SYSTEM AND METHOD FOR PRODUCING A SINGLE- OR MULTI-LAYER NONWOVEN
20230304200 · 2023-09-28
Assignee
Inventors
- Thomas Weigert (Sulzbach, DE)
- Kai PÖHLER (Vettweiss, DE)
- Ralf SCHRÖDER (Langen, DE)
- Andreas SCHILZ (Aachen, DE)
Cpc classification
B32B5/266
PERFORMING OPERATIONS; TRANSPORTING
D04H11/08
TEXTILES; PAPER
B32B2307/718
PERFORMING OPERATIONS; TRANSPORTING
B32B5/067
PERFORMING OPERATIONS; TRANSPORTING
B32B2250/20
PERFORMING OPERATIONS; TRANSPORTING
B32B5/26
PERFORMING OPERATIONS; TRANSPORTING
International classification
Abstract
The invention relates to an installation and to a method of producing a web, wherein the installation includes a device for producing a layer of wet laid fibres, which has an entangling device and at least one dryer disposed downstream in material transport direction. The device for producing the wet laid fibres is formed as a cylinder mould former.
Claims
1. An installation for producing a multilayer web, comprising: a circulating belt having a material transport direction; first device for at least one of producing and depositing a first web on the circulating belt, a second device disposed following the first device in the material transport direction for applying a layer of wet laid fibres on the first web; and a third device following the second device in the material transport direction for at least one of entangling and bonding the first web to the layer of wet laid fibres, wherein there is a distance of 10 m is maintained between a point of depositing the first web on the circulating belt and a point of depositing the layer of wet laid fibres on the first web.
2. An installation for producing a multilayer web, comprising: a circulating belt having a material transport direction; first device for at least one of producing and depositing a first web on the circulating belt; a second device disposed following the first device for at least one of producing and depositing a second web on the circulating belt; and a third device disposed between the first device and the second device for producing and depositing a layer of wet laid fibres on the first web for being disposed between the first and the second webs on the circulating belt, wherein there is a distance of 25 m maximum between a point of depositing the first web on the circulating belt and a point of depositing the second web on the layer of wet laid fibres.
3. The installation for producing a multilayer web according to claim 1, wherein the first device for producing the first web comprises one of a roller card, an unwind station and a spunbond installation.
4. The installation for producing a multilayer web according to claim 1, wherein the device for producing the second web comprises one of a roller card, an unwind station or and a spunbond installation.
5. The installation for producing a multilayer web according to claim 1, wherein the second device comprises a cylinder mould former.
6. An installation for producing a web, comprising: a device comprising a cylinder mould former for producing a layer of wet laid fibres an entangling device following the cylinder mould former; and at least one dryer disposed downstream in material transport direction from the entangling device.
7. The installation for producing a web according to claim 6, wherein the cylinder mould former includes a rotating cylinder and a headbox formed for depositing a fibre suspension on the rotating cylinder.
8. The installation for producing a web according to claim 7, wherein the rotating cylinder includes a suction device.
9. The installation for producing a web according to claim 7, wherein the cylinder mould former includes a circulating belt formed for compacting a fibre suspension at the rotating cylinder to create a layer of wet laid fibres.
10. The installation for producing a web according to claim 9, wherein one of the rotating cylinder and the circulating belt cooperate with at least one of a couch roll and overhead suction.
11. The installation for producing a web according to claim 9, further including a doffer that cooperates with the circulating belt in an area where the wet laid fibres detach from the rorating cylinder.
12. The installation for producing a web according to claim 9, wherein the wet laid fibres are deposited on the circulating belt of the installation, wherein, in an area of a transfer of the wet laid fibres to the circulating belt, the cylinder mould former includes a at least one of a suction separator and a pressure device.
13. The installation for producing a web according to claim 9, further including a plurality of deflection rollers arranged to support the circulating belt of the cylinder mould former, and including at least one deflection in an area of a transfer of the wet laid fibres to the circulating belt of the installation, said at least one deflection roller is disposed to be at least one of swivelable and adjustable.
14. The installation for producing a web according to claim 6, wherein t the cylinder mould former includes a dilution water regulator.
15. The installation for producing a web according to claim 7, wherein the head box of the cylinder mould former includes headbox heating.
16. The installation for producing a web according to claim 6, wherein the cylinder mould former includes lateral suctioning.
17. The installation for producing a web according to claim 6, wherein the cylinder mould former includes a rack which is at least one of a) formed for being mounted at least partially underfloor and b) including a free space for the passage of the circulating belt of the installation.
18. The installation for producing a web according to claim 6, further including at least one further device formed for introducing a further web into the installation.
19. The installation for producing a web according to claim 18, wherein the further device comprises at least one of a roller card, an unwind station, and a spunbond installation.
20. A method of producing a web, comprising: depositing a fibre suspension on a rotating cylinder; drawing off at least a portion of liquid in the fibre suspension with the rotating cylinder to create a layer of wet laid fibres; taking the layer of wet fibers with a circulating belt and transferring the layer of wet fibres to a further circulating belt; and entangling and drying the layer of wet laid fibres on its own or together with at least one further web.
21. The method according to claim 20, further including compacting the layer of wet laid fibres between the rotating cylinder and the circulating belt.
22. The method according to claim 20, further including depositing the layer of wet laid fibres on a first web and transporting the first web on the further circulating belt.
23. The method according to claim 22, further including, prior to entangling, covering the layer of wet laid fibres with a further web.
24. The method according to claim 20, wherein the layer of wet laid fibres comprises biodegradable fibres with a weight per unit area of 10 to 50 g/m2.
25. The installation for producing a multilayer web according to claim 2, wherein the device for producing the second web comprises one of a roller card, an unwind station and a spun bond installation.
26. The installation for producing a multilayer web according to claims 2, the second device comprises a cylinder mould former.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] Further measures enhancing the invention are illustrated in more detail in the following in conjunction with the description of a preferred exemplary embodiment of the invention based on the Figures, wherein:
[0020]
[0021]
[0022]
[0023]
[0024]
[0025]
[0026]
[0027]
DETAILED DESCRIPTION
[0028]
[0029] A cylinder mould former 20 makes a layer of wet laid fibres 24 and deposits the same on a circulating belt 3. For this purpose, the cylinder mould former 20 has a headbox 23, by means of which a pipeline deposits a fibre suspension, for example from pulp, on a driven rotating cylinder 22. Preferably, the rotating cylinder 22 can have a perforated envelope with a plurality of holes and can have an inside suction. A stationary suction device in the rotating cylinder 22 can draw off most of the water from the fibre suspension. Thereby, the wet fibres 24, which were deposited on the cylinder 22, are transported with the top side thereof by a circulating belt 21, which preferably can be formed as a perforated belt. The top side of the wet fibres 24 is maintained by a side of the belt 21 and transported away, which, in this exemplary embodiment, is directed downwards and thereby deposits the wet fibres 24 through gravity on the circulating belt 3. The result is a single-layer web, which can be fed to further processing in an entangled, dried and wound-up manner. Preferably, prior to entangling, the layer of wet laid fibres 24 can be treated with a binding agent.
[0030] Preferably, the installation 1 includes at least one device for producing a carded web, which, in transport direction, is disposed upstream the cylinder mould former 20. The device can be formed as a roller card 2. In this case, the layer of wet laid fibres 24 is deposited on the web 2a of the roller card 2. Thus, creating a two-layered web, comprising a layer of carded web 2a with a layer of wet laid fibres 24, which are entangled with each other, dried and further processed as a web 10 or are wound up by means of a winder 11.
[0031] Optionally, another roller card 6 can cover the wet laid fibres 24 with a further carded web 6a, so that the wet laid fibres 24 are chambered on both sides by a web 2a, 6a. Likewise, the carded web 6a can consist of viscose having 1.7 denier and 40 mm fibre length, for example. In the following, the three layers can be entangled with each other, dried and, as a web 10, further processed or wound up by means of a winder 11. The illustration of the roller card 6 above the cylinder mould former is just diagrammatically illustrated. Actually, the installation components 2, 20 and 6 are disposed in transport direction following each other. Also, the illustration of depositing the webs 2a, 6a on one or more circulating belts 3 is only diagrammatically illustrated. Usually, depositing the carded webs from the roller card is realized at a slight angle from above the one or more transport belt/s. The circulating belt 3 does not limit the number of circulating belts, which deposit the wet laid fibres 24 and/or carded webs 2a, 6a. Also, several circulating belts can be used.
[0032] All three variants have in common, that the hydroentangling 7 can be operable in single stage or multistage at a pressure of 40 to 400 bars, wherein a suction device 8 can be disposed underneath the circulating belt 3, which suctions off the water of the hydroentangling 7. Subsequently, the entangled multilayer web passes a dryer 9, which can be formed as a drum dryer or belt dryer. After drying, the single-layer or multilayer web 10 can be wound on a winder 11. An advantage of the inventive installation 1 is the low space requirement for producing a single-layer or multilayer web, the uniform distribution of the wet laid fibres 24 across the width of the emerging web, and the potential use of secondary fibres, regenerated fibres and/or recycled fibres so as to be able to produce a biodegradable web. Another advantage is found in that the installation can be operated with only one layer of wet laid fibres 24, or with two layers (2a and 24) or (24 and 6a) or with three layers (2a and 24 and 6a) of fibres or webs, and the compactness and low investment cost allow for a very affordable operation.
[0033] The distance L amounts to 25 m maximum between the points of depositing, at which the webs 2a and 6a are placed on one or more belt/s 3, and between which the layer of wet laid fibres 24 is applied. The distance I amounts to 10 m maximum between the point of depositing a web 2a on one or more belt/s 3 and the following point in transport direction, at which the wet laid fibres 24 are placed on the web 2a. Thus, creating a short and compact installation, which cannot be achieved when using a traditional inclined wire former.
[0034]
[0035] Optimizing the quality of the wet laid fibres 24 can be achieved at the headbox 23 by means of a dilution water regulator, whereby the transverse profile of the wet laid fibres 24 can be even more harmonized. For a working width of the installation of up to 5 m, in particular for a thin and light layer of wet laid fibres, the cross-section can be harmonized thereby. Another improvement can be achieved with a headbox heating, which likewise can further improve the cross-sectional profile of the wet laid fibres 24. A lateral suctioning allows for creating the border of the wet laid fibres with sharper edges.
[0036] The cylinder mould former 20 is mounted to a rack 29, which can be disposed optionally in the area of a feed of further fibres or of a web 2a above a belt 3. Depending on the embodiment of the cylinder mould former, a modified belt guide can deposit the layer of wet laid fibres also with the wire side on another transport belt, which follows the circulating belt 21.
[0037] In the embodiment of
[0038] Thereby, the cylinder 22 rotates about the stationary suction 22a. Alternatives are possible, for example a stepwise suction, which, on the circumference of the cylinder, can continually or stepwise decrease from the headbox 23 to the transfer onto the belt 21. A couch roll 30 above the belt 21 compacts the wet laid fibres 24 and increases the dryness of the fibres 24. As an alternative, instead of the couch roll 30, also a suction device, not illustrated in detail, could be disposed overhead above the belt 21 in the area, at which the wet laid fibres 24 are transferred from the cylinder 22 to the belt 21.
[0039]
[0040] Compared to an air laid method, the cylinder mould former 20 is advantageous in that the wet laid fibres 24 can be further processed with two smooth or planar surfaces, which are smoothed by the cylinder 22 on the wire side and by the belt 21 on the top side of the wet laid fibres 24. Based on the smoothed surfaces, in particular with light and thin wet laid fibres, is achieved a very uniform material distribution or a very uniform weight per unit area, which cannot be achieved with other methods (air laid, meltblown). Compared to the traditional inclined wire former, the advantage of the cylinder mould former 20 is the compactness and the low investment and operating cost.
[0041] The alternative embodiment of the installation according to
[0042] Also in this exemplary embodiment, the distance L amounts to 25 m maximum between the points of depositing, at which the webs 16a and 17a are placed on one or more belt/s 3, and between which the layer of wet laid fibres 24 is applied. The distance I amounts to 10 m maximum between the point of depositing a web 16a on one or more belt/s 3 and the following point of depositing in transport direction, at which the wet laid fibres 24 are placed on the web 16a. Thus creating a short and compact installation, which cannot be achieved when using a traditional inclined wire former. Another advantage is found in that the installation can be operated with only one layer of wet laid fibres 24, or with two layers (16a and 24) or (24 and 17a) or with three layers (16a and 24 and 17a) of fibres or webs, and the compactness thereof and low investment cost allow for a very affordable operation.
[0043] The exemplary embodiment of
[0044] The embodiments of the cylinder mould former 20 according to the
[0045]
[0046]
[0047] All embodiment variants of the cylinder mould former can be combined with each other optionally according to the application cases. The cylinder mould former 20 is suitable for a mass per unit area of 10 to 50 g/m.sup.2. The working speed can be from 50 to 400 m/min. The maximum working width can be up to 5 m. For all application cases of
[0048] According to an embodiment, the layer of wet laid fibres can consist of at least partially short synthetic fibres having a fibre length of 1 to 3 mm, preferably of 1 to 12 mm, such as polyester, polyamide, polypropylene or polyolefin. Also, fibre blends of synthetic and natural fibres are possible. Likewise, the layer of wet laid fibres can consist of 100 % pulp or other natural fibres, which have a high water-retention capacity, and preferably are biodegradable. Using secondary fibres, recycled fibres or regenerated fibres is advantageous for producing biodegradable fibres.
[0049] The fibre suspension can consist of a blend of fibres having a high content of pulp and a smaller content of short synthetic fibres with a fibre length of 1 to 3 mm, preferably of 1 to 12 mm, such as polyester, polyamide, polyolefin, polypropylene or viscose or lyocell. Preferably, the weight per unit area of the dried web 10 can be 20 to 70 g/m.sup.2.
[0050] Depending on the embodiment, the web 12a, 14a can consist for example of polyester, viscose, a cotton blend or a blend of synthetic and/or natural fibres, for example also one or both webs 12a, 14a made from tissue or paper can be used. Preferably, the weight per unit area of the web 10 is between 20 to 70 g/m.sup.2. The fibres of the webs 12a, 14a can consist of short fibres, for example staple fibres having a length of 3 to 60 mm, or of synthetic endless filaments.
[0051] According to another embodiment a very compact and flexible installation for producing a single-layer or multilayer web 10, which can consist of only the layer of wet laid fibres 24 or only of a carded web 2a with or without the carded web 6a. As an alternative, the web 10 can consist of two or more layers, for example of the wet laid fibres 24 with one or two webs 2a, 6a of the roller cards 2 and/or 6 or of the wet laid fibres 24 with the webs 12a and/or 14a and/or another web 16a and/or 17a of a spunbond installation 16 and/or 17.