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Home Nonmetallic Processes Method-for-the-production-of-a-nonwoven-fabric

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 Method for the production of a nonwoven fabric

Details
Inventors: Platt, Louis; Wishman, Marvin; Gentry, David R.; Williams, Jake E.;
Assignee: Phillips Petroleum Company (Bartlesville, OK)
Primary Examiner: Wityshyn; Michael G.
Assistant Examiner:
Attorney, Agent or Firm:

A nonwoven fabric is produced by forming a batt comprising staple fibers oriented primarily in the fill direction, drafting the batt in the warp direction in a first warp-drafting zone, needling the drafted batt, drafting the needled batt in the warp direction in a second warp-drafting zone, and drafting the warp-drafted, needled batt in the fill direction in a fill-drafting zone. A fabric, apparatus for producing the fabric, and a method for fusing a nonwoven batt are provided.

DETAILED DESCRIPTION OF THE INVENTION The apparatus of the invention is more fully understood by referring to the drawings and in particular FIGS.
1 and 2 wherein the embodiment of the apparatus shows a batt-forming means comprising two web-forming trains A and A' in which feed means 10,10' such as bale breakers, blender boxes, feed boxes, etc.
, feed fibers in the form of staple, such as polypropylene staple, to breaker carding machines 12,12'.
The carding machines 12,12' produce carded webs 14,14' of fibers which are picked up by the takeoff aprons 16,16' of crosslappers 20,20'.
Crosslappers 20,20' also comprise lapper aprons 18,18' which traverse a carrier means, such as intermediate aprons 22,22', in a reciprocating motion laying the webs 14,14' to form intermediate batts 24,24' on the intermediate aprons 22,22'.
The intermediate batts 24,24' are passed to finisher carding machines 26,26' by intermediate aprons 22,22'.
Carding machines 26,26' produce carded webs 28,28' which are picked up by takeup aprons 30,30' of crosslappers 34,34'.
Crosslappers 34,34' also comprise lapper aprons 32,32' which form a batt of fibers 36 as the lapper aprons 32,32' traverse floor apron 38.
The carded webs 28,28' are laid on floor apron 38 to build up several thicknesses to produce batt 36.
It is pointed out that only a means for forming a batt with the fibers oriented primarily in the fill direction is essential to practice the invention which can be accomplished by any suitable means.
As an example, only one feed means, carding machine, and crosslapper are actually needed to form a batt.
The use of two carding machines such as a breaker carding machine and a finisher carding machine and associated aprons and crosslappers are not essential to practice the invention.
The use of two carding machines tends to open up the fibers better to form a more uniform web and to provide some randomization of the staple fibers forming the webs which form the batt; however, the fibers of batt 36 are still primarily oriented in the fill direction



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