CA1234484A - Ribbed terry cloth-like nonwoven fabric - Google Patents
Ribbed terry cloth-like nonwoven fabricInfo
- Publication number
- CA1234484A CA1234484A CA000457087A CA457087A CA1234484A CA 1234484 A CA1234484 A CA 1234484A CA 000457087 A CA000457087 A CA 000457087A CA 457087 A CA457087 A CA 457087A CA 1234484 A CA1234484 A CA 1234484A
- Authority
- CA
- Canada
- Prior art keywords
- fabric
- fibers
- ribs
- bundles
- nodules
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H18/00—Needling machines
- D04H18/04—Needling machines with water jets
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
- D04H1/492—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet
- D04H1/495—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet for formation of patterns, e.g. drilling or rearrangement
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
Abstract
RIBBED TERRY CLOTH-LIKE NONWOVEN FABRIC
ABSTRACT
A nonwoven fabric having the appearance of apertured ribbed terry cloth, said fabric characterized by a repeating pattern of spaced, parallel ribs, said ribs comprising areas of nodule-like tangled fibers alternating with parallelized strands of fibers running substantially in the direction of the longitudinal axes of the ribs, said nodules being interconnected to the nodules in the neighbor-ing ribs through a network of bundles of fibers, each of which bundles is substantially entangled, said bundles defining rows of apertures running parallel to the ribs.
ABSTRACT
A nonwoven fabric having the appearance of apertured ribbed terry cloth, said fabric characterized by a repeating pattern of spaced, parallel ribs, said ribs comprising areas of nodule-like tangled fibers alternating with parallelized strands of fibers running substantially in the direction of the longitudinal axes of the ribs, said nodules being interconnected to the nodules in the neighbor-ing ribs through a network of bundles of fibers, each of which bundles is substantially entangled, said bundles defining rows of apertures running parallel to the ribs.
Description
RIBBED TERRY CLOTH-LIKE NONWOVEN_FABRIC AND PROCESS AND
APPARATUS FOR MAKING SAME
This invention relates to a ribbed terry cloth-like non-woven fabric and to a process and apparatus for producing it.
BACKGROUND OF THE INVENTION
Methods for preparing non woven fabrics by means of fluid rearrangement and entangling of fibers are well known.
See for instance Kilts' U.S. Patent Nos. 2,862,251 and 3,033,721; Griswold et at. U.S. Patent No. 3,081,500;
Evans U.S. Patent No. 3,485,706; Bunting et at. U.S.
Patent No. 3,493,462 and Moulton U.S. Patent No.
4,144,370. This basic technology has been used to produce a wide variety of non woven fabrics. The present invention utilizes fluid rearrangement and entanglement to provide a ribbed terry cloth-like non woven fabric by carrying out the fluid rearrangements/entanglement on a particular type of carrier belt.
SUMMARY OF THE INVENTION
In accordance with the present invention there is provided a non woven fabric having the appearance of aperture ribbed terry cloth, said fabric being characterized by a repeating pattern of spaced, parallel ribs, said ribs comprising areas of nodule-like tangled fibers alternating with parallelized strands of fibers running substantially in the direction of the longitudinal axes of the ribs, said nodules being interconnected to the nodules in neighboring ribs through a network of bundles of fibers, each of which bundles is substantially entangled, said 23~
bundles defining rows of apertures running parallel to thy ribs. The core of each nodule comprises fibers oriented substantially perpendicular to the longitudinal axis of each rib, the surface fibers of the nodules being highly randomized in direction.
The fabric of the invention is preferably made of rayon fibers and weighs from about 1 to about 4 ounces per square yard. The fabric of the invention is prepared on a forming means comprising a woven belt having a cross section through eight successive warps as described herein. The detailed structure of the belt is discussed hereinafter.
The fabric of the invention is produced by a process which comprises:
(a) Supporting a layer of fibrous starting material whose individual fibers are in mechanical engagement with one another but which are capable of movement under applied liquid forces, on a liquid previous support member, adapted to Jove in a predetermined direction and on which fiber movement in directions both in and at an angle to the plane of said layer is permitted in response to applied liquid forces, said support member comprising a woven belt having a cross section through eight successive warps as described herein;
(b) moving the supported layer in said predetermined direction through a fiber rearranging zone within which streams of high pressure, fine, essentially columnar jets of liquid are projected directly onto said layer; and (c) passing said streams of liquid through said layer and said support member in said fiber rearranging zone to '14~
effect movement of fibers such that the non woven fabric, defined above, is formed.
The apparatus for producing the fabric of the invention comprises:
(a) liquid previous forming means for supporting a layer of fibrous starting material whose individual gibers are capable of movement under applied liquid forces;
(b) means for projecting streams of high pressure, fine, essentially columnar jets of liquid; and (c) means for passing said layer of fibrous starting material directly under said streams while said layer is supported on said liquid previous forming means, said liquid previous forming means comprising a woven belt having a cross section through eight consecutive warps as described herein.
The apparatus of the present invention preferably includes vacuum means beneath the liquid previous forming means, said vacuum means being positioned directly under said means for projecting streams of high pressure, fine, essentially columnar jets of liquid.
The woven belt which is preferably used in accordance with the present invention contains I warps per inch and 32 picks per inch. Preferably, both the warps and the picks of the woven belt are about 0.157 inch in diameter.
THE PRIOR ART
In Evans et at. U.S. Patent No. 3,498,874, there is disk closed entangled non woven fabric produced by fluid rearrangements/entanglement on a woven carrier belt having ....
Lo heavier wires in one direction and 3 to 5 times as many finer wires in the other direction. Although Figure 23 ox said U.S. Patent No. 3,498,874 shows a fabric structure having certain similarities to the fabric of the present invention, nevertheless there is no disclosure of clearly defined parallel raised ribs which comprise areas of nodule-like tangled fibers alternating with parallelized strands of fibers running in the direction of the longitudinal axis of the rib.
U.S. Patent No. 3,485,706, also issued to Evans, discloses in Figure 32, a fabric having certain similarities to the fabric of the present invention. However, the structure of the ribs and interconnecting bundles of the present invention clearly distinguishes over the Evans fabrics.
U.S. Patent No. 4,379,799 relates to a non woven fabric having the appearance of aperture ribbed terry cloth, but the structure of the ribs thereof is quite different from the structure of the ribs of the present fabric.
Canadian Patent No. 1,189~29~ discloses fabrics somewhat similar to those of the present invention but the reference fabric is constructed in such a way that a small amount of adhesive binder is required to resist wet collapse of the web. No adhesive binder is required in connection with the present fabric.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a schematic side elevation of an arrangement of an apparatus that can be used to carry out the process of the invention.
I
Figure 2 is a photograph of the fabric of Example 1, the original photograph showing the fabric at 2X
magnification.
Figure 3 is a photomacrograph of the fabric of Figure 2, originally taken at a magnification of 10X.
Figure 4 is a photomacrograph of the fabric of Figure 2, illuminated from below and at a magnification of 20X.
Figure 5 is a photomacrograph of the fabric of Figure 2, illuminated from above, at a magnification of 20X.
Figures 6 and 7 are photomacrographs of the top and bottom sides respectively of the forming or carrier belt used in producing the fabric of Example 1 (magnification 5X).
Figure 8 is a photomacrograph (magnification 3X) of the forming or carrier belt used in Example 1, with a portion of the fabric formed thereon also shown.
Figure 9 is a photomacrograph (magnification 35X, using polarized light) of a cross sectional view taken along line 50-50 of Figure 5.
Figure 10 is a schematic cross section through eight successive warps of the forming belt used in Example 1.
DETAILED DESCRIPTION OF THE INVENTION
The non woven fabric of this invention is produced by the fluid rearrangement/entanglement of a web comprising a loose array of fibers, on a liquid previous forming belt of special construction which is described fully below.
For instance, referring first to Figure 1, a carded or random laid web 10 of staple fibers can be passed onto an AL
endless belt 12 which constitutes the woven forming belt.
The belt 12 carries the web of fibers 10 under a series of high pressure, fine, essentially columnar jets of water 14. The high pressure water is supplied from the manifold 16. The jets 14 are arranged in rows disposed transverse-lye across the path of travel of the forming belt 12.
Preferably there is a vacuum slot (not shown) pulling a vacuum of e.g. 1 to 15 inches of mercury, beneath the forming belt 12, directly under each row of jets 14, in order to optimize durability of the fabric product. The fibers in the web 10 are rearranged and entangled by the jets 14 as the liquid from the jets 14 passes through the fibrolJs web 10 and then through the belt 12 to form the fabric 18 of the invention. The fabric 18 is carried by the belt 12 over a vacuum detouring station 20 and then proceeds to a series of drying cans 22 and from there to a windup 24.
Evans in U.S. Patent No. 3,485,706, describes a process and apparatus for rearranging/entangling fibrous webs by carrying such webs on a woven belt on a series of high pressure, fine, columnar jets of water.
The invention can use a wide variety of staple fibers, including rayon, polyester, nylon, polypropylene, bloom-potent fibers, cotton and the like, including mixtures thereof. Staple fibers are used, that is fibers having lengths of up to about 3 inches. The belt speeds, water jet pressure and the number of rows of jets have not been found to be narrowly critical. Representative conditions are as follows:
Belt speed: about 30 to 300 feet/minute Jet pressure: about 500 to 2000 psi Rows of jets: about 12 to 100 to I
Carded or random laid webs can be used. Typical web weights are from about 1-1/2 to about 6 ounces per square yard.
As a general rule the heavier webs use slower belt speed and/or higher jet pressure and/or more rows of jets. Also in order to achieve maximum durability of the heavier fabrics (e.g., fabrics weighing about 3 ounces or more per square yard), sequential entangling is often desirable.
"Sequential entangling" refers to the practice of first rearranging/entangling a web having a basis weight of a fraction (e.g., about 1/2) of that of the final product, and without removing the rearranged/entangled web from the forming belt, adding another web of fibers on top of the first and subjecting the combined layers to the rearranging/entangling step.
The principle novelty in the process and apparatus of the present invention resides in the use of the special form-in belt. An illustration of such a belt is shown in Figure 10. The belt is woven from fine warp monofilaments (preferably of 0.0157 inch diameter) which extend in the direction of travel of the belt, and fine pick manful-mints which are preferably of the same diameter as those of the warp monofilaments. The belt is woven in such a manner that the topography of the top surface of the belt (that is the surface which the fibers will contact) has lower parallel valleys alternating with flat highlands.
The lowered valleys are formed by the intricate weave of the warp monofilaments 40. The weave of the forming belt is such that groups of twelve pick monofilaments 41 are separated by depressions in the top surface. In Figure 10, it will be noted, that the circles 41 are picks and the lines aye through 40h are warps, the pattern being repeated every eight warps. The belt has considerable thickness which is obtained by weaving in repeating groups of twelve picks 41 which, in the final belt product, are pressed slightly out of normal position due to the tension or force unparted by the warps A. The manner in which the successive warps aye through oh are woven between groups of twelve picks is clearly illustrated in Figure 10. The preferred belt used in accordance with the present invention contains 84 warps per inch and 32 picks per inch, all of which are made of polyester and are 0.0157 inch in diameter.
The invention will be further illustrated in greater detail by the following examples. It should be under-stood, however, that although the examples may describe in particular detail some of the more specific features of the present invention, they are given primarily for purposes of illustration and the invention in its broader aspect is not to be construed as limited thereto.
Example 1 Avtex SUN 1913 1.5 denier, 1-1/8 inch staple rayon was processed through an opener blender and fed through a random air layering unit which deposited a 2-ounce per square yard web of random formed fibers on the forming belt. The forming belt contained 84 warps per inch and 32 picks per inch, all of which were made of polyester and were of 0.0157 inch in diameter. The web was passed under a water whir to wet the fiber and then processed under 15 orifice strips. The orifice strips contained a row of holes, 50 holes per inch, of 0.005 inch diameter, through which the water jetted. Under the manifold the web is exposed to water jets operating at the following pressures:
I
g First three strips 100 prig Second three strips 300 prig text nine strips 1000 prig Under the forming belt directly under the row of holes in each orifice strip there was located a series of vacuum slots. Each slot was 1/4 inch wide and pulled a vacuum of about 13 to 14 inches of mercury. The entangled web was detoured and another 2 ounce web of the same rayon was added on top. The entangled web was not removed from the forming belt but stayed in registry with it. The combined webs were processed under the same conditions as defined above.
The entire process was operated at 10 yards per minute.
The completed entangled fabric was dried over 2 stacks of steam cans operating at 60 pounds and 80 pounds of steam, respectively, and was then rolled up.
Example 2 Three samples were made using the rayon fiber described in Example 1. The equipment described in Example 1 was used except that only 12 strips were used. The strip pressures were the following.
First three strips 100 prig Second three strips 400 prig 30Mext six strips 1200 prig The line speed was 10 yards per minute. Steam cans were operated at 325F. The three fabrics differed in grain weight as follows:
A 450 grains per square yard B 900 grains per square yard C 1700 grains per square yard Samples A and B were processed as a single layer of fiber and removed from the forming belt. Sample C was produced by sequential entangling of two 850 grain webs as described in Example 1. With samples A and B the vacuum pull on the slots beneath the rows ox jets was about 7 to 8 inches of mercury. In sample C, the vacuum was about 13 to 14 inches of mercury.
The fabric prepared in accordance with Example 1 is shown in Figures 2 through 5 and 8. Figure 2, which shows the fabric of the invention at a 2X magnification shows the apertures which are defined between the bundles. however, there is insufficient magnification in Figure 2 in order to observe the ribs clearly. The repeating pattern of spaced parallel ribs 31 are clearly evident in Figure 3.
It will be noted that said ribs comprise alternating nodules 32 and parallelized fibers 33. It will be further noted that the nodules 32 are interconnected by a network of bundles of fibers 34 which extend obliquely from the nodules 32 and form, together with the ribs 31 a net-like structure. It will also be noted that apertures 35 are defined between the bundles 34. Each interconnecting bundle 34 is substantially wholly entangled. The apertures 35 are substantially congruent, that is they are all about the same size and shape when viewed with the naked eye.
Figures 4 and 5 are 20X magnifications of a denser portion of rib 31 and clearly illustrate the nodules 32 and parallelized fibers 33. In Figure 4 the camera is focused on the bottom of the fabric, whereas, in Figure 5, the camera is focused on the top of the fabric.
I
If a cross section of one of the nodules 32 is examined under high magnification (as shown in Figure 9), it is clearly evident that the core of each nodule comprises fibers I oriented substantially perpendicular to the longitudinal axis of each rib. It will also be observed that the surface fibers 37 of the nodule 32 are highly randomized in direction. In Figure 9, the dots or specks are fibers cut at right angles to the long axis of each fiber. If a fiber is at an angle to the cut, it appears as an elongated white slash.
APPARATUS FOR MAKING SAME
This invention relates to a ribbed terry cloth-like non-woven fabric and to a process and apparatus for producing it.
BACKGROUND OF THE INVENTION
Methods for preparing non woven fabrics by means of fluid rearrangement and entangling of fibers are well known.
See for instance Kilts' U.S. Patent Nos. 2,862,251 and 3,033,721; Griswold et at. U.S. Patent No. 3,081,500;
Evans U.S. Patent No. 3,485,706; Bunting et at. U.S.
Patent No. 3,493,462 and Moulton U.S. Patent No.
4,144,370. This basic technology has been used to produce a wide variety of non woven fabrics. The present invention utilizes fluid rearrangement and entanglement to provide a ribbed terry cloth-like non woven fabric by carrying out the fluid rearrangements/entanglement on a particular type of carrier belt.
SUMMARY OF THE INVENTION
In accordance with the present invention there is provided a non woven fabric having the appearance of aperture ribbed terry cloth, said fabric being characterized by a repeating pattern of spaced, parallel ribs, said ribs comprising areas of nodule-like tangled fibers alternating with parallelized strands of fibers running substantially in the direction of the longitudinal axes of the ribs, said nodules being interconnected to the nodules in neighboring ribs through a network of bundles of fibers, each of which bundles is substantially entangled, said 23~
bundles defining rows of apertures running parallel to thy ribs. The core of each nodule comprises fibers oriented substantially perpendicular to the longitudinal axis of each rib, the surface fibers of the nodules being highly randomized in direction.
The fabric of the invention is preferably made of rayon fibers and weighs from about 1 to about 4 ounces per square yard. The fabric of the invention is prepared on a forming means comprising a woven belt having a cross section through eight successive warps as described herein. The detailed structure of the belt is discussed hereinafter.
The fabric of the invention is produced by a process which comprises:
(a) Supporting a layer of fibrous starting material whose individual fibers are in mechanical engagement with one another but which are capable of movement under applied liquid forces, on a liquid previous support member, adapted to Jove in a predetermined direction and on which fiber movement in directions both in and at an angle to the plane of said layer is permitted in response to applied liquid forces, said support member comprising a woven belt having a cross section through eight successive warps as described herein;
(b) moving the supported layer in said predetermined direction through a fiber rearranging zone within which streams of high pressure, fine, essentially columnar jets of liquid are projected directly onto said layer; and (c) passing said streams of liquid through said layer and said support member in said fiber rearranging zone to '14~
effect movement of fibers such that the non woven fabric, defined above, is formed.
The apparatus for producing the fabric of the invention comprises:
(a) liquid previous forming means for supporting a layer of fibrous starting material whose individual gibers are capable of movement under applied liquid forces;
(b) means for projecting streams of high pressure, fine, essentially columnar jets of liquid; and (c) means for passing said layer of fibrous starting material directly under said streams while said layer is supported on said liquid previous forming means, said liquid previous forming means comprising a woven belt having a cross section through eight consecutive warps as described herein.
The apparatus of the present invention preferably includes vacuum means beneath the liquid previous forming means, said vacuum means being positioned directly under said means for projecting streams of high pressure, fine, essentially columnar jets of liquid.
The woven belt which is preferably used in accordance with the present invention contains I warps per inch and 32 picks per inch. Preferably, both the warps and the picks of the woven belt are about 0.157 inch in diameter.
THE PRIOR ART
In Evans et at. U.S. Patent No. 3,498,874, there is disk closed entangled non woven fabric produced by fluid rearrangements/entanglement on a woven carrier belt having ....
Lo heavier wires in one direction and 3 to 5 times as many finer wires in the other direction. Although Figure 23 ox said U.S. Patent No. 3,498,874 shows a fabric structure having certain similarities to the fabric of the present invention, nevertheless there is no disclosure of clearly defined parallel raised ribs which comprise areas of nodule-like tangled fibers alternating with parallelized strands of fibers running in the direction of the longitudinal axis of the rib.
U.S. Patent No. 3,485,706, also issued to Evans, discloses in Figure 32, a fabric having certain similarities to the fabric of the present invention. However, the structure of the ribs and interconnecting bundles of the present invention clearly distinguishes over the Evans fabrics.
U.S. Patent No. 4,379,799 relates to a non woven fabric having the appearance of aperture ribbed terry cloth, but the structure of the ribs thereof is quite different from the structure of the ribs of the present fabric.
Canadian Patent No. 1,189~29~ discloses fabrics somewhat similar to those of the present invention but the reference fabric is constructed in such a way that a small amount of adhesive binder is required to resist wet collapse of the web. No adhesive binder is required in connection with the present fabric.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a schematic side elevation of an arrangement of an apparatus that can be used to carry out the process of the invention.
I
Figure 2 is a photograph of the fabric of Example 1, the original photograph showing the fabric at 2X
magnification.
Figure 3 is a photomacrograph of the fabric of Figure 2, originally taken at a magnification of 10X.
Figure 4 is a photomacrograph of the fabric of Figure 2, illuminated from below and at a magnification of 20X.
Figure 5 is a photomacrograph of the fabric of Figure 2, illuminated from above, at a magnification of 20X.
Figures 6 and 7 are photomacrographs of the top and bottom sides respectively of the forming or carrier belt used in producing the fabric of Example 1 (magnification 5X).
Figure 8 is a photomacrograph (magnification 3X) of the forming or carrier belt used in Example 1, with a portion of the fabric formed thereon also shown.
Figure 9 is a photomacrograph (magnification 35X, using polarized light) of a cross sectional view taken along line 50-50 of Figure 5.
Figure 10 is a schematic cross section through eight successive warps of the forming belt used in Example 1.
DETAILED DESCRIPTION OF THE INVENTION
The non woven fabric of this invention is produced by the fluid rearrangement/entanglement of a web comprising a loose array of fibers, on a liquid previous forming belt of special construction which is described fully below.
For instance, referring first to Figure 1, a carded or random laid web 10 of staple fibers can be passed onto an AL
endless belt 12 which constitutes the woven forming belt.
The belt 12 carries the web of fibers 10 under a series of high pressure, fine, essentially columnar jets of water 14. The high pressure water is supplied from the manifold 16. The jets 14 are arranged in rows disposed transverse-lye across the path of travel of the forming belt 12.
Preferably there is a vacuum slot (not shown) pulling a vacuum of e.g. 1 to 15 inches of mercury, beneath the forming belt 12, directly under each row of jets 14, in order to optimize durability of the fabric product. The fibers in the web 10 are rearranged and entangled by the jets 14 as the liquid from the jets 14 passes through the fibrolJs web 10 and then through the belt 12 to form the fabric 18 of the invention. The fabric 18 is carried by the belt 12 over a vacuum detouring station 20 and then proceeds to a series of drying cans 22 and from there to a windup 24.
Evans in U.S. Patent No. 3,485,706, describes a process and apparatus for rearranging/entangling fibrous webs by carrying such webs on a woven belt on a series of high pressure, fine, columnar jets of water.
The invention can use a wide variety of staple fibers, including rayon, polyester, nylon, polypropylene, bloom-potent fibers, cotton and the like, including mixtures thereof. Staple fibers are used, that is fibers having lengths of up to about 3 inches. The belt speeds, water jet pressure and the number of rows of jets have not been found to be narrowly critical. Representative conditions are as follows:
Belt speed: about 30 to 300 feet/minute Jet pressure: about 500 to 2000 psi Rows of jets: about 12 to 100 to I
Carded or random laid webs can be used. Typical web weights are from about 1-1/2 to about 6 ounces per square yard.
As a general rule the heavier webs use slower belt speed and/or higher jet pressure and/or more rows of jets. Also in order to achieve maximum durability of the heavier fabrics (e.g., fabrics weighing about 3 ounces or more per square yard), sequential entangling is often desirable.
"Sequential entangling" refers to the practice of first rearranging/entangling a web having a basis weight of a fraction (e.g., about 1/2) of that of the final product, and without removing the rearranged/entangled web from the forming belt, adding another web of fibers on top of the first and subjecting the combined layers to the rearranging/entangling step.
The principle novelty in the process and apparatus of the present invention resides in the use of the special form-in belt. An illustration of such a belt is shown in Figure 10. The belt is woven from fine warp monofilaments (preferably of 0.0157 inch diameter) which extend in the direction of travel of the belt, and fine pick manful-mints which are preferably of the same diameter as those of the warp monofilaments. The belt is woven in such a manner that the topography of the top surface of the belt (that is the surface which the fibers will contact) has lower parallel valleys alternating with flat highlands.
The lowered valleys are formed by the intricate weave of the warp monofilaments 40. The weave of the forming belt is such that groups of twelve pick monofilaments 41 are separated by depressions in the top surface. In Figure 10, it will be noted, that the circles 41 are picks and the lines aye through 40h are warps, the pattern being repeated every eight warps. The belt has considerable thickness which is obtained by weaving in repeating groups of twelve picks 41 which, in the final belt product, are pressed slightly out of normal position due to the tension or force unparted by the warps A. The manner in which the successive warps aye through oh are woven between groups of twelve picks is clearly illustrated in Figure 10. The preferred belt used in accordance with the present invention contains 84 warps per inch and 32 picks per inch, all of which are made of polyester and are 0.0157 inch in diameter.
The invention will be further illustrated in greater detail by the following examples. It should be under-stood, however, that although the examples may describe in particular detail some of the more specific features of the present invention, they are given primarily for purposes of illustration and the invention in its broader aspect is not to be construed as limited thereto.
Example 1 Avtex SUN 1913 1.5 denier, 1-1/8 inch staple rayon was processed through an opener blender and fed through a random air layering unit which deposited a 2-ounce per square yard web of random formed fibers on the forming belt. The forming belt contained 84 warps per inch and 32 picks per inch, all of which were made of polyester and were of 0.0157 inch in diameter. The web was passed under a water whir to wet the fiber and then processed under 15 orifice strips. The orifice strips contained a row of holes, 50 holes per inch, of 0.005 inch diameter, through which the water jetted. Under the manifold the web is exposed to water jets operating at the following pressures:
I
g First three strips 100 prig Second three strips 300 prig text nine strips 1000 prig Under the forming belt directly under the row of holes in each orifice strip there was located a series of vacuum slots. Each slot was 1/4 inch wide and pulled a vacuum of about 13 to 14 inches of mercury. The entangled web was detoured and another 2 ounce web of the same rayon was added on top. The entangled web was not removed from the forming belt but stayed in registry with it. The combined webs were processed under the same conditions as defined above.
The entire process was operated at 10 yards per minute.
The completed entangled fabric was dried over 2 stacks of steam cans operating at 60 pounds and 80 pounds of steam, respectively, and was then rolled up.
Example 2 Three samples were made using the rayon fiber described in Example 1. The equipment described in Example 1 was used except that only 12 strips were used. The strip pressures were the following.
First three strips 100 prig Second three strips 400 prig 30Mext six strips 1200 prig The line speed was 10 yards per minute. Steam cans were operated at 325F. The three fabrics differed in grain weight as follows:
A 450 grains per square yard B 900 grains per square yard C 1700 grains per square yard Samples A and B were processed as a single layer of fiber and removed from the forming belt. Sample C was produced by sequential entangling of two 850 grain webs as described in Example 1. With samples A and B the vacuum pull on the slots beneath the rows ox jets was about 7 to 8 inches of mercury. In sample C, the vacuum was about 13 to 14 inches of mercury.
The fabric prepared in accordance with Example 1 is shown in Figures 2 through 5 and 8. Figure 2, which shows the fabric of the invention at a 2X magnification shows the apertures which are defined between the bundles. however, there is insufficient magnification in Figure 2 in order to observe the ribs clearly. The repeating pattern of spaced parallel ribs 31 are clearly evident in Figure 3.
It will be noted that said ribs comprise alternating nodules 32 and parallelized fibers 33. It will be further noted that the nodules 32 are interconnected by a network of bundles of fibers 34 which extend obliquely from the nodules 32 and form, together with the ribs 31 a net-like structure. It will also be noted that apertures 35 are defined between the bundles 34. Each interconnecting bundle 34 is substantially wholly entangled. The apertures 35 are substantially congruent, that is they are all about the same size and shape when viewed with the naked eye.
Figures 4 and 5 are 20X magnifications of a denser portion of rib 31 and clearly illustrate the nodules 32 and parallelized fibers 33. In Figure 4 the camera is focused on the bottom of the fabric, whereas, in Figure 5, the camera is focused on the top of the fabric.
I
If a cross section of one of the nodules 32 is examined under high magnification (as shown in Figure 9), it is clearly evident that the core of each nodule comprises fibers I oriented substantially perpendicular to the longitudinal axis of each rib. It will also be observed that the surface fibers 37 of the nodule 32 are highly randomized in direction. In Figure 9, the dots or specks are fibers cut at right angles to the long axis of each fiber. If a fiber is at an angle to the cut, it appears as an elongated white slash.
Claims (5)
1. A nonwoven fabric having the appearance of apertured ribbed terry cloth, said fabric being characterized by a repeating pattern of spaced parallel ribs, said ribs comprising areas of nodule-like tangled fibers alternating with parallelized strands of fibers running substantially in the direction of the longitudinal axes of the ribs, said nodules being interconnected to the nodules in neighboring ribs through a network of bundles of fibers each of which bundles is substantially entangled, said bundles defining rows of apertures running parallel to the ribs.
2. The fabric of claim 1 wherein the core of each nodule comprises fibers oriented substantially perpendicular to the longitudinal axis of each rib, the surface fibers of the nodules being highly randomized in direction.
3. The fabric of claim 2 wherein the fabric weighs from about 1 to about 4 ounces per square yard.
4. The fabric of claim 2 wherein said fabric is made of rayon fibers.
5. The fabric of claim 2 wherein the fabric is made of blends of rayon and polyester fibers.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US507,414 | 1983-06-23 | ||
| US06/507,414 US4465726A (en) | 1983-06-23 | 1983-06-23 | Ribbed terry cloth-like nonwoven fabric and process and apparatus for making same |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1234484A true CA1234484A (en) | 1988-03-29 |
Family
ID=24018559
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000457087A Expired CA1234484A (en) | 1983-06-23 | 1984-06-21 | Ribbed terry cloth-like nonwoven fabric |
Country Status (17)
| Country | Link |
|---|---|
| US (1) | US4465726A (en) |
| EP (1) | EP0130070B1 (en) |
| JP (1) | JPH0655986B2 (en) |
| AT (1) | ATE68217T1 (en) |
| AU (1) | AU564797B2 (en) |
| BR (1) | BR8403066A (en) |
| CA (1) | CA1234484A (en) |
| DE (1) | DE3485140D1 (en) |
| DK (1) | DK305284A (en) |
| ES (2) | ES297017Y (en) |
| IE (1) | IE57166B1 (en) |
| MX (1) | MX158703A (en) |
| NO (1) | NO842538L (en) |
| NZ (1) | NZ208479A (en) |
| PH (1) | PH18728A (en) |
| PT (1) | PT78782A (en) |
| ZA (1) | ZA844769B (en) |
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| US4693922A (en) * | 1985-09-26 | 1987-09-15 | Chicopee | Light weight entangled non-woven fabric having excellent machine direction and cross direction strength and process for making the same |
| US4695500A (en) * | 1986-07-10 | 1987-09-22 | Johnson & Johnson Products, Inc. | Stabilized fabric |
| US4925722A (en) * | 1988-07-20 | 1990-05-15 | International Paper Company | Disposable semi-durable nonwoven fabric |
| US4959894A (en) * | 1988-07-20 | 1990-10-02 | International Paper Company | Disposable semi-durable nonwoven fabric and related method of manufacture |
| US5244711A (en) * | 1990-03-12 | 1993-09-14 | Mcneil-Ppc, Inc. | Apertured non-woven fabric |
| US5098764A (en) * | 1990-03-12 | 1992-03-24 | Chicopee | Non-woven fabric and method and apparatus for making the same |
| US5115544A (en) * | 1990-04-03 | 1992-05-26 | Albany International Corp. | Non-wovens manufacturing process |
| US5204158A (en) * | 1991-05-30 | 1993-04-20 | Chicopee | Irregular patterned entangled nonwoven fabrics and their production |
| RU2132893C1 (en) * | 1993-08-30 | 1999-07-10 | Макнейл Ппс, Инк. | Nonwoven material (versions) |
| AU693461B2 (en) * | 1993-09-13 | 1998-07-02 | Mcneil-Ppc, Inc. | Tricot nonwoven fabric |
| US8877316B2 (en) * | 2002-12-20 | 2014-11-04 | The Procter & Gamble Company | Cloth-like personal care articles |
| US7682686B2 (en) | 2002-12-20 | 2010-03-23 | The Procter & Gamble Company | Tufted fibrous web |
| US7732657B2 (en) | 2002-12-20 | 2010-06-08 | The Procter & Gamble Company | Absorbent article with lotion-containing topsheet |
| KR100803015B1 (en) | 2002-12-20 | 2008-02-14 | 더 프록터 앤드 갬블 캄파니 | Tufted laminate web |
| US7270861B2 (en) * | 2002-12-20 | 2007-09-18 | The Procter & Gamble Company | Laminated structurally elastic-like film web substrate |
| US7838099B2 (en) | 2002-12-20 | 2010-11-23 | The Procter & Gamble Company | Looped nonwoven web |
| WO2004058214A1 (en) | 2002-12-20 | 2004-07-15 | The Procter & Gamble Company | Cloth-like personal care articles |
| US7507459B2 (en) | 2002-12-20 | 2009-03-24 | The Procter & Gamble Company | Compression resistant nonwovens |
| US7553532B2 (en) | 2002-12-20 | 2009-06-30 | The Procter & Gamble Company | Tufted fibrous web |
| ES2829812T3 (en) | 2002-12-20 | 2021-06-02 | Procter & Gamble | Plush laminated band |
| US8241543B2 (en) | 2003-08-07 | 2012-08-14 | The Procter & Gamble Company | Method and apparatus for making an apertured web |
| US7910195B2 (en) | 2003-12-16 | 2011-03-22 | The Procter & Gamble Company | Absorbent article with lotion-containing topsheet |
| SE527160C2 (en) * | 2004-03-24 | 2006-01-10 | Delaval Holding Ab | behavior Milking |
| US7754050B2 (en) * | 2004-06-21 | 2010-07-13 | The Procter + Gamble Company | Fibrous structures comprising a tuft |
| US7579062B2 (en) * | 2004-06-21 | 2009-08-25 | The Procter & Gamble Company | Hydroxyl polymer web structures comprising a tuft |
| US7426776B2 (en) * | 2007-02-07 | 2008-09-23 | Milliken & Company | Nonwoven towel with microsponges |
| US20080221539A1 (en) * | 2007-03-05 | 2008-09-11 | Jean Jianqun Zhao | Absorbent core for disposable absorbent article |
| US7935207B2 (en) | 2007-03-05 | 2011-05-03 | Procter And Gamble Company | Absorbent core for disposable absorbent article |
| US8502013B2 (en) | 2007-03-05 | 2013-08-06 | The Procter And Gamble Company | Disposable absorbent article |
| US8158043B2 (en) | 2009-02-06 | 2012-04-17 | The Procter & Gamble Company | Method for making an apertured web |
| US8153226B2 (en) | 2009-03-31 | 2012-04-10 | The Procter & Gamble Company | Capped tufted laminate web |
| US9044353B2 (en) | 2011-04-26 | 2015-06-02 | The Procter & Gamble Company | Process for making a micro-textured web |
| US9925731B2 (en) | 2011-04-26 | 2018-03-27 | The Procter & Gamble Company | Corrugated and apertured web |
| US8708687B2 (en) | 2011-04-26 | 2014-04-29 | The Procter & Gamble Company | Apparatus for making a micro-textured web |
| US8657596B2 (en) | 2011-04-26 | 2014-02-25 | The Procter & Gamble Company | Method and apparatus for deforming a web |
| US9724245B2 (en) | 2011-04-26 | 2017-08-08 | The Procter & Gamble Company | Formed web comprising chads |
| US9242406B2 (en) | 2011-04-26 | 2016-01-26 | The Procter & Gamble Company | Apparatus and process for aperturing and stretching a web |
| JP5712194B2 (en) * | 2012-12-04 | 2015-05-07 | 花王株式会社 | Nonwoven fabric substrate for wipe sheet |
| JP5712195B2 (en) * | 2012-12-04 | 2015-05-07 | 花王株式会社 | Nonwoven fabric substrate for wipe sheet |
| WO2015094459A1 (en) | 2013-12-20 | 2015-06-25 | The Procter & Gamble Company | Method for fabricating absorbent articles |
| US20150173956A1 (en) | 2013-12-20 | 2015-06-25 | The Procter & Gamble Company | Method for fabricating absorbent articles |
| US20170027262A1 (en) * | 2015-07-30 | 2017-02-02 | Virtuosa Beauty LLC | Breathable protective head covering |
| US20170296396A1 (en) | 2016-04-14 | 2017-10-19 | The Procter & Gamble Company | Absorbent article manufacturing process incorporating in situ process sensors |
| WO2020041534A1 (en) | 2018-08-22 | 2020-02-27 | The Procter & Gamble Company | Disposable absorbent article |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE1065364B (en) * | 1954-06-16 | 1959-09-17 | John Joseph Smith, Highland Park N. J. (V. St. A.) | Non-woven fiber |
| US2862251A (en) * | 1955-04-12 | 1958-12-02 | Chicopee Mfg Corp | Method of and apparatus for producing nonwoven product |
| US3493462A (en) * | 1962-07-06 | 1970-02-03 | Du Pont | Nonpatterned,nonwoven fabric |
| US3498874A (en) * | 1965-09-10 | 1970-03-03 | Du Pont | Apertured tanglelaced nonwoven textile fabric |
| US3485706A (en) * | 1968-01-18 | 1969-12-23 | Du Pont | Textile-like patterned nonwoven fabrics and their production |
| GB1550955A (en) * | 1975-12-29 | 1979-08-22 | Johnson & Johnson | Textile fabric and method of manufacturing the same |
| US4379799A (en) * | 1981-02-20 | 1983-04-12 | Chicopee | Nonwoven fabric having the appearance of apertured, ribbed terry cloth |
-
1983
- 1983-06-23 US US06/507,414 patent/US4465726A/en not_active Expired - Lifetime
-
1984
- 1984-06-12 NZ NZ208479A patent/NZ208479A/en unknown
- 1984-06-19 ES ES1984297017U patent/ES297017Y/en not_active Expired
- 1984-06-21 CA CA000457087A patent/CA1234484A/en not_active Expired
- 1984-06-22 DE DE8484304248T patent/DE3485140D1/en not_active Expired - Lifetime
- 1984-06-22 AT AT84304248T patent/ATE68217T1/en not_active IP Right Cessation
- 1984-06-22 NO NO842538A patent/NO842538L/en unknown
- 1984-06-22 PH PH30870A patent/PH18728A/en unknown
- 1984-06-22 MX MX201750A patent/MX158703A/en unknown
- 1984-06-22 AU AU29776/84A patent/AU564797B2/en not_active Ceased
- 1984-06-22 BR BR8403066A patent/BR8403066A/en not_active IP Right Cessation
- 1984-06-22 EP EP84304248A patent/EP0130070B1/en not_active Expired - Lifetime
- 1984-06-22 DK DK305284A patent/DK305284A/en not_active Application Discontinuation
- 1984-06-22 IE IE1588/84A patent/IE57166B1/en not_active IP Right Cessation
- 1984-06-22 JP JP59127691A patent/JPH0655986B2/en not_active Expired - Fee Related
- 1984-06-22 ZA ZA844769A patent/ZA844769B/en unknown
- 1984-06-22 PT PT78782A patent/PT78782A/en not_active IP Right Cessation
-
1987
- 1987-04-13 ES ES557494A patent/ES8900114A1/en not_active Expired
Also Published As
| Publication number | Publication date |
|---|---|
| ES557494A0 (en) | 1988-12-16 |
| NZ208479A (en) | 1987-04-30 |
| ZA844769B (en) | 1986-02-26 |
| NO842538L (en) | 1984-12-27 |
| DK305284D0 (en) | 1984-06-22 |
| EP0130070A2 (en) | 1985-01-02 |
| DK305284A (en) | 1984-12-24 |
| ATE68217T1 (en) | 1991-10-15 |
| AU2977684A (en) | 1985-01-03 |
| JPS6021955A (en) | 1985-02-04 |
| AU564797B2 (en) | 1987-08-27 |
| EP0130070B1 (en) | 1991-10-09 |
| ES8900114A1 (en) | 1988-12-16 |
| MX158703A (en) | 1989-02-27 |
| ES297017Y (en) | 1989-02-16 |
| BR8403066A (en) | 1985-05-28 |
| PH18728A (en) | 1985-09-11 |
| EP0130070A3 (en) | 1987-02-25 |
| IE841588L (en) | 1984-12-23 |
| JPH0655986B2 (en) | 1994-07-27 |
| IE57166B1 (en) | 1992-05-20 |
| US4465726A (en) | 1984-08-14 |
| PT78782A (en) | 1984-07-01 |
| ES297017U (en) | 1988-07-01 |
| DE3485140D1 (en) | 1991-11-14 |
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| MKEX | Expiry |