US3808639A

US3808639A - Apparatus for altering the width, weight and thickness of fabric webs

Info

Publication number: US3808639A
Application number: US00323596A
Authority: US
Inventors: B Tautvaisas
Original assignee: Kendall Co
Current assignee: Fiber Technology Corp
Priority date: 1973-01-15
Filing date: 1973-01-15
Publication date: 1974-05-07
Anticipated expiration: 1991-05-07
Also published as: BR7400247D0; FI56407C; DE2401614C2; FR2214007A1; BE809792A; FR2214007B1; JPS5724426B2; GB1389400A; NO740051L; DE2401614A1; DK145991B; NO136257B; SE405741B; NL172086B; IT1002657B; NO136257C; CH573999A5; CA993180A; JPS49108376A; ES422253A1

Abstract

A plurality of disks, mounted on a rotatable shaft, each having a plurality of spaced apart flexible protuberances extending radially out from the perimeter thereof. Each disk is composed of two concentric rings - the innermost ring being attached to the rotatable shaft by means of two swivel pins that are mounted on the shaft directly opposite each other, thereby facilitating the free arcuate movement in a horizontal plane of the ring about the shaft, while the outermost ring is mounted on two swivel points that are positioned on the perimeter of the inner ring at 90* from the swivel pins, thereby facilitating the free, arcuate movement in a vertical plane of the inner ring about the shaft and producing a gyroscopic movement of the disk about the shaft. Guiding means are provided to orient the disks in a diverging or converging manner as desired, via the swivel pins and swivel points. A web of fabric, moving into the disks on the converging side thereof, is then engaged by the flexible protuberances and drawn along divergent lines so as to increase the width of the web while decreasing the thickness thereof. The thickness, uniformity, weight and the width of the web can be accurately controlled by simply varying the angle of divergence of the individual disks.

Description

United States Patent [191 Tautvaisas APPARATUS FOR ALTERING THE WIDTH,

WEIGHT AND THICKNESS OF FABRIC [58] Field of Search 19/161 R, 81, 155; 26/63, 26/58; 226/193, 196

[ 56] References Cited UNITED STATES PATENTS 2,709,282 5/1955 Lindel et al.., 19/161 R 3,303,547 2/1967 Kalwaites 19/161 R X FOREIGN PATENTS 0R APPLICATIONS 469,500 12/1928 Germany l9/8l Primary Examiner-Dorsey Newton Attorney, Agent, or FirmEdward J. Scahill, Jr.

[451 May 7, 1974 [57] ABSTRACT A plurality of disks, mounted on a rotatable shaft, each having a plurality of spaced apart flexible protuberances extending radially out from the perimeter thereof. Each disk is composed of two concentric rings the innermost ring being attached to the rotatable shaft by means of two swivel pins that are mounted on the shaft directly oppositeeach other, thereby facilitating the free arcuate movement in a horizontal plane of the ring about the shaft, while the outermost ring is mounted on two swivel points that are positioned on the perimeter of the inner ring at 90 from the swivel pins, thereby facilitating the free, arcuate movement in a vertical plane of the inner ring about the shaft and producing a gyroscopic movement of the disk about the shaft. Guiding means are provided to orient the disks in a diverging or converging manner as desired, via the swivel pins and swivel points. A web of fabric, moving into the disks on the converging side thereof, is then engaged by the flexible protuberances and drawn along divergent lines so as to increase the width of the web while decreasing the thickness thereof. The thickness, uniformity, weight and the width of the web can be accurately controlled by simply varying the angle of divergence of the individual disks.

6 Claims, 5 Drawing Figures PATENTEDHAY 7 1974 3L808Q639 sum 1 nr- 2 APPARATUS FOR ALTERING THE WIDTH, WEIGHT AND THICKNESS OF FABRIC WEBS BACKGROUND OF THE INVENTION This invention relates to an apparatus for altering the width and thickness of fabric webs, and more particularly, to an apparatus for increasing the width of a web of nonwoven fabrics while decreasing its weight and thickness.

In the manufacture of nonwoven fabrics, a web of tibers formed by a carding action, from raw material laps or the like, is continuously passed through various processes, such as bonding steps or the like, to ultimately form the desired end product. However, since the processes used in the manufacture of nonwovens today generally produce raw material laps of rather standardized dimensions, it has become somewhat of a problem to vary. this width during subsequent processing steps for purposes of efficiency, or simply to obtain a particular web width. For example, many variations of a machine having a stretchable carrier portion thereon have been used for this purpose, wherein the web is stretched or widened, over or across, the stretchable carrier portion of the machine. However, such types of apparatus are subject to breakdown through the constant stress and strain being put thereon, and also, these machines are slow and lack ease of control of the width of the webs coming out therefrom.

Another type of apparatus that has been used for this purposeis a machine, such as described in US. Pat. No. 2,709,282, having a plurality of disks mounted on a grooved stationary shaft with the rigidly fixed disks being oriented along the divergent lines, defined by the grooves. Each disk has a plurality of needles affixed to the outer periphery thereof that pierce a web of fibers and-stretch the web as it is carried along the divergent lines. The individual disks have openings thereon, and a bar extends through the aligned openings on the disks and is connected at its opposite ends to a pair of gears which are freely mounted on the stationary shaft for rotation thereabout. The disks are rotated in this manner to pierce the web as described above and carry same along the divergent lines formed by the thusly grooved shaft. This type of machine suffers a number of drawbacks. For example, the needlepiercing members produce unwanted holes in the web that adversely affect the strength of the web; also, in order for widths of the web to be varied in such an apparatus, whole new sets of disks and shafts must be tooled and grooved accordingly to replace the disks and shaft in the machine at that time (an expensive and time consuming project, at best). Additionally, the individual disks may not be moved or altered once they are mounted within the grooves on the shaft.

Accordingly, an object of this invention is to provide an improved apparatus for altering the width, weight and thickness of a nonwoven fabric web.

It is another object of the present invention to provide an apparatus that can be economically adjusted to increase or decrease the width of the fabric web while decreasing or increasing the thickness thereof, respectively.

It is a further object of the instant invention to provide an apparatus for altering the width and thickness of a nonwoven fabric, while producing a uniform weight distribution across the width of the fabric, without having such apparatus cause holes to appear on the altered nonwoven fabric.

SUMMARY OF THE INVENTION An improved apparatus for altering the width, weight and thickness of fabric webs comprises a plurality of disks mounted on a rotatable shaft, each disk having a plurality of spaced apart flexible protuberances extending radially out from the perimeter thereof. The perimeter of each disk is capable of a gimbaled or gyroscopic type movement about the shaft. Each disk may include an innermost ring that is attached to the rotatable shaft by means of two swivel pins that are mounted on the shaft directly opposite each other, thereby facilitating the free, arcuate movement in a horizontal plane of the ring about the shaft, and an outermost ring .that is mounted on two swivel points positioned opposite each other on the perimeter of the inner ring at from the swivel pins, thereby facilitating the free arcuate movement in a vertical plane of the outer. ring about the shaft. The disks are oriented in'a diverging manner, away from an oncoming web, to increase the width of the web. Once oriented in a particular manner, the disks are held in that position by a guiding means, such as an inexpensive board of a self-lubricating plastic material having teeth cut out thereon in a manner much like a comb, each cut out portion thereof being at a particular'desired angle that produces a particular desired degree of divergence, and subsequent width increase in the nonwoven fabric. Using the same shaft and disks, the amount of stretching at a particular point can be altered by simply orienting the disks differently by means of other guiding board orientations. A web of fabric moving into the disks on the converged side of the disks, is then engaged by the flexible protuberances thereon and gently drawn along divergent lines so as to increase the width of the web, while decreasing the thickness thereof.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. I is a perspective view of the web altering apparatus of this invention;

FIG. 2 is a partial elevational view of the apparatus of FIG. 1;

. FIG. 3 is a plan view of a disk mounted on a shaft, as used in this invention;

. FIG. 4 is a perspective view of another embodiment of the guiding board or comb shown in FIG. 2; and

FIG. 5 is a plan view of another embodiment of a disk as described in this invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. I shows the apparatus of this invention where-in a web of fibers 11 for producing nonwoven fabrics is carried, by means of a conveyer 12 or the like, onto a rotating set of disks [3 attached to a rotatable power driven shaft 14 on asupporting means. The disks 13 are oriented in a diverging direction away from the conveyer 12 that carries the web to be stretched, and are held in that position by a guiding means, such as

guide boards

15 and 16 of a plastic material.

The angle of divergence of each disk can be controlled individually because the disks 13 are mounted on the rotatable shaft 14 by means of a two-stage hinged arrangement capable of a gyroscopic or gimbaled movement, wherein a first or inner ring 17 is attached to the shaft 14 with a pair of swivel pins 19 that extend from the shaft at 180 from each other and that permit this ring and an outer ring attached thereto to swing arcuately back and forth in a horizontal plane on the shaft 14 (See arrow A in FIG. 3). A second or outer ring 18 is then fitted onto swivel points 21 located on the perimeter of the inner ring 17 at 90 from each swivel pin 19, the outer ring 18 having two apertures on the inner rim thereof at 180 from each other for accepting the swivel points 21 thereby facilitating the free arcuate movement of the disk in a vertical plane (See arrow B in FIG. 3). For the purpose of this invention, the terms swivel points" and swivel pins" describe ball-bearing types of structures, however, any construction is acceptable that will permit the relatively free arcuate movement of a plane about an axis, such as is shown in the drawings. Such a disk design advantageously permits the perimeter of the disks 13 to be freely swung, in a gyroscopic manner, through a wide spectrum of diverging and converging lines through a 360 revolution of the disks.

On the perimeter of the disks 13 are a plurality of spaced apart flexible protuberances 22, extending radially outward therefrom. These protuberances 22, rotating on the disks l3 driven in a clockwise manner, gently engage an oncoming web of fibers 11 and carry it forward, along diverging lines that causes the width of the web to be increased while simultaneously decreasing the thickness thereof. A take-off roller 23 then assists in removing the web 11 from the disks l3 and depositing it onto a second conveyer system 24 to be forwarded for further processing as desired.

The mode of operation ofthe apparatus of this invention can perhaps be better understood by reference to FlGS.'2 and 3 of the drawings wherein the rotatably driven shaft 14 carries the plurality of disks 13 along a divergent direction as shown by the arrow thereon. The angle of divergence is set and maintained by means of guide boards and 16, which are shown herein in the shape of a comb, at the front and back portions of the disks 13.

The individual teeth such as at 15a and 16a of the guide combs 15 and 16 respectively, can be positioned at a slightly different angle from the other teeth thereon, so as to position the disk held therebetween at a different angle of divergence than the remaining disks. This capability advantageously helps to prevent the appearance of weak-spots in the stretched web. For example, it may be observed during a trial run, that a particular portion of the web is stretched to a higher degree than is desired, and this may be prevented by simply changing the angle of divergence of the particular teeth guiding the problem disk or disks, thereby giving less stretch so that area or more stretch to an adjacent area. The

guide combs

15 and 16 are advantageously made ofa self-lubricating plastic material, such as a high molecular weight polyethylene, that will not unduly produce friction upon contact with the rotating disks 13. However, it should be noted that nearly any type of durable material could be used for this purpose. Of course, the design for the guide comb could be such that the angles of the teeth could be adjusted on an individual basis by techniques known to those skilled in the art.

The gimbaled mechanism of the disks on the shaft can be seen in FIG. 2, wherein all disks 13 were initially put on the shaft 14 so that they sat in a plane perpendicular to the shaft. The disks 13 were then converged at one end and held in that position by guide comb 16 at that end, and by guide comb 15 at the resultant divergent end of the disks. When the disks 13 are drawn together in this manner, it can be seen that the inner rings 17 of the disks are all inclined towards the center of the arrangement. However, it should also be ob served that this novel swivel-type disk can be completely reversed by simply changing the guide comb angles. In this manner, a web of fabric can be made more narrow and consequently thicker and heavier, if such a characteristic is desired in the web.

Another method of controlling the thickness and uniformity of the web is by controlling the spacing of the flexible protuberances on the outer perimeter of the disks 13. For example, FIG. 2 shows the two end disks on each side as having many more protuberances 13 thereon than the other disks mounted on the shaft 14, which was done to prevent a curling of the outer edges of the web that may occur when each disk 13 in the setup has the same number of protuberances 22. The extra protuberances on the outer disks also aid in assuring that the on-coming web is grabbed properly by the protuberances when the spreading operation starts. The number of protuberances 22 of other individual disks may also be vaired if it is determined that this is beneficial. For example, it may be observed that a portion of the web is being stretched too much, or not enough, and the number of protuberances 22 may be increased or decreased respectively to achieve the desired web uniformity. It should be emphasized that the greater the number of protuberances on the disks, the greater the amount of uniform stretching occurring on the web, and consequently the greater degree of uniformity of weight distribution across the entire width of the stretched web.

When all of the disks have the same diameter, they produce a convex curve from end to end when viewed from above, see FIG. 2. This may cause some problems when the web is picked up by, and/or taken off from, the flexible protuberances 22, since the rim speeds at the various locations are different because the radii of rotation of the disks are different. Furthermore, since the web will not land on all the disks at the same instant, it will take a while for the web to be picked up by the outer disks, possibly allowing it to flap loosely, causing scalloped edges, loss of spreadability and lack of uniform weight distribution across the width of the web. This problem can be avoided at least two ways. For example, the size of the outer disks can be of an increasing diameter so as to form a substantially straight line when the disks are viewed from above. In this manner, the web can be picked up by, and taken off from, all of the disks at substantially the same time. FIG. 5 shows an alternative to making larger disks wherein extension fingers 41 having flexible protuberances 42 thereon are mounted on the rim of the disk 43 so as to increase its effective diameter. At least two thusly constructed disks can be used to form a substantially straight line for the disks when they are viewed from above, thereby enabling the web to be uniformly and simultaneously engaged by the disks.

Still another technique for controlling the width and thickness of the web using the novel apparatus of this invention is to simply control the point at which the web is put on the rotating disks. This can be achieved by simply introducing the web to the disks at a higher position thereon than heretofore described herein so that the web will be removed from the disks before it has been stretched to its maximum possible width. However, this technique only affects the width and thickness of the web, and not necessarily its uniformity.

The protuberances 22 should advantageously be of flexible material that will not pierce or break through the web, but will, rather, gently engage the web and carry it forward with gentle stretching motion. Neoprene 70, a trademark for a synthetic rubber material sold by du Pont, is preferred herein for this purpose, but other rubber, rubber-like, or non-rigid plastic materials will work with similar, although possibly somewhat less desirable, results.

FIG. 4 shows another embodiment of the guide comb, wherein the comb 31 has arm-like extensions 33 at approximately 45 angles from the slots behind each of the teeth 32. This structure prevents loose or extraneous pieces of the web from falling between the disks and possibly jamming the apparatus.

A preferred apparatus arrangement for increasing the width of a 40 inch web to approximately 100 inches would be as follows: a metal rotatable shaft of approximately 8 inches diameter has 43 disks mounted thereon, each disk being approximately 6 feet in diameter and being attached to the shaft by the swivel-type joints described herein. The disks are placed along the shaft at l inch intervals, each disk being parallel to the next adjacent one and perpendicular to the horizontal plane of the shaft. Flexible Neoprene 70 protuberances, less than an inch in height, extend radially out of the perimeter of each disk at 6 inch intervals from each other, while the two disks at each outer end of the arrangement have protuberances extending radially outward therefrom at 2 inch intervals from each other so as to prevent curling at the outer edge of the stretched web. Guide combs are then provided that cause the disks to converge at the pick-up portion of the apparatus, keeping each disk 1 inch from each adjacent disk at that end, while causing the disks to be kept 2.5 inches from each other at the most diverging portion of the disks. In this manner, a 40 inchwide web will be increased in width by 2.5 times, or to approximately 100 inches.

It should be apparent to those skilled in the art that many modifications and changes can be made herein without departing from the spirit or scope of the present invention. It is therefore intended that this invention be limited only by the following claims.

What is claimed is:

1. An apparatus for altering the width and thickness of a web of fabric comprising: a rotatable shaft mounted on a supporting means; a plurality of spaced apart disks each of said disks being affixed to said shaft by a swivel means for permitting the arcuate movement thereof in a plane about said shaft in a gyroscopic manner; a plurality of spaced apart flexible protuberances disposed on, and extending radially outward from, the perimeter of each of said disks; guiding means positioned in working relation with each of said disks for orienting the disks through diverging and converging lines through a 360 revolution of each of said disks; and power means for rotating said shaft and said plurality of disks in such a mannerso as to cause an oncoming'web offabric to be gently engaged by said flexible protuberances on said plurality of disks, and carried forward along the oriented lines established by said guiding means.

2. The apparatus of claim 1 wherein said swivel means includes spaced apart pairs of swivel pins that extend radially out from said shaft at 180 from each other onto which is attached an inner ring within each of said disks having two swivel points thereon that are disposed within apertures on the inner rim portion of each of said disks, said swivel .points being at angles to said swivel pins; and said guiding means includes at least one board of self-lubricating material having a plurality of spaced apart teeth thereon wherein the direction of each of said disks is oriented by a pair of said spaced apart teeth.

3. The apparatus of claim 2 wherein said flexible pro tuberances are of Neoprene 70, and each of said protuberances on the two end disks on each end of said shaft are spaced at 2 inch intervals from each other, and said protuberances on each of said remaining disks are spaced at 6 inch intervals from each other; and said plurality of spaced apart disks on said shaft comprising 43 disks spaced 1.75 inches from each other, said disks are oriented in a diverging manner away from the oncoming web so as to be spaced at 1 inch intervals from each other at the most convergent point thereon, and said disks are spaced at 2.5 inch intervals from each other at the most divergent point thereon.

4. The apparatus of claim 3 wherein said protuberances on at least two of said disks are disposed on extension fingers attached to the outer rim of said at least two disks.

5. The apparatus of claim 3 wherein said guiding means includes a plurality of arm-like extensions protruding out from said board at approximately .45 angles therewith, said extensions being disposed behind said spaced apart teeth.

6. An apparatus for increasing the width of a web 0 fabric comprising: a rotatable shaft mounted on a supporting means; a plurality of disks, each of said disks being affixed to said shaft by a swivel means for permitting the arcuate movement of each of said disks about said shaft in a gyroscopic manner, each of said disks having a diameter of approximately 6 feet and being disposed on said shaft at l.75 inch intervals from each other, said swivel means including spaced apart pairs of swivel pins that extend radially out from said shaft at from each other onto which is attached an inner ring within each of said disk having two swivel points thereon that are disposed within apertures on the inner rim portion of each of said disk, said swivel points being at 90 angles to said swivel pins; a plurality of flexible rubberized protuberances disposed on, and radially extending outward from, the perimeter of each of said disks, said protuberances being spaced at 2 inch intervals from each other on at least the two end disks on each end of said shaft, and being spaced at 6 inch intervals from each other on the remaining disks; at least one guide board of high molecular weight polyethylene positioned in working relation with said disks, said board having a plurality of spaced apart teeth thereon, each of said disks being held between a pair of said teeth so as to cause said plurality of disks to be oriented in a diverging manner; and power means for rotating said shaft and said plurality of disks in such a manner as to cause an on-coming web of fabric to be gently engaged by said protuberances on said disks, and carried forward along the diverging lines established by said guide board.

Claims

1. An apparatus for altering the width and thickness of a web of fabric comprising: a rotatable shaft mounted on a supporting means; a plurality of spaced apart disks each of said disks being affixed to said shaft by a swivel means for permitting the arcuate movement thereof in a plane about said shaft in a gyroscopic manner; a plurality of spaced apart flexible protuberances disposed on, and extending radially outward from, the perimeter of each of said disks; guiding means positioned in working relation with each of said disks for orienting the disks through diverging and converging lines through a 360* revolution of each of said disks; and power means for rotating said shaft and said plurality of disks in such a manner so as to cause an on-coming web of fabric to be gently engaged by said flexible protuberances on said plurality of disks, and carried forward along the oriented lines established by said guiding means.

2. The apparatus of claim 1 wherein said swivel means includes spaced apart pairs of swivel pins that extend radially out from said shaft at 180* from each other onto which is attached an inner ring within each of said disks having two swivel points thereon that are disposed within apertures on the inner rim portion of each of said disks, said swivel points being at 90* angles to said swivel pins; and said guiding means includes at least one board of self-lubricating material having a plurality of spaced apart teeth thereon wherein the direction of each of said disks is oriented by a pair of said spaced apart teeth.

3. The apparatus of claim 2 wherein said flexible protuberances are of Neoprene 70, and each of said protuberances on the two end disks on each end of said shaft are spaced at 2 inch intervals from each other, and said protuberances on each of said remaining disks are spaced at 6 inch intervals from each other; and said plurality of spaced apart disks on said shaft comprising 43 diSks spaced 1.75 inches from each other, said disks are oriented in a diverging manner away from the on-coming web so as to be spaced at 1 inch intervals from each other at the most convergent point thereon, and said disks are spaced at 2.5 inch intervals from each other at the most divergent point thereon.

5. The apparatus of claim 3 wherein said guiding means includes a plurality of arm-like extensions protruding out from said board at approximately 45* angles therewith, said extensions being disposed behind said spaced apart teeth.

6. An apparatus for increasing the width of a web of fabric comprising: a rotatable shaft mounted on a supporting means; a plurality of disks, each of said disks being affixed to said shaft by a swivel means for permitting the arcuate movement of each of said disks about said shaft in a gyroscopic manner, each of said disks having a diameter of approximately 6 feet and being disposed on said shaft at 1.75 inch intervals from each other, said swivel means including spaced apart pairs of swivel pins that extend radially out from said shaft at 180* from each other onto which is attached an inner ring within each of said disk having two swivel points thereon that are disposed within apertures on the inner rim portion of each of said disk, said swivel points being at 90* angles to said swivel pins; a plurality of flexible rubberized protuberances disposed on, and radially extending outward from, the perimeter of each of said disks, said protuberances being spaced at 2 inch intervals from each other on at least the two end disks on each end of said shaft, and being spaced at 6 inch intervals from each other on the remaining disks; at least one guide board of high molecular weight polyethylene positioned in working relation with said disks, said board having a plurality of spaced apart teeth thereon, each of said disks being held between a pair of said teeth so as to cause said plurality of disks to be oriented in a diverging manner; and power means for rotating said shaft and said plurality of disks in such a manner as to cause an on-coming web of fabric to be gently engaged by said protuberances on said disks, and carried forward along the diverging lines established by said guide board.