 20.2, 20.3) independently of each other in their suction power adjustable.
Oberhalb der mittleren Saugkammer (18.2) weist die Schmelzblaseinrichtung (12) einen Spinnkopf (13) auf, der durch eine Schmelzleitung (34) mit einem Extruder (14) gekoppelt ist. Der Spinnkopf (13) weist auch einen Anschluss an eine Druckgaszuführung (15), z.B. Druckluftzuführung, auf, die über ein Steuerventil (16) mit einer Druckluftquelle (hier nicht dargestellt) verbunden ist. Der Spinnkopf (13) weist an seiner Unterseite eine Schmelzblasdüse auf, die sich im Wesentlichen über die gesamte Breite des Ablagebandes (11) erstreckt. Die Breite der Schmelzblasdüse des Spinnkopfes (13) ist identisch mit der Arbeitsbreite der Kardiereinrichtung (1). So können die Arbeitsbreiten der Kardiereinrichtung (1) im Bereich von 2 m bis 4 m und darüber ausgebildet sein. Dementsprechend ist die Breite der Schmelzblasdüse ebenfalls im Bereich von 2 m bis 4 m ausgeführt.Above the middle suction chamber (18.2), the melt blowing device (12) has a spinner head (13), which is coupled by a melt line (34) to an extruder (14). The spinning head (13) also has a connection to a pressurized gas supply (15), eg compressed air supply, via a control valve (16) with a compressed air source (not shown here) is connected. The spinner head (13) has on its underside a melt-blowing nozzle which extends substantially over the entire width of the depositing belt (11). The width of the melt-blowing nozzle of the spinning head (13) is identical to the working width of the carding device (1). Thus, the working widths of the carding device (1) may be in the range of 2 m to 4 m and above. Accordingly, the width of the meltblowing die is also in the range of 2 m to 4 m.
Der Spinnkopf (13) sowie der Extruder (14) sind in diesem Ausführungsbeispiel an einem beweglichen Träger (21) gehalten, durch welchen der Spinnkopf (13) zwischen einer Betriebsposition und einer Ruheposition hin und her führbar ist. Zur Veranschaulichung ist ein Querschnitt der Schmelzblaseinrichtung (12) in
In der Betriebsstellung befindet sich der Spinnkopf (13) der Schmelzblaseinrichtung (12) unmittelbar oberhalb des Ablagebandes (11), das an seiner Unterseite durch die Saugkammer (18.2) besaugt wird. Die Saugkammer (18.2) ist über die Saugleitung (19.2) und einem Steuermittel (20.2) mit einer hier nicht dargestellten Unterdruckquelle verbunden.In the operating position, the spinning head (13) of the melt blowing device (12) is located directly above the depositing belt (11), which is sucked on its underside by the suction chamber (18.2). The suction chamber (18.2) is connected via the suction line (19.2) and a control means (20.2) with a vacuum source, not shown here.
Der Träger (21) des Spinnkopfes (13) und des Extruders (14) ist beweglich ausgebildet und lässt sich beispielsweise über ein Schienensystem oder ein Rollensystem quer zum Ablageband (11) hin und her verschieben. Hierbei bleiben die Anschlüsse an dem Spinnkopf (13) unverändert. So ist der Spinnkopf (13) über die Schmelzleitung (34) mit dem Extruder (14) verbunden.The carrier (21) of the spinning head (13) and the extruder (14) is designed to be movable and can be moved back and forth, for example via a rail system or a roller system transversely to the storage belt (11). In this case, the connections to the spinning head (13) remain unchanged. Thus, the spinning head (13) via the melt line (34) to the extruder (14).
Über die Druckluftzuführung (15) und dem Steuerventil (16) ist eine Anbindung an eine Druckquelle vorgesehen.A connection to a pressure source is provided via the compressed air supply (15) and the control valve (16).
Wie in
Wie in der Darstellung in
Die Förderbandeinrichtung (23) wird dementsprechend in Abhängigkeit von der Anzahl der Lagen und von der Ablagebreite mit geringerer Bandgeschwindigkeit betrieben. Die Förderrichtung der Förderbandeinrichtung (23) ist somit quer zur Transportrichtung der Transporteinrichtung (9) ausgerichtet. Die nachfolgenden Einrichtungen der erfindungsgemäßen Vorrichtung bilden eine zweite Maschinenlängsseite an welchen die Einrichtungen hintereinander zur Weiterbehandlung eines Verbundvlieses angeordnet sind.The conveyor belt device (23) is accordingly operated at a lower belt speed depending on the number of layers and on the delivery width. The conveying direction of the conveyor belt device (23) is thus aligned transversely to the transport direction of the transport device (9). The following devices of the device according to the invention form a second machine longitudinal side on which the devices are arranged one behind the other for further treatment of a composite nonwoven fabric.
So ist in
Das durch die Vlieslegereinrichtung (22) gelegte, mehrlagige Verbundvlies (36) wird hierzu durch die Förderbandeinrichtung (23) der Verfestigungseinrichtung (24) kontinuierlich zugeführt.The multilayer composite nonwoven fabric (36) laid by the nonwoven laying device (22) is continuously fed to the solidification device (24) by the conveyor belt device (23).
Auf der Auslassseite der Verfestigungseinrichtung (24) ist die Speichereinrichtung (28) vorgesehen, die in diesem Ausführungsbeispiel durch eine Wickelstation (29) gebildet ist. Die Wickelstation (29) erzeugt aus dem kontinuierlich zugeführten Verbundvlies (36) ein Vlieswickel (30).On the outlet side of the solidification device (24), the storage device (28) is provided, which is formed in this embodiment by a winding station (29). The winding station (29) generates a nonwoven roll (30) from the continuously supplied composite nonwoven (36).
Die in
Bei dem Verfahren, wird wie in
Im weiteren Verlauf wird das Faserflor (32) von dem ersten Transportband (10.1) an dem Ablageband (11) übergeben, dass das Faserflor (32) zu der Schmelzblaseinrichtung (12) führt, in welcher an der Oberfläche des Faserflors (32) eine Vlieslage (35) aus Synthetikfasern (33) gelegt und der Compound gebildet wird. Zur Aufnahme und zur Erzeugung der Vlieslage (35) an der Oberfläche des Faserflors (32) wird der Faserflor (32) an dem Ablageband (11) durch eine Haltezone, z.B. eine Saugzone, geführt. Die Saugzone wird in diesem Ausführungsbeispiel durch die drei Saugkammern (18.1, 18.2 und 18.3) gebildet In der Saugzone wird die Unterseite des Ablagebandes (11), das gasdurchlässig ausgebildet ist und beispielsweise ein Siebband oder Gewebeband sein kann, besaugt. Dadurch wird eine Haltekraft an dem Faserflor (32) erzeugt, so dass in der Ablagezone der Synthetikfasern (33) die Struktur des Faserflors (32) trotz der beim Schmelzblasen entstehenden Luftströmungen erhalten bleibt.In the further course, the batt (32) is transferred from the first conveyor belt (10.1) to the delivery belt (11) such that the batt (32) leads to the meltblowing device (12) in which a nonwoven layer is formed on the surface of the batt (32) (35) made of synthetic fibers (33) laid and the compound is formed. For receiving and for producing the fleece layer (35) on the surface of the fibrous web (32), the fibrous web (32) is guided on the depositing belt (11) through a holding zone, for example a suction zone. The suction zone is formed in this embodiment by the three suction chambers (18.1, 18.2 and 18.3) in the suction zone, the underside of the storage belt (11), which is gas-permeable and, for example, may be a mesh belt or fabric tape, sucked. As a result, a holding force is generated on the batt (32), so that in the deposition zone of the synthetic fibers (33), the structure of the batt (32) is maintained despite the air flows generated during meltblowing.
Bei dem Schmelzblasen wird über einen Extruder (14) eine Polymerschmelze aufgeschmolzen und einem Spinnkopf (13) zugeführt. An der Unterseite des Spinnkopfes (13) ist eine Schmelzblasdüse vorgesehen, durch welche eine Vielzahl von Synthetikfasern (33) extrudiert werden und über ein im Spinnkopf (13) ebenfalls zugeführtes Druckgas, z.B. Druckluft, abgezogen und in Richtung des Ablagebandes (11) geblasen wird. Die Schmelzblasdüse, der Schmelzdurchsatz sowie die Drucklufteinstellung sind hierbei bevorzugt derart gewählt, dass relativ feine Synthetikfasern (33) erzeugt werden. Die Synthetikfasern (33) weisen vorzugsweise einen feinen Faserquerschnitt im Bereich von 0,5 µm bis 3 µm auf, um die Vlieslage (35) an der Oberfläche des Faserflors (32) zu bilden.During meltblowing, a polymer melt is melted via an extruder (14) and fed to a spinning head (13). On the underside of the spinning head (13) there is provided a meltblowing die through which a plurality of synthetic fibers (33) are extruded and fed through a pressurized gas also supplied in the spinning head (13), e.g. Compressed air, withdrawn and blown in the direction of the storage belt (11). The melt-blowing nozzle, the melt throughput and the compressed air setting are hereby preferably chosen such that relatively fine synthetic fibers (33) are produced. The synthetic fibers (33) preferably have a fine fiber cross section in the range of 0.5 μm to 3 μm to form the nonwoven layer (35) on the surface of the batt (32).
Die Synthetikfasern (33) werden vorzugsweise im mittleren Bereich der Saugzone auf dem Faserflor (32) abgelegt, so dass durch die separat einstellbaren Saugleistungen der Saugkammern (18.1 bis 18.3) in einem Einlaufbereich, in einem Anlagebereich und in einem Auslaufbereich des Faserflors (32) beim Schmelzblasen unterschiedliche Einstellungen der Saugleistungen möglich sind. Einerseits lässt sich beim Einlaufen des Faserflors (32) eine ausreichende Haltekraft an dem Faserflor (32) erzeugen. Andererseits können über unterschiedliche Saugleistungen die Ablagen der Synthetikfasern (33) beeinflusst werden. Daneben kann die beim Schmelzblasen erzeugte Blasluft durch die Saugkammerumgebungsluft in den Ablageprozess der Synthetikfasern mit eingebunden werden. Damit lassen sich so zusätzliche Effekte und Strukturen in der Vlieslage erzeugen.The synthetic fibers (33) are preferably deposited on the fibrous web (32) in the middle region of the suction zone, so that the separately adjustable suction capacities of the suction chambers (18.1 to 18.3) in an inlet region, in an abutment region and in an outlet region of the fibrous web (32). During melt blowing different settings of the suction power are possible. On the one hand, a sufficient holding force can be generated on the fiber web (32) when the fibrous web (32) enters. On the other hand, the deposits of the synthetic fibers (33) can be influenced by different suction powers. In addition, the blown air generated by melt blowing can be incorporated into the deposition process of the synthetic fibers by the suction chamber ambient air. This allows additional effects and structures to be produced in the nonwoven layer.
Nachdem die Vlieslage (35) an der Oberfläche des Faserflors (32) gelegt ist, wird der Faserflor (32) mit der Vlieslage (35), d.h. der Compound, durch das Transportband (10.2) der Vlieslegereinrichtung (22) zugeführt. Durch die Vlieslegereinrichtung (22) wird der Faserflor (32) mit der Vlieslage (35) in mehreren Lagen zu dem gewünschten Verbundvlies (36) gelegt. Das Verbundvlies (36) weist z.B. mindestens zwei aufeinander gelegte Lagen des Faserflors (32) oder mehrere doppelte Lagen des Faserflors (32) bzw. Compounds auf. Das Verbundvlies (36) wird durch die Förderbandeinrichtung (23) kontinuierlich abgeführt und der Verfestigungseinrichtung (24) zugeführt. Die Bandgeschwindigkeit der Förderbandeinrichtung (23) ist hierbei in der Abhängigkeit von der Anzahl der Lagen und von der Legebreite der Vlieslegereinrichtung (22) abhängig.After the nonwoven layer (35) is placed on the surface of the batt (32), the batt (32) with the nonwoven layer (35), ie the compound, through the conveyor belt (10.2) of the batt (22) is supplied. By the fleece laying device (22) is the Fibrous web (32) with the nonwoven layer (35) laid in multiple layers to the desired composite nonwoven fabric (36). The composite nonwoven (36) has, for example, at least two superimposed layers of the batt (32) or a plurality of double layers of the batt (32) or compounds. The composite web (36) is continuously removed by the conveyor belt device (23) and fed to the solidification device (24). The belt speed of the conveyor belt device (23) is dependent on the number of layers and the laying width of the fleece laying device (22).
Innerhalb der Verfestigungseinrichtung (24) wird das Verbundvlies (36) thermisch verfestigt, wo insbesondere in einer Kalibrierzone über das Zusammenwirken des Führungsbandes (26) und des Kalibrierbandes (27) die Materialstärke des Verbundvlieses (36) bestimmt wird.Within the solidifying device (24), the composite fleece (36) is thermally consolidated, where in particular in a calibration zone on the interaction of the guide belt (26) and the Kalibrierbandes (27), the material thickness of the composite web (36) is determined.
Nach dem Verfestigen wird das Verbundvlies (36) zu dem Vlieswickel (30) aufgewickelt.After solidification, the composite nonwoven fabric (36) is wound up into the nonwoven roll (30).
Bei dem in den
Das Ausführungsbeispiel nach
Grundsätzlich besteht dabei die Möglichkeit, eines oder beide Faserflore aus einem Fasergemisch aus synthetischen Fasern und natürlichen Fasern zu bilden. Um bei einer Thermobondieren eine ausreichende Festigkeit zu erhalten werden zumindest 10 % der Fasern durch synthetische Fasern gebildet.In principle, it is possible to form one or both batt made of a fiber blend of synthetic fibers and natural fibers. In order to obtain sufficient strength in a thermobonding, at least 10% of the fibers are formed by synthetic fibers.
Bei dem in
Bei dem in
Im Bereich zwischen der Schmelzblaseinrichtung (12) und der Vlieslegeinrichtung (22) werden beide Bandanordnungen (38.1) und (38.2) der Transporteinrichtung (9) derart zusammengeführt, dass die beiden Faserflore (32.1) und (32.2) sandwichartig zusammengelegt werden und zwischen sich die Vlieslage (35) einschließen. Anschließend wird das so gebildete Mehrschichtvlies oder Mehrschichtcompound der Vlieslegeeinrichtung (22) zugeführt und in mehreren Lagen zu dem Verbundvlies (36) abgelegt.In the area between the melt blowing device (12) and the web laying device (22), both belt assemblies (38.1) and (38.2) of the transport device (9) are brought together in such a way that the two fiber webs (32.1) and (32.2) are combined in a sandwich and between them Include nonwoven layer (35). Subsequently, the multilayer nonwoven fabric or multilayer compound thus formed is fed to the nonwoven laying device (22) and laid down in several layers to form the composite nonwoven fabric (36).
Bei der Bildung der Vlieslage (35) durch die Schmelzblaseinrichtung (12) wird in diesem Ausführungsbeispiel die Saugzone nur durch eine Saugkammer (18) der Saugeinrichtung (17) gebildet. Hierbei erstreckt sich die Saugkammer (18) vorzugsweise in Längsrichtung des Ablagebandes (11) derart, dass unmittelbar vor oder bei Einlauf des Faserflors (32) in die Ablagezone der Schmelzblaseinrichtung (12) eine Haltekraft an dem Faserflor (32) durch die Saugwirkung der Saugkammer (18) erzeugt wird.In the formation of the nonwoven layer (35) by the melt blowing device (12), the suction zone is formed in this embodiment only by a suction chamber (18) of the suction device (17). Here, the suction chamber (18) preferably extends in the longitudinal direction of the storage belt (11) such that immediately before or at the inlet of the batt (32) in the deposition zone of the meltblowing device (12) a holding force on the batt (32) by the suction of the suction chamber (18) is produced.
Mit dem in
Grundsätzlich besteht jedoch auch die Möglichkeit, dass beide Faserflore (32.1) und (32.2) mit einer Vlieslage (35.1,35.2) aus Synthetikfasern belegt werden. So ist in
Gegenüber dem Ausführungsbeispiel nach
Anschließend werden die beiden Faserflore (32.1) und (32.2) mit den an den Oberflächen gelegten Vlieslagen (35.1) und (35.2) zusammengeführt und als ein Mehrschichtvlies oder Mehrschichtcompound der Vlieslegereinrichtung (22) zugeführt. Insoweit sind das gezeigte Verfahren und die gezeigte Vorrichtung flexibel erweiterbar, um einlagige oder mehrlagige Faserflore zur Herstellung von Verbundvliesen zu erzeugen.Subsequently, the two batts (32.1) and (32.2) are brought together with the nonwoven layers (35.1) and (35.2) laid on the surfaces and fed as a multi-layer nonwoven or multi-layer compound to the nonwoven laying device (22). In that regard, that is The method shown and the apparatus shown can be expanded flexibly to produce single-layer or multi-ply batt for the production of composite nonwovens.
Bei einer vorteilhaften Variante der Erfindung könnten beispielweise mittels einer Kadiereinrichtung gleichzeitig durch drei separate Abnehmerstellen drei Faserflore erzeugt werden, die über drei Transportbandsysteme zu einem Mehrschichtvlies oder Mehrschichtcompound zusammengelegt und einer Vlieslegereinrichtung zugeführt werden. Zwischen der Kadiereinrichtung und der Vlieslegereinrichtung könnten zwei Schmelzblaseinrichtungen angeordnet sein, die den Transportbandsystemen zugeordnet sind, so dass zwei der drei Faserflore mit einer Vlieslage aus Synthetikfasern vor dem Zusammenführen belegt werden. Mit dieser Variante der Erfindung können vorteilhaft Mehrschichtvliese erzeugt werden, die Synthetikfasern aus zwei unterschiedlichen Polymeren enthalten.In an advantageous variant of the invention, for example by means of a kadi device three fiber piles could simultaneously be produced by three separate pickup locations, which are combined via three conveyor belt systems to form a multi-layer nonwoven or multi-layer compound and fed to a fleece laying device. Between the caddy device and the fleece laying device, two meltblowing devices could be arranged, which are associated with the conveyor belt systems, so that two of the three fiber webs are covered with a nonwoven layer of synthetic fibers prior to the joining. With this variant of the invention, multilayer nonwovens can advantageously be produced which contain synthetic fibers of two different polymers.
Alternativ könnten die Schmelzblaseinrichtungen auch hintereinander einem Transportbandsystem zugeordnet sein, um auf einem Faserflor zwei Vliesschichten abzulegen.Alternatively, the meltblowing devices could also be assigned one after the other to a conveyor belt system in order to deposit two nonwoven layers on a batt.
Die insbesondere in
Weitere Abwandlungen der gezeigten und vorbeschriebenen Ausführungsformen sind in verschiedener Weise möglich. Die Halteeinrichtung (17) kann in anderer Weise ausgebildet und angeordnet sein, z.B. als elektrostatische oder mechanische Halteeinrichtung, die den Faserflor (32) mit elektrostatischen Kräften, Haken oder Nadeln oder dgl. auf dem Ablageband (11, 11.1, 11.2) hält und gegen Verblasen stabilisiert. Das Ablageband (11, 11.1, 11.2) kann dabei wiederum gasdurchlässig sein. Auf eine Saugeinrichtung kann in diesen Fällen verzichtet werden. Eine Saugeinrichtung kann alternativ vorhanden, aber schwächer ausgelegt sein. Ferner ist es möglich, eine Saugeinrichtung an anderer Stelle anzuordnen. In den gezeigten Ausführungsbeispielen saugt sie aus dem Ablageband (11, 11.1, 11.2) und wirkt an der Unterseite des dortigen Obertrums. Sie kann alternativ an anderer Stelle und außerhalb des Ablagebands angeordnet sein.Further modifications of the illustrated and described embodiments are possible in various ways. The holding device (17) may be formed and arranged in another way, e.g. as electrostatic or mechanical holding device which holds the batt (32) with electrostatic forces, hooks or needles or the like. On the storage belt (11, 11.1, 11.2) and stabilized against blowing. The storage belt (11, 11.1, 11.2) can in turn be gas-permeable. On a suction device can be omitted in these cases. A suction device may alternatively be present, but designed to be weaker. Furthermore, it is possible to arrange a suction device elsewhere. In the embodiments shown, it sucks from the storage belt (11, 11.1, 11.2) and acts on the underside of the upper run there. It can alternatively be arranged elsewhere and outside the storage belt.
Statt der beschriebenen Transport- oder Förderbänder können andere Fördermittel für den Faserflor (32) eingesetzt werden.Instead of the transport or conveyor belts described other funding for the batt (32) can be used.
In den gezeigten und beschriebenen Ausführungsbeispielen ist die Weiterbehandlung(seinrichtung) als Vlieslegeeinrichtung (22) z.B. als Kreuzleger, insbesondere als Bandleger, ausgeführt, die den zugeführten einschichtigen oder mehrschichtigen Compound auf dem Abführband (23) zickzackförmig und mit geschuppter Lagenbildung abtäfelt bzw. ablegt. Alternativ kann eine Vlieslegeeinrichtung (22) als Wagenleger, Camel-back-Leger oder dgl. ausgebildet sein. Der ein- oder mehrschichtige Compound kann in weiterer Variation vor der Ablage geschnitten und in Stücke unterteilt werden, wobei die Stücke einzeln und ggf. fluchtend übereinander zur Bildung eines mehrlagigen Verbundvlieses (36) aufeinander abgelegt werden. Die Vlieslegeeinrichtung (22) ist hierfür in entsprechend abgeänderter Weise ausgebildet.In the exemplary embodiments shown and described, the further treatment (device) is designed as a fleece laying device (22), for example as a crosslapper, in particular as a leveler, which screens or deposits the supplied single-layer or multilayer compound on the discharge belt (23) in a zigzag shape and with shingled layer formation. Alternatively, a fleece laying device (22) may be designed as a feeder, Camel-back-Leger or the like. The single-layer or multi-layer compound can be cut before the tray in a further variation and subdivided into pieces, the pieces being laid one on top of the other and possibly aligned one above the other to form a multilayer composite nonwoven (36). The fleece laying device (22) is designed for this purpose in a correspondingly modified manner.
In den gezeigten und bevorzugten Ausführungsbeispielen wird der ein- oder mehrschichtige Compound gleich nach seiner Bildung einer Vlieslegeeinrichtung (22) zugeführt. In Variation hierzu kann ein Zwischenschritt zwischen der Compoundbildung und einer Vlieslegeeinrichtung (22) eingeschoben werden. Hierbei kann z.B. der ein- oder mehrschichtige Compound aufgenommen und zwischengelagert werden, wobei er erst zu einem späteren Zeitpunkt einer Vlieslegeeinrichtung (22) oder einem anderen Weiterbehandlungsprozess zugeführt wird. Bei dem Zwischenschritt kann der besagte Compound z.B. in geeigneter Weise stabilisiert und aufgewickelt werden.In the illustrated and preferred embodiments, the mono- or multi-layer compound is fed to a nonwoven laying device (22) as soon as it is formed. In variation, an intermediate step between the compound formation and a nonwoven laying device (22) can be inserted. Here, e.g. the single-layer or multi-layered compound are taken up and temporarily stored, whereby it is supplied to a nonwoven laying device (22) or another further processing process at a later point in time. In the intermediate step, said compound may e.g. stabilized and wound up in a suitable manner.
Aus dem einlagigen oder mehrlagigen Verbundvlies (36) können mattenartige, schalenartige oder in sonstiger Weise geformte Schalldämmteile bzw. schallabsorbierende Vlieselemente hergestellt werden. Hierfür kann ggf. ein Formgebungsprozess mit Pressen und ggf. Erwärmen eingeschoben werden. Ein mehrlagiges Verbundvlies (36) mit einer außenliegenden und/oder innenliegenden Vlieslage (35, 35.1, 35.2) hat besondere Vorteile für die Schalldämmung. Die gezeigten Ausführungsbeispiele für eine Mehrlagen- oder Sandwichbildung des Verbundvlieses (36) sind hierfür besonders vorteilhaft. Ein Verbundvlies kann in der vorgenannten Weise auch einlagig hergestellt und zu Dämmzwecken eingesetzt werden.From the single-ply or multi-ply composite non-woven fabric (36), mat-like, shell-like or otherwise shaped soundproofing parts or sound-absorbing nonwoven elements can be produced. For this purpose, if necessary, a shaping process with pressing and possibly heating can be inserted. A multilayer composite fleece (36) with an outer and / or inner fleece layer (35, 35.1, 35.2) has particular advantages for the sound insulation. The exemplary embodiments shown for multilayer or sandwich formation of the composite nonwoven (36) are particularly advantageous for this purpose. A composite nonwoven fabric can also be produced in one layer in the aforementioned manner and used for insulation purposes.
- 11
- Kardiereinrichtungcarding
- 22
- Speiseeinrichtungfeeder
- 33
- Speisesystemfeed system
- 44
- Vortrommelpreturret
- 55
- Haupttrommelmain drum
- 66
- Kardierelementecarding
- 77
- Abnehmereinrichtungcollecting equipment
- 88th
- AbnehmerwalzensystemPickup roller system
- 99
- Transporteinrichtungtransport means
- 10, 10.1, 10.210, 10.1, 10.2
- Transportbandconveyor belt
- 10.310.3
- Transportabschnitttransport section
- 11, 11.1, 11.211, 11.1, 11.2
- Ablagebanddepositing belt
- 1212
- Schmelzblaseinrichtungmelt blowing
- 13, 13.1, 13.2.13, 13.1, 13.2.
- Spinnkopfspinning head
- 1414
- Extruderextruder
- 1515
- DruckluftzuführungCompressed air supply
- 1616
- Steuerventilcontrol valve
- 1717
- Halteeinrichtung, SaugeinrichtungHolding device, suction device
- 18, 18.1, 18.2, 18.318, 18.1, 18.2, 18.3
- Saugkammersuction chamber
- 19, 19.1, 19.2, 19.319, 19.1, 19.2, 19.3
- Saugleitungsuction
- 20, 20.1, 20.2, 20.320, 20.1, 20.2, 20.3
- Steuermittelcontrol means
- 2121
- Trägercarrier
- 2222
- Weiterbehandlung, VliesleereinrichtungFurther treatment, fleece blanket
- 2323
- FörderbandeinrichtungConveyor belt means
- 2424
- Verfestigungseinrichtungsolidifying device
- 2525
- Bandtrocknerbelt dryer
- 2626
- Führungsbandguide band
- 2727
- KalibrierbandKalibrierband
- 2828
- Speichereinrichtungmemory device
- 2929
- Wickelstationwinding station
- 3030
- Vlieswickelfleece wrap
- 3131
- Fasernfibers
- 32, 32.1, 32.232, 32.1, 32.2
- Faserflorbatt
- 3333
- Synthetikfasernsynthetic fibers
- 3434
- Schmelzleitungmelting line
- 35, 35.1, 35.235, 35.1, 35.2
- Vlieslagenonwoven layer
- 3636
- Verbundvliescomposite nonwoven
- 37.1, 37.237.1, 37.2
- Abnehmerstellecustomer location
- 38.138.1
- untere Bandanordnunglower band arrangement
- 38.238.2
- obere Bandanordnungupper band arrangement
Claims (15)
- Method for producing a composite non-woven (36) in a continuous processing sequence having a plurality of steps:- infeeding a continuous fibrous stream which is composed of fibres or fibre mixings to a carding installation (1);- carding and doffing the fibres to form at least one fibrous web (32);- guiding the fibrous web (32) to a holding zone and holding the fibrous web (32) on a running conveying means within the holding zone;- melt-blowing a multiplicity of synthetic fibres (33) which have been extruded from a polymer melt, and depositing the synthetic fibres (33) to form a non-woven layer (35) on the fibrous web (32) in the region of the holding zone;- delivering the fibrous web (32) having the non-woven layer (35) from the holding zone to a non-woven laying installation (22).
- Method according to Claim 1, characterized in that the fibrous web (32) in a holding zone which is configured as a suction zone is drawn by suction onto the conveying means.
- Method according to Claim 1 or 2, characterized in that the fibrous web (32) having the non-woven layer (35) in the non-woven laying installation (22) is laid in a plurality of layers so as to form a composite non-woven (36).
- Method according to Claim 1, 2, or 3, characterized in that the fibres or fibre mixings for forming the fibrous web (32) are formed from synthetic fibres in a proportion ranging between 10% and 100% by weight.
- Method according to one of the preceding claims, characterized in that the fibre material of the synthetic fibres and the polymer melt for extruding the synthetic fibres (33) are formed using an identical primary material.
- Method according to one of the preceding claims, characterized in that the synthetic fibres (33) during melt blowing, having a fine fibre cross section in the range of 0.2 µm to 3 µm, are laid to form the non-woven layer (35) on the fibrous web (32).
- Method according to one of the preceding claims, characterized in that a plurality of fibrous webs (32.1, 32.2) are doffed from the carding installation (1) so as to be on top of one another, and after melt blowing and depositing of the synthetic fibres (33) are placed together in a sandwich-like manner, wherein the non-woven layer (35) forms an intermediate layer between the fibrous webs (32.1, 32.2), or in that a plurality of fibrous webs (32.1, 32.2) are in each case covered by one non-woven layer (35.1, 35.2), and in that the fibrous webs (32.1, 32.2) having the non-woven layers (35.1, 35.2) ahead of the non-woven laying installation (22) are brought together to form a multilayered non-woven (36).
- Method according to one of the preceding claims, characterized in that a composite non-woven (36) which has been laid by a non-woven laying installation (22) is continuously infed to a consolidation installation (24) and consolidated, or is infed to a storage installation (28) and is stored as a roll or as a stack.
- Device for producing a composite non-woven (36), having a carding installation (1), a doffing installation (7), a transport installation (9), and a non-woven laying installation (22), wherein a station (12) for creating a non-woven layer (35) is provided between the doffing installation (7) and the non-woven laying installation (22), which station (12) is configured as a melt-blowing installation (12), and wherein the melt-blowing installation (12) is assigned a holding installation (17) for the fibrous web (32), which holding installation is disposed on the transport installation (9).
- Device according to Claim 9, characterized in that the holding installation (17) is configured as a suction installation which is disposed below a conveying means (11), in particular below a depositing belt, of the transport installation (9).
- Device according to Claim 9 or 10, characterized in that the melt-blowing installation (12) has a movable spinning head (13) which is guidable between an operating position above the conveying means (11), in particular above the depositing belt, and a rest position laterally beside the conveying means (11).
- Device according to Claim 9, 10, or 11, characterized in that the doffing installation (7) has two separate doffing points (37.1 37.2) which for receiving and delivering a plurality of fibrous webs (32.1, 32.2) interact with two belt assemblies (38.1, 38.2) of the transport installation (9).
- Device according to one of Claims 9 to 12, characterized in that the non-woven laying installation (22) interacts with a conveyor-belt installation (23), a consolidation installation (24), and a storage installation (28), wherein the composite non-woven (36) laid by the non-woven laying installation (22) in a storage station (29) is guided to form a roll (30) or a stack.
- Device according to one of Claims 9 to 13, characterized in that the consolidation installation (24) has a belt dryer (25) having a guide belt (26) and a calibration belt (27) which is disposed above the guide belt (26), and in that the calibration belt (27) is configured so as to be height adjustable in relation to the guide belt (26).
- Sound-absorbing non-woven element, characterized in that the non-woven element has a composite non-woven (36) and is produced by a method according to Claims 1 to 8.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE102010049180 | 2010-10-21 | ||
PCT/EP2011/068408 WO2012052535A1 (en) | 2010-10-21 | 2011-10-21 | Method and apparatus for producing a composite nonwoven |
Publications (2)
Publication Number | Publication Date |
---|---|
EP2630287A1 EP2630287A1 (en) | 2013-08-28 |
EP2630287B1 true EP2630287B1 (en) | 2016-02-24 |
Family
ID=44936251
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP11781766.8A Not-in-force EP2630287B1 (en) | 2010-10-21 | 2011-10-21 | Method and apparatus for producing a composite nonwoven |
Country Status (4)
Country | Link |
---|---|
US (1) | US20130269154A1 (en) |
EP (1) | EP2630287B1 (en) |
CN (1) | CN103180501B (en) |
WO (1) | WO2012052535A1 (en) |
Families Citing this family (15)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN104831435B (en) * | 2015-04-27 | 2017-01-04 | 东华大学 | A kind of processing method of denim yarn |
US10413081B2 (en) * | 2015-05-29 | 2019-09-17 | Therapedic Of New England, Llc | Synthetic or natural fiber mattress with enhanced compression resistance |
CN105420931A (en) * | 2015-12-30 | 2016-03-23 | 佛山市格菲林卫材科技有限公司 | High water-pressure resistant hot air water-repellent non-woven fabric, and production method and production system thereof |
CN105780204B (en) * | 2016-05-03 | 2017-04-26 | 王宇轩 | Carding device |
CN105887337A (en) * | 2016-06-03 | 2016-08-24 | 佛山市格菲林卫材科技有限公司 | Production system and method for ultra-soft hydrophobic non-woven fabric |
DE102016223571B4 (en) * | 2016-11-28 | 2020-08-13 | Adidas Ag | Manufacture of nonwovens including one component |
CA3108141A1 (en) * | 2018-07-30 | 2020-02-06 | Swm Luxembourg | Apparatus and method for making fibrous webs having isotropic structure |
DE102019104847A1 (en) * | 2019-02-26 | 2020-08-27 | Adler Pelzer Holding Gmbh | Material structure of a needle punch |
DE102019104851A1 (en) * | 2019-02-26 | 2020-08-27 | Adler Pelzer Holding Gmbh | Device for the production of needle felts |
DE102019110494A1 (en) | 2019-04-23 | 2020-10-29 | Adler Pelzer Holding Gmbh | Absorptive needled layer composite |
EP3771760B1 (en) * | 2019-07-30 | 2023-06-07 | Asahi Kasei Kabushiki Kaisha | Method and apparatus for producing a nonwoven fabric made of crimped synthetic fibers |
CN112226903B (en) * | 2020-10-13 | 2021-12-21 | 山东双利华新材料股份有限公司 | Flattening equipment suitable for non-woven fabric processing |
DE102021125783A1 (en) | 2021-10-05 | 2023-04-06 | Adler Pelzer Holding Gmbh | Recycling sandwich nonwovens with different partial basis weight distribution and method for their production |
DE102022110033A1 (en) | 2022-04-26 | 2023-10-26 | Röchling Automotive SE | Method for producing a fleece with reinforcement running in the fleece material and such fleece |
CN115341310A (en) * | 2022-08-24 | 2022-11-15 | 江苏锋特技术有限公司 | Gear type raising machine using automatic pin striking device |
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2011
- 2011-10-21 US US13/880,861 patent/US20130269154A1/en not_active Abandoned
- 2011-10-21 CN CN201180050397.XA patent/CN103180501B/en not_active Expired - Fee Related
- 2011-10-21 WO PCT/EP2011/068408 patent/WO2012052535A1/en active Application Filing
- 2011-10-21 EP EP11781766.8A patent/EP2630287B1/en not_active Not-in-force
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US4315721A (en) * | 1979-07-19 | 1982-02-16 | American Can Company | Fibrous web structure and its manufacture |
US5806154A (en) * | 1993-08-27 | 1998-09-15 | Springs Industries, Inc. | Method of making textile laminate |
DE19927785A1 (en) * | 1999-06-18 | 2000-12-21 | Sandler C H Gmbh | Textile composite combining softness with high interlayer adhesion for use in e.g. diapers, comprises calendered thermobonding fleece layer and melt-blown microfiber layer |
Also Published As
Publication number | Publication date |
---|---|
WO2012052535A1 (en) | 2012-04-26 |
CN103180501A (en) | 2013-06-26 |
US20130269154A1 (en) | 2013-10-17 |
CN103180501B (en) | 2017-06-06 |
EP2630287A1 (en) | 2013-08-28 |
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