Industrial fabric for production of nonwovens, and method of making thereof.
Abstract
Se describe una tela industrial tal como una banda sinfín o funda para utilizarse en la producción de productos no tejidos, y un método para su fabricación. La tela incluye una pluralidad de huecos pasantes, en donde cada uno de los huecos tiene una primera abertura asociada con la superficie superior de la tela y un primer borde elevado circunferencialmente adecente a la primera abertura. Los huecos pueden cada uno incluir además una segunda abertura asociada con la superficie inferior de la tela y un segundo borde elevado circunferencialmente adyacente a la segunda abertura, de tal manera que la primera abertura puede tener un área superficial que es mayor o igual que la segunda abertura.

Term
3.3 yearsleft in the term
Expires 27 January 2030.
- Priority
- Filed
- Granted
- Today
- Expires
18 claims: 3 independent, 15 dependent
- 1REIVINDICACIONES 1. Una tela industrial para la tejidos que comprende una pluralidad de huecos pasantes, comprendiendo cada hueco pasante:una primera abertura asociada con una superficie superior de dicha tela;una segunda abertura asociada con una superficie inferior de dicha tela;caracterizada porque los huecos pasantes comprenden cada uno por lo menos un borde u orilla elevada circunferencialmente adyacente a al menos una de dichas aberturas primera y segunda, en donde el borde u orilla elevada forma una orilla elevada continuo alrededor de dicha abertura.
- 2La tela como se reivindica en la reivindicación 1, en donde cada uno de la pluralidad de huecos pasantes incluye una superficie interior conformada sustancialmente cónica o cilindrica.
- 3La tela como se reivindica en la reivindicación 1, en donde la altura de un primer borde elevado se encuentra en la superficie superior y un segundo borde elevado en la superficie inferior está en el intervalo de 5-10 pm.
- 4La tela como se reivindica en la reivindicación 1, en donde los huecos pasantes están formados en una cinta de material que tela. forma una
- 5La tela como se reivindica en la reivindicación 4, en donde dicha cinta de material es una película, cinta metálica o una cinta de material no tejido.
- 6La tela como se reivindica en la reivindicación 5, en donde dicha película o cinta metálica comprende fibras de refuerzo en MD, CD o MD y CD o en una dirección aleatoria.
- 7La tela como se reivindica en la reivindicación 5, en donde la cinta de material no tejido está cubierta para mejorar la liberación y/o la integridad estructural de la hoja.
- 8Un método para generar huecos pasantes en una tela industrial como se reivindica en la reivindicación 1, el método que comprende:una fuente óptica operativa para generar radiación láser enfocada;una unidad de control acoplada a la fuente óptica y adaptada para controlar al menos una característica asociada con la radiación láser enfocada;y un aparato operativo para retener la tela y facilitar el movimiento relativo entre la fuente óptica y la tela, de tal manera que la radiación láser enfocada perfore la tela y genere los huecos pasantes. '· MSXICANO V // ιΛ PKGFIEi;,»¡D £' industrial
- 9El método como se reivindica en la reivindicación 8, en donde el aparato c omprende* “una pluralidad de componentes motorizados operables para proporcionar el movimiento de la tela en una o más direcciones y movimiento a una cabeza asociado con la fuente óptica, en donde la cabeza está adaptado para moverse con relación a la tela en una dirección x, y ó z.
- 10El sistema como se reivindica en la reivindicación 8, en donde la por lo menos una característica asociada con la radiación láser enfocada es una característica de potencia de o de modulación de salida.
- 11El sistema como se reivindica en la reivindicación 8, que además comprende componentes de conformación de haz para dar forma a la radiación láser enfocada antes de aplicar la radiación láser enfocada a la tela.
- 12Un método de generación de huecos pasantes en una tela industrial utilizada en la producción de no tejidos, que comprende:generar radiación láser enfocada para impactar en dicha tela;y controlar al· menos una característica asociada con la radiación láser enfocada de manera que la radiación láser enfocada genera huecos pasantes que incluyen cada uno al menos un borde u orilla elevada circunferencialmente adyacente a una abertura creada superficies superior e inferior donde el borde u orilla elevada continua alrededor de la abertura. en al asociada forma y. y W .··;?/a j.í v/, menos · /ná*· 1 · denlas s con· -ia™·-una orilla elevada comprende la generación de huecos pasantes que incluyen cada uno una abertura de la superficie superior que tiene un área de superficie más grande que una abertura de la superficie inferior.
- 1314. La tela como se reivindica en la reivindicación 1, que comprende uno o más cintas enrolladas en espiral de material polimérico, en donde cintas adyacentes de las cintas enrolladas en espiral de material polimérico están acopladas, las cintas enrolladas en espiral comprenden una pluralidad de dichos huecos pasantes.
- 1415. La tela de conformidad con la reivindicación 14, que además comprende:una o más capas de materiales o tejidos, arreglos de hilo MD o CD, cintas enrolladas en espiral de material tejido que tienen una anchura menor que la anchura de la banda o de la manga, redes fibrosas, películas, o una combinación de los mismos, en donde la una o más capas están formadas en la parte superior o debajo de las cintas IMPK INSTITUTO t¿ E XI CAN O LA PROPIEDAD INDUSTRIAL ·- . . A enrolladas en espiral. 1
- 1516. La tela según la reivindicaciÓK^T7™STr’ , Tiu i n , de' :· las cintas adyacentes están acopladas usando al menos uno de soldadura láser, infrarroja, y ultrasónica.
- 1617. La tela como se reivindica en la reivindicación 1, en donde la tela es una banda o una manga utilizada en procesos de aplicación por chorro de aire, fusión por soplado, unión por hilado o hidroenredado.
- 1718. La tela como se reivindica en la reivindicación 14, en donde los huecos pasantes están separados por áreas planas.
- 1819. La tela como se reivindica en la reivindicación 18, en donde el área plana tiene una forma geométrica seleccionada del grupo que consiste de diamante, cuadrado, rectángulo, círculo, paralelogramo, hexagonal, floral y poligonal. ΠλΡΪΟ. ,
Independent claims18
260 paragraphs in 18 sections, as filed
(54) Title: INDUSTRIAL FABRIC FOR THE PRODUCTION OF NON-WOVEN PRODUCTS AND METHOD FOR THEIR MANUFACTURE.
(54) Tltle: INDUSTRIAL FABRIC FOR PRODUCTION OF NONWOVENS, AND METHOD OF MAKING THEREOF.
(57) Summary
An industrial fabric such as an endless belt or sheath for use in the production of nonwovens, and a method for their manufacture, is described. The fabric includes a plurality of through holes, where each of the holes has a first opening associated with the top surface of the fabric and a first circumferentially raised edge adjacent the first opening. The recesses may each further include a second opening associated with the bottom surface of the fabric and a second raised edge circumferentially adjacent to the second opening, such that the first opening may have a surface area that is greater than or equal to the second. opening.
(57) Abstract
An industrial fabric such as an endless belt or sleeve for use in the production of nonwovens, and a method of making thereof are disclosed. The fabric ineludes a plurality of through voids, where each of the voids has a first opening associated with a top surface of the fabric and a first raised edge circumferentially adjacent to the first opening. The voids may each further inelude a second opening associated with a bottom surface of the fabric and a second raised edge circumferentially adjacent to the second opening, such that the first opening may have a surface area that is larger than or the same as the second opening .
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_I KNOW_
SECRfTAftM í) l W ONOMY
Institute
Mexican Property
Industrial i
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PATENT TITLE NO. 337965
Headlines):
Home:
Denomination:
Classification:
Inventor (s):
ALBANY INTERNATIONAL CORP.
1373 Broadway, Albany, New York, 12204, USA
INDUSTRIAL FABRIC FOR THE PRODUCTION OF NON-WOVEN PRODUCTS AND
METHOD FOR ITS MANUFACTURE.
lnt.CI.8: B32B5 / 26; D04H1 / 44; D04H1 / 46; D04H5 / 02
SABRI MOURAD; JOÑAS KARLSSON
Humerus:
MX / a / 2011/007973
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TUD presentation of January 2010 * »» »<· *
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| B
I
Country:
US
Validity: Twen and Fincha de Vencí ios
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of the 'Law of the preservation of *
faith
PRIORITY
Date:
January 2009
Number:
61 / 147,894 lientos 27xle January 2030, torga with (0ndaml ^^ n articles 1 2 * fraction V; 6f fpcciipryjlt, and 59 of the Industrial Property Law.
I Industrial, this patent is valid for twenty years ImpÓrogables, international and will be subject to payment of the fee to keep the {industrial piety (Official Diano de
D1 / 2004, 06/16/2005, 25J01 / 2OO6, 0 'a), 4th and 12th fraction I and lll
D7 / 2002, 07/15/2004, 28r | 7/2004 and | Mexican Institute of the 'subparagraph a) of the Agreement qi ilo lo hdfce with fundam Federación' '<sup>1 </sup>5 / 2009,06 / 01 Regulation of I9 / 2007); lustrial articles 1 (DOF 12/27/19® property and delegates f <dores DI '8, reform
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Results in the General Directors (to by articles 6 ° ftacdonaa Ni and 7? Bis 2 of the Law of the amended law on 02 / oe / ies *, 25 / WI9W, 12/26/1997, # / 05/1999, 1 / 2010, 27 / QW2012 and ΟΜΜΒΗΝ}: articles 1, 3 'la P »« ieUHeMW<sup>!</sup>4éJÜ'f 12/14/1999, ny lll and 30 of the Statutory 08/04/2004 and 09/13/21
ÍWWOliwaÍliiftMiW ador, Divisional Directors, Title V signed the Organic 7); 1st, 3rd is property
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Issue Date: March 28, 2016
THE DIVISIONAL DIRECTOR OF PATENTS
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NAHANNY CANAL REYES
Arenal No. 550, Floor 1,
Col. Pueblo Santa Mgria Tepepan, Xochimilco, CP 16020.
Mexico City
Tel. (55) 53 34 07 00 www.impi.pob.mx <5 · Τιί. you
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MX / 2016/23613
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METHOD FOR ITS MANUFACTURE—
CROSS REFERENCE WITH RELATED REQUESTS
This application claims the priority benefit of US Provisional Patent Application No.
61 / 147,894, filed on January 28, 2009.
INCORPORATION THROUGH REFERENCE
All patents, patent applications, documents, references, manufacturer's instructions, descriptions, product specifications, and product sheets for any of the products mentioned herein are incorporated by reference herein, and may be used in practice. of the invention.
BACKGROUND OF THE INVENTION
one. Field of Invention
The present invention is directed to endless fabrics, and particularly, industrial fabrics used in the production of nonwovens. More particularly, the current invention is directed to support members such as bands or sleeves used in the production of patterned or marked nonwovens. Furthermore, the present invention can be used as a web and / or sheath used in the production of nonwovens by processes such as air blasting, melt blown, spun bonding, and hydroentangling.
two. Description of the Prior Art ........__ _
The processes for making nonwovens have been known for many years. In one process, a fiber batt or web is treated with streams or jets of water to make the fibers entangle with each other and improve physical properties such as the strength of the web. Such techniques for water jet treatment have been known for decades, as can be understood from the disclosures in US Pat. Nos. 3,214,819, 3,508,308 and 3,485,706.
In general terms, this method involves the interlacing of elemental fibers with each other by means of the action of jets of water under pressure, which act on the fibrous structure like needles and make it possible to reorient part of the fibers forming the network in the thickness direction .
Such technology has been widely developed today and is used not only to produce what are known as entangled or hydroentangled jet structures for textile use, such as in particular for applications in the medical fields and hospitals for cleaning, filtration and wrapping for tea bags. , and the articles obtained can be regular and homogeneous, as can be understood from the description of US Patent No. 3,508,308, and if required, include designs resulting from reorientation
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fibers, this being essential for ...... an aesthetic purpose, as can be understood from the description of US Patent No. 3,485,706.
Concerning tangled or hydroentangled jet type products it has long been known that the final properties of the product can be adapted when producing material mixtures, for example by combining a plurality of networks consisting of fibers of different types, for example of natural, artificial or synthetic fibers, or even nets in which the fibers are previously mixed (tangled jet nets, etc.) with reinforcements that can be incorporated into the non-woven structure.
French patents FR-A-2 730 246 and 2 734 285, corresponding respectively to US Patent No. 5,718,022 and US Patent No. 5,768,756, describe solutions that make it possible to successfully treat hydrophobic fibers or mixtures of these fibers with other hydrophilic fibers or even webs consisting entirely of natural fibers by means of water jets.
In general terms, according to the teachings of these documents, the treatment involves treating a basic network composed of elemental fibers of the same or different types, compressing and wetting this basic network and then interlacing the fibers by means of at least one support of contiguous jets of water under high i ;;;?: ”. · pressure acting on the network. basic. —_________________________
For this purpose, the basic network is positively advanced on a porous endless moving support, and carried on the surface of a rotating cylindrical perforated drum, inside which a partial vacuum is applied. The basic network is mechanically compressed between the porous support and the rotating drum which both advance at substantially the same speed. Immediately downstream of the compression zone, a curtain of water is said over the net and passes successively through the porous support, the compressed basic net, and the perforated support drum where a vacuum source removes excess water.
The elementary fibers are continuously interlaced, even on the rotating cylindrical drum, by the compressed and wet network that is subjected to the action of at least one support of jets of water under high pressure. In general, the union is carried out by means of a plurality of successive supports of water jets which act either on the same surface or alternatively against the two surfaces of the network, varying the pressure within the supports and the speed of the jets discharged from one support to the next and usually progressively.
It is important to note, as can be understood from fr 2 734 285, that the perforated roller / drum may comprise
JK
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randomly distributed micro perforations
If required, after the initial bonding treatment, the fibrous nonwoven structure can undergo a second treatment applied towards the reverse surface.
In the process of producing knotted or hydroentangled nonwovens, it is often desired to impart a design or branding on the finished product, thereby creating a desired design on the product. This design or mark is typically developed using a secondary process, separate from the nonwoven sheet forming and winding process, where an engraved / embossed calendering roll is used. These rollers are typically expensive and operate on the principle of compressing certain areas of the fibrous web to create the required patterns or markings. However, there are several disadvantages to using a separate process to create the design or branding on the nonwoven product. For example, a high initial investment would be required for the calendering rollers, which can limit the duration of the production steps, which can be economically justified by the producer. Second, higher processing costs would be incurred due to a separate stamping and marking step. Third, the final product would have a higher material content than required to maintain the product's gauge (thickness) after compression in the pressing stage.
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or Mexican LA l'HOPIEDAÍO
INCU5TJUAL calendered. Finally, the two-stage process * e © «d« «Áxia, at a lower volume in the finished product than desired due to high pressure compression during calendering. Prior art nonwovens made with these known embossing processes do not have well-defined clear raised portions and therefore the desired designs are difficult to see. Furthermore, the raised portions of the prior art engraved nonwovens are not dimensionally stable and their raised portions tend to lose their three-dimensional structure when stressed after a period of time depending on the application.
US Patent Nos. 5,098,764 and 5,244,711 describe the use of a support member in a more recent method of producing webs or nonwovens.
The support members have a topographic feature configuration as well as an aperture arrangement. In this process, an initial fiber network is placed on the survey support member. The support member with the fibrous network thereon is passed under the jets of high pressure fluid, typically water. The jets of water cause the fiber to entangle and entangle each other in a particular pattern, based on the topographical configuration of the support member.
The pattern of topographic features and
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The particular openings in the support member is critical to the structure of the resulting nonwoven product. In addition, the support member must have sufficient integrity and structural strength to support a fibrous web while the fluid jets rearrange the fibers and entangle them in their new arrangement to provide a stable fabric. The support member must not undergo any substantial distortion under the force of the fluid jets. Also, the support member must have means for withdrawing relatively large volumes of fluid to entangle in order to avoid flooding of the fibrous web, which would interfere with effective entanglement. Typically, the support member includes drain openings which must be small enough in size to maintain the integrity of the fibrous network and prevent fiber loss through the forming surface. Furthermore, the support member must be substantially free of burrs, hooks, or similar irregularities that may interfere with removal therefrom of the entangled fibrous nonwoven product. At the same time, the support member must be such that the fibers of the fibrous web that are processed therein are not washed away (ie, good retention and support of the fiber) under the influence of the fluid jets.
One of the main problems that arises during '”O MEXICANO
US'fPJAL
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the production of nonwovens is to achieve the cohesion of the fibers that make up the nonwoven product in order to give the nonwoven products the resistance characteristics according to the application in question, while maintaining or imparting the particular physical characteristics such as volume, touch, appearance, etc.
The properties of volume, absorbency, strength, smoothness and aesthetic appearance are in fact important for many products when used for their intended purpose. To produce a nonwoven product having these characteristics, a support member will often be constructed such that the sheet-contacting surface exhibits topographical variations.
It should be appreciated that these support members (fabrics, bands, sleeves) can take the form of endless cycles and function in the form of conveyors. It should be further appreciated that the production of nonwovens is a continuous process that proceeds at considerable speeds. That is, the elemental fibers or webs can be continuously deposited on a forming fabric / web in the forming section, while a freshly entangled nonwoven fabric is continuously transferred from the support member to a subsequent process.
The present invention provides bands and sleeves that function in place of traditional woven fabrics, and
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imparts the desired texture, feel and volume to the nonwovens produced therein.
SUMMARY OF THE INVENTION
It is therefore a primary objective of the present invention to provide an improved web or sheath that imparts the desired texture, feel, volume, appearance, absorbency and strength to the nonwoven products produced therein.
Yet another object of the invention is to provide a jet-entangled or hydroentangled support member such as a band or sheath having through holes in a desired pattern. The support member can also be used as a process band or sleeve, in air blast, melt blown or spun bond processes.
It is a further object to provide a band or sleeve that can have a topography or texture on one or both surfaces due to the through-hole or void design. These and other objects and advantages are provided by the present invention. Other advantages are provided such as, but not limited to, improved fiber support and release (no repellency) over prior art woven fabrics, and easier cleaning as a result of no yarn crossovers to trap elemental fibers. The surface texture of the web or sheath results in a more effective pattern / texture that is transferred to the nonwoven, and also results in better physical properties such as bulk / absorbency.
The present invention relates to an endless support member such as a belt or sheath for supporting and transporting natural, artificial or synthetic fibers in a jet-entangling or hydroentangling process. The present porous structures, bands, or sleeves exhibit the following non-limiting advantages through calendering technology: cloth sleeves are a relatively less expensive item without large capital investments in stationary equipment; the pattern is self-executing during the entangling process, eliminating the need for a separate calendering process; a lower material content can be achieved in the final product as the thickness / thickness is not degraded by compression; the finished product can be produced in a larger volume as it is not compressed in the calendering stage. For the producer of laminated nonwoven articles, these process advantages further lead to the end product advantages of: lower cost of jet-entangled or hydroentangled nets with desired patterns, markings or texture; the ability to customize products as the size / duration of the production phase for particular products is reduced; the production of higher performance products, such as high volume products that impart the higher absorbency characteristics, which is of great value in consumer applications ^^.
Thus the invention, according to an exemplary embodiment, is an industrial fabric, such as a band or sheath, that includes a plurality of through holes. Each of the through-holes has a first opening associated with the top surface of the fabric, a second opening associated with the bottom surface of the fabric, and at least one raised edge circumferentially adjacent to at least one of the first and second openings.
Another exemplary embodiment of the present invention is a system for producing through holes in an industrial fabric, such as a band or sheath. The system includes an optical source operable to generate incident optical radiation, a drive unit coupled to the optical source and adapted to control at least one characteristic associated with incident optical radiation, and apparatus operable to retain the fabric and facilitate movement. relative between the optical source and the fabric in such a way that the incident optical radiation pierces the fabric and generates the through holes. The through holes include at least one raised edge circumferentially adjacent to an opening created on at least one of the top and bottom surfaces associated with the fabric.
Another exemplary embodiment of the present invention is'<sup>ώ</sup>'rv-7? '<sup>!Sic</sup>'> no <sup>D ,:</sup> THE INDVSTKIAI PROPERTY.
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- 12 a method to generate through holes ~ “-ea = -. -.a.,.,, t.ela industrial, such as a band or sleeve. The method includes the steps of producing a first opening associated with the upper surface of the fabric, producing a second opening associated with the lower surface of the fabric, and producing at least one raised edge circumferentially adjacent to at least one of the first and second openings. .
Yet another exemplary embodiment of the present invention is a method of generating through holes in an industrial fabric, such as a band or sheath. The method includes the steps of generating incident optical radiation to impact the fabric, and controlling at least one characteristic associated with the incident optical radiation such that the incident optical radiation generates through holes that each include at least one raised edge circumferentially adjacent to an opening created on at least one of the upper and lower surfaces associated with the fabric.
Yet another exemplary embodiment of the present invention is an industrial fabric, such as a web or sheath, that includes one or more spiral wound tapes of polymeric material, wherein adjacent tapes of the spirally wound tapes of polymeric material are engaged. The spirally wound tapes comprise a plurality of through holes each having a first opening associated with the upper surface of the fabric, a second<sup>τ</sup><<VLO Í.ÍUICANO i '-'¿ Ι.Λ P? .G¡'iro / .D industriai.
<img file="MX337965B_D0019.tif" />
There is an opening associated with the bottom surface of the fabric and at least one circumferentially raised edge adjacent to at least one of the first and second openings.
Yet another exemplary embodiment of the present invention is an industrial fabric, such as a web or sheath that includes tapes of polymeric material wound in a spiral such that adjacent tapes of polymeric material engage to form a web, and a plurality of gaps pass-throughs distributed over the formed band, wherein the plurality of through holes comprise at least one circumferentially raised edge adjacent to at least one of a first and second apertures associated with each of the plurality of distributed through holes.
Although the term fabric and fabric structure is used, the fabric, belt, carrier, sleeve, support member, and fabric structure are used interchangeably to describe the structures of the present invention. Similarly, the terms material tape and material tapes are used interchangeably throughout the description.
The various features of the novelty that characterize the invention are pointed out in particular in the appended claims and form a part of this description. For a better understanding of the invention, its advantages
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operational and its specific objectives achieved by its uses, reference is made to the accompanying descriptive matter in which the preferred embodiments of the invention are illustrated in the accompanying drawings in which the corresponding components are defined by the same reference numerals.
BRIEF DESCRIPTION OF THE DRAWINGS
The following detailed description, given by way of example and not intended to limit the present invention solely thereto, will be better appreciated in conjunction with the accompanying drawings, wherein like reference numerals denote like elements and parts in which:
Figures IA and IB are an example of an industrial fabric, band, or sheath having through holes in accordance with one aspect of the present invention;
Figure 2A is an example of the cross section of a fabric, web, or sheath having through holes in accordance with one aspect of the present invention;
Figure 2B is an example of the cross section of the fabric, web or sheath having a branched hollow structure in accordance with one aspect of the present invention;
Figure 3A is a block diagram of the system for generating a fabric, web, or sheath having through holes in accordance with one aspect of the present invention;
'// ¡¿τΐΥΐ Y¿
Figure 3B illustrates an apparatus used in generating through holes in a fabric, band, or sheath in accordance with one aspect of the invention;
Figures 4A and 4B are schematic views of different types of apparatus for producing non-woven nets using the fabric, band or sheath of the present invention;
Figure 5 is a flow chart describing the process for generating through holes in a fabric, web, or sheath in accordance with one aspect of the present invention;
Figure 6 illustrates images of a perforated fabric, band or sleeve in accordance with one aspect of the present invention;
Figure 7 illustrates images of a perforated fabric, band or sleeve in accordance with another aspect of the present
<img file="MX337965B_D0021.tif" />
invention;
Figures 8A-G illustrate images of a perforated fabric, band or sleeve in accordance with one aspect of the present invention;
Figure 9 illustrates images of both upper and lower surfaces of the drilled through holes corresponding to Figure 8G;
Figure 10 depicts various through holes in accordance with yet another aspect of the present invention generated;
Figure 11 is a perspective view of a
KiTrruroMM ¡, · ,,, ...., i · '·. I-.ÍOflkDAÓ
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cloth, band or sheath in accordance with an aspect of ... the. '. pxese invention;
Figure 12 illustrates a method by which the fabric of the present invention can be constructed;
Figures 13A-B illustrate, respectively, a top and a bottom image of a fabric, band, or sheath having through-holes drilled in a pattern in accordance with one aspect of the present invention; and
Figures 14A-C are images of exemplary fabrics, bands, or sleeves having through holes drilled in various patterns in accordance with another aspect of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED MODALITIES
The present invention will now be more fully described hereinafter with reference to the accompanying drawings, in which the preferred embodiments of the invention are shown. However, this invention can be incorporated in many different ways and should not be construed as limited to the embodiments set forth herein. Rather, these illustrated embodiments are provided so that this discussion will be detailed and complete and will fully convey the scope of the invention to those skilled in the art.
The present invention provides a continuous support member t | al as an endless band for use in the apparatus shown for example in Figure 4 (a). Although the following description is primarily for the jet-entangling process and fabrics or bands used therein, the application is not limited to this. The inventive web / sleeves are useful for other nonwoven processes, such as for example air blasting, melt blown or spun bonding processes. The nonwoven product support member functions in place of a traditional woven product support member, and imparts the desired texture, feel and volume to the nonwoven products produced therein. The support member of the present invention can reduce manufacturing time and costs associated with the production of nonwovens.
Figure 4 (a) depicts an apparatus for continuously producing nonwoven fabrics using a support member according to the present invention. The apparatus of Figure 4 (a) includes a conveyor belt 80 that actually serves as the topographic support member in accordance with the present invention. The band is continuously moving in a counterclockwise direction around a separate pair of rollers as is well known in the art. Disposed above the band 80 is a fluid ejector manifold 79 connecting a plurality of lines or groups 81 of orifices. Each group has one or more rows of very fine diameter holes, each approximately 0.007 inches in diameter with 30 such holes per inch. Water is supplied to the groups 81 of orifices under a predetermined pressure and is expelled from the orifices in the form of very fine substantially columnar non-divergent streams or jets of water. The manifold is equipped with pressure gauges 88 and control valves 87 to regulate fluid pressure in each line or group of orifices. Each line or group of orifices arranged below is a suction chamber 82 to remove excess water, and to prevent the area from being unduly flooded. The network of fibers 83 to be formed in the nonwoven product is fed to the conveyor belt of the topographical support member of the present invention. Water is sprayed through an appropriate nozzle 84 onto the fibrous web to pre-wet the incoming web 83 and to help control the fibers as they pass under the fluid ejector manifolds. A suction slot 85 is placed under this water nozzle to remove excess water. The fibrous web passes under the fluid ejector manifold in a counter-clockwise direction. The pressure at which any given group 81 of orifices is operated can be set independently of the pressure at which any of the other groups 81 of orifices are operated. However, typically, the group 81 of holes closest to the
ύ) 'Τ rolling nozzle 84 is operated at a relatively low pressure, eg, 100 psi. This helps to position the incoming web on the surface of the support member. As the web passes in the counterclockwise direction in Figure 4 (a), the pressures at which the orifice groups 81 are operated commonly increase. It is not necessary for each successive group 81 of orifices to be operated at a pressure greater than the one next to it in a clockwise direction. For example, two or more adjacent groups 81 of ports can be operated at the same pressure, after which the next successive group 81 of ports (in the counterclockwise direction) can be operated at a different pressure. Most typically, the pressures operating at the end of the conveyor belt where the net is removed are greater than the operating pressures where the net is initially fed onto the conveyor belt. Although six groups 81 of holes are shown in Figure 4 (a), this number is not critical, but will depend on the weight of the net, the speed, the pressure used, the number of rows of holes in each group, etc. After passing between the fluid ejector manifold and the suction manifolds, the now formed nonwoven fabric is passed over a further suction slot 86 to remove excess water. The distance from the lower surfaces of the hole groups 81 to the upper surface of the fibrous web 83 tipTc'añTéfíte- '·' varies from about 0.5 inches to about 2.0 inches; a range of about 0.75 inches to about 1.0 inches is preferred. It will be apparent that the network cannot be spread too close to the distributor so that the network makes contact with the distributor. On the other hand, if the distance between the lower surfaces of the holes and the upper surface of the net is too great, the fluid streams will lose energy and the process will be less efficient.
A preferred apparatus for producing nonwoven fabrics using the support members of the present invention is schematically depicted in Figure 4 (b). In this apparatus, the survey support member is a rotatable drum sleeve 91. The drum under the drum sleeve 91 rotates in a counterclockwise direction. The outer surface of the drum sleeve 91 comprises the desired topographic support configuration. Disposed around a portion of the periphery of the drum is a manifold 89 that connects a plurality of tapes with holes 92 for applying water or other fluid to a fibrous web 93 positioned on the outer surface of the curved plates. Each orifice tape may comprise one or more rows of very fine diameter holes or openings of the / <· τ? 'O kbpcako: .λ / λ:> =; ϊθΛα [Wcustsial type previously mentioned herein. Typically the openings are for example about 0.005 inches to 0.01 inches in nominal diameter. Other sizes, shapes, and orientations can obviously be used, if appropriate for the purpose. There may also be for example as many as 50 or 60 holes per inch or more if desired. Water or other fluid is directed through the rows of holes. In general, and as explained before, the pressure in each group of orifices typically increases from the first group under which the fibrous network passes to the last group. The pressure is controlled by appropriate control valves 97 and monitored by pressure gauges 98. The drum is connected to a manifold 94 over which a vacuum can be drawn to aid removal of water and to prevent the area from flooding. In operation, the fibrous web 93 is placed on the upper surface of the topographic support member before the water ejector manifold 89 as seen in Figure 4 {b). The fibrous web passes under the hole tapes and is formed into a nonwoven product. The formed nonwoven is then passed over a section 95 of apparatus 95 where there are no tapes with holes, but a vacuum is continued to be applied. The fabric after being dehydrated is removed from the drum and passed around a series of drying vessels 96 to dry the fabric.
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<img file="MX337965B_D0023.tif" />
Turning now to the supporting structure, fabrics, bands, or covers, the support members may have a through-hole pattern. The through voids may include, among other things, geometric features that provide improved topography and volume to the nonwoven products or net when produced for example on a support member, band or sleeve. Other advantages of the present support members include easier release from the web, improved resistance to contamination, and reduced repellency of the fiber. Still another advantage is that it avoids the limitations and need for a conventional weaving loom since the through holes can be placed in any desired location or pattern. In addition, fabrics, bands, or covers constructed in accordance with the present invention will result in deeper cavities resulting in a nonwoven product with higher absorbency and lower density.
It will be appreciated that the term "through hole" is synonymous with the term "through hole" and represents any opening that passes completely through a support member such as a band or sleeve. A support member as referred to herein includes, but is not limited to, industrial fabrics such as belts or conveyors, and sleeves or cylindrical belts specifically used in the production of nonwovens,
<img file="MX337965B_D0024.tif" />
such as for example, in processes such as air jet, melt blown, spun bonding, and hydroentanglement. As mentioned above, although the term fabric and fabric structure is used to describe the preferred embodiments, fabric, belt, conveyor, sleeve, support member and fabric structure are used interchangeably to describe the structures of the present invention. .
Figures IA and IB illustrate a plan view of a plurality of through holes 102 that are produced in a portion of a fabric, band or sheath 104 in accordance with an exemplary embodiment. According to one aspect, the through holes serve as drain holes that are used in jet-entangled or hydroentangled processes for the production of nonwovens. Figure IA shows the plurality of through holes 102 from the perspective of a top surface 106 (ie, laser side) facing a laser source (not shown), whereby the laser source is operable to create the through holes or through holes in fabric 104. Each through hole 102 may have a conical shape, wherein the inner surface 108 of each through hole 102 tapers inward from the opening 110 on the upper surface 106 through the opening 112 (Figure IB) on the lower surface 114 (Figure IB) of fabric 104. The diameter along the
<img file="MX337965B_D0025.tif" />
direction of the x-coordinate for the abé'rturS ^ ± d ^ ™ ~ -ea ^. ^, represented as Δχι while the diameter along the direction of the y-coordinate for the opening 110 is represented as Ayi. Referring to Figure IB, similarly, the diameter along the x-coordinate direction for aperture 112 is represented as Ax<sub>2 </sub>while the diameter along the y-coordinate direction for aperture 112 is represented as Ay<sub>2</sub>. As is apparent from Figures IA and IB, the
<td>diameter</td><td>Δχι</td><td>to what</td><td>length of x direction for</td><td>the</td><td>opening</td>
<td>110 on</td><td>he</td><td>side</td><td>top 106 of fabric 104 is</td><td colspan="2">Older than him</td>
<td>diameter</td><td>Ax<sub>2</sub></td><td>to what</td><td>length of x direction for</td><td>the</td><td>opening</td>
<td>112 on</td><td>he</td><td>side</td><td>bottom 114 of fabric 104.</td><td colspan="2">He too</td>
<td>diameter</td><td>Ayi</td><td>to what</td><td>along the address and for</td><td>the</td><td>opening</td>
<td>110 on</td><td>he</td><td>side</td><td>top 106 of fabric 104 is</td><td colspan="2">Older than him</td>
<td>diameter</td><td>Oh<sub>2</sub></td><td>to what</td><td>along the address and for</td><td>the</td><td>opening</td>
<td>112 on</td><td>he</td><td>side</td><td>bottom 114 of fabric 104.</td><td></td><td></td>
<td></td><td>The</td><td colspan="2">Figure 2A illustrates a view</td><td>in</td><td>section</td>
cross section of one of the through-holes 102 shown in Figures IA and IB. As previously described, each through hole 102 may have a conical shape, wherein the inner surface 108 of each through hole 102 tapers inward from the opening 110 on the upper surface 106 through the opening 112 on the lower surface. 114 of fabric 104. The conical shape of each hole '<á. / Γ Γ!
-<sup>:</sup>'goes -/ \. <'<-' · ía <? A í and í.r '- / -, 5; <
VV · <.
--- ···. •• 'O * · - j ^. ·· through 102 may be created as a result of incident optical radiation 202 generated from an optical source such as a CO2 or other laser device. By applying laser radiation 202 of appropriate characteristics (eg, output energy, focal length, pulse width, etc.) for example to a nonwoven fabric, a through gap 102 can be created as a result of laser radiation that pierces the surfaces. 106, 114 of fabric 104. The creation of through holes using laser devices will be described in later paragraphs with the help of experimental data.
As illustrated in Figure 2A, according to one aspect, laser radiation 202 creates upon impact, a first edge or ledge 204 raised on top surface 106 and a second edge or ledge 206 raised on bottom surface 114 of the fabric. 104. These raised edges 204, 206 can also be referred to as a raised edge or ledge. A top plan view for raised edge 204 is represented by 204A. Similarly, a plan view of the bottom of the raised edge 206 is represented by 206A. In both depicted views 204A and 206A, dotted lines 205A and 205B are illustrative graphical representations of a raised edge or ledge. Consequently, dotted lines 205A and 205B are not intended to represent striations. The height of each raised edge 204, 206 can be in the range of 5-10
<img file="MX337965B_D0026.tif" />
mm. Height is calculated as the surface of the fabric and the top portion of the raised edge. For example, the height of the raised edge 204 is measured as the difference in level between the surface 106 and the upper portion 208 of the raised edge 204. Raised edges such as 2 04 and 206 provide among other advantages, local mechanical reinforcement for each through hole or through hole, which in turn contributes to the overall strength of a given perforated fabric (eg, a creasing fabric). Also, the deeper voids result in deeper cavities in the produced nonwovens, and also result in eg more volume and lower density. It should be noted that Δχι / Δχ<sub>2</sub> can be 1.1 or higher and Áyi / Áy<sub>2</sub> it can be 1.1 or higher in all cases. Alternatively, in some or all cases Δχι / Δχ<sub>2 </sub>can be equal to 1 and Ayi / Áy<sub>2</sub> it can be equal to 1, thereby forming through holes of a cylindrical shape.
Although the creation of through-holes having raised edges in a fabric can be accomplished using a laser device, it is envisioned that other devices capable of creating such effects may also be employed. Drilling or mechanical stamping can be used after drilling. For example, the nonwoven fabric can be embossed with a pattern of corresponding protrusions and depressions on the surface in the required design. Then you can by
<img file="MX337965B_D0027.tif" />
For example, each protrusion can be mechanically drilled or laser drilled.
Figure 3A illustrates an exemplary embodiment of a system 300 for generating through holes 304 in a fabric 302. The system 300 may include a laser device 306, a laser drive unit 308, a laser head 310, and mechanical devices 316 in the which fabric is placed 302.
The laser drive unit 308 controls the various conditions that vary the output generated by the laser. For example, the drive unit 308 may allow the adjustment of the laser output energy and the provision of various modulation characteristics. For example, the laser can be pulsed for a fixed or continuous period of time, whereby the pulse width can be adjusted over a particular range.
Laser head 310 supplies incident optical radiation 312 to fabric 3 02 through nozzle 314 to create through holes 304. Incident optical radiation 312 can be subjected to various beamforming components before exiting nozzle 314 . For example, different optical lens settings can be used to achieve a desired operating distance (ie, D „) between the nozzle 314 of the laser head 310 and the top surface of the fabric, band or sleeve 302.
<img file="MX337965B_D0028.tif" />
Also, optical dividers, .., ... side splitters, polarizers, slits and / or other components can be used to vary the different attributes associated with the incident optical radiation 312 emitted from the laser head 310. For example Control of the size of the beam impact and the shape of the beam impact may be a desired attribute. In effect, incident optical radiation is the drilling (or cutting) of through holes or through holes in the fabric
302.
The fabric, band or cover 302 can be installed or placed in a suitable apparatus (eg, see Figure 3B) that has different components, rails, rollers, etc., motorized in order to facilitate the movement of the fabric 302 and / or the head. of laser 310 in a specific direction of the xy coordinate. By controlling the movement of the fabric 302 along the xy coordinate direction, a topography of the through holes can be created on the fabric in accordance with the different designs desired. In addition to movement in the xy direction, the operating distance D „can be varied by installing the laser head 310 on a motorized platform that provides movement along a z-coordinate direction. It may be possible to design a system whereby the laser head moves in three dimensions while the fabric remains fixed. Alternatively, the laser head can
<img file="MX337965B_D0029.tif" />
traverse the fabric in a width x or CD way
WMMUMttia -----_____ (cross-machine direction) while the fabric is moving in the machine direction (MD) or y-axis. It may also be possible to establish a system whereby the fabric moves in three dimensions relative to the mechanically fixed laser head.
Figure 3B illustrates an exemplary embodiment of an apparatus 320 used in generating through holes in a fabric, band, or sheath, in accordance with one aspect of the invention. Fabric 322 shown in Figure 3B should be understood to be a relatively short portion of the entire length of fabric 322. Where fabric 322 is endless, it would more conveniently be installed around a pair of rollers, not illustrated in the figure but more familiar to those of ordinary skill in the art. In such a situation, the apparatus 320 would be positioned in one of the two passes, most conveniently the top pass, of the fabric 322 between the two rollers. However, whether endless or not, fabric 322 is preferably placed under an appropriate degree of tension during the process. Additionally, to prevent sagging, fabric 322 can be supported from below by a horizontal support member as it moves through apparatus 320.
Referring now more specifically to Figure 3B, where the fabric 322 is indicated moving in a
- hee
In the upward direction through the apparatus -'- 3'fl — as the method of the present invention is practiced, the apparatus 320 comprises a sequence of various stations through which the fabric 322 can pass from increased manner as the fabric is manufactured therein.
The fabric, band, or sheath described in the above embodiment is an example of a fabric that would be perforated in accordance with the systems and methods described herein. The desirable characteristics of the described through-holes created in the fabric would enhance one or more of the characteristics associated with a nonwoven made therein. Fabrics constructed in accordance with the present invention improve performance over the nonwoven production machine because the through holes in the fabric are preferably cone-shaped with wide openings on one side of the web or sheet and small openings on the machine side, which in turn allows the fabric to operate at higher levels of drag or lower basis weights. Figure 5 illustrates a flow chart 500 describing the process for generating through holes in a fabric in accordance with an exemplary embodiment. At step 502, it is determined whether a laser device will operate in a single-pass mode or a multi-pass mode. In single-pass mode, the laser creates a through hole in a single pass as it moves through the fabric. At
<img file="MX337965B_D0030.tif" />
Multi-pass mode, the laser passes through the fabric two or more times and applies the optical radiation at the same locations on the fabric until the creation of the desired through holes is completed.
If it is determined in step 504 that the single-pass mode is selected, a set of laser parameters is accessed (step 506). These laser parameters can include the various settings that apply to a laser drive unit such as unit 308 (Figure 3). At step 508, based on the laser parameters accessed, the output of the optical radiation from the laser pierces the fabric in order to generate a desired shape of the through hole. In step 510, once the shape / geometry of a generated through hole is analyzed (eg, visual inspection, image acquisition / processing, etc.), it is determined whether the through hole meets the desired shape criteria ( step 512). If the through hole meets the desired shape criteria (step 512), the accessed laser settings are saved (step 514) so that they can be reused in the drilling process for identical or similar fabrics. If on the other hand it is determined that the through gap fails to meet the desired shape criteria (512), the laser parameters used to drive the laser are re-adjusted (step 516) in an attempt
<img file="MX337965B_D0031.tif" />
to produce a through hole having the desired shape crj.he.rios. Process steps 512, 516, 508, and 510 continue to run until the through-hole shape criteria are met. Once the shape of a generated through hole meets the required shape criteria, the entire fabric can be pierced.
If it is determined in step 504 that the multi-step mode is selected, a set of laser parameters is accessed (step 520). These laser parameters can include the various settings that apply to a laser drive unit such as unit 308 (Figure 3). In step 522, based on the laser parameters accessed, the output of the optical radiation from the laser pierces the fabric in order to generate the desired shape of the through hole. At step 524, once the shape / geometry of a generated through hole or perforation is analyzed (eg, visual inspection, image processing, etc.), it is determined whether the perforation of the fabric has generated a through hole. and whether the through gap generated meets the desired shape criteria (step 526). If a through hole is generated and meets the desired shape criteria (step 526), the accessed laser settings are saved (step 528) so that they can be reused in the identical fabric punching process. or similar. If on the other hand .15 is determined.
M) '' '' dd; dd ¿that either a through hole has not been generated (eg, a perforation of the fabric surface) or a generated through hole does not meet the desired shape criteria (526), the laser it is passed through the through hole for a subsequent time and the optical radiation is applied to the through hole (step 530). Process steps 526, 530, 532 (optional step), and 524 continue to run until both the through gap is created and the required through gap shape criteria are satisfied. Once the shape of a generated through hole meets the required shape criteria, the entire fabric can be pierced. In optional step 532, the laser parameters used to drive the laser can also be readjusted to aid in both generating the through gap and / or establishing a through gap that meets the desired shape criteria. However, it will be appreciated that the number of passes to generate a through gap varies according to many factors such as, but not limited to, fabric material, fabric thickness, type of laser device, laser drive or operating parameters. , etc.
Figure 6 illustrates images of a perforated fabric in accordance with one or more aspects of the present invention. Image 602 illustrates through holes drilled in a fabric, as viewed from the top surface (ie, laser side) of the fabric. Image 604 illustrates the
<img file="MX337965B_D0032.tif" />
perforated through holes, as observed * 7? - “pyyrb ^^ - of the bottom surface (ie, opposite side) of the fabric. The drilling criteria were to achieve round shaped through holes that have a larger aperture area on the laser side or top surface. Images 602 and 604 show larger openings (Figure 602) on the laser side or upper surface in relation to the openings on the lower surface (Figure 604). Through-holes can be drilled using a CO2 laser that can be programmed or operated to generate optical pulses of a predefined pulse width for a predefined period of time. Various other parameters associated with the through hole drilling process may include for example, but are not limited to setting the output energy (Watts) generated by the laser, the drilling speed, the incremental movement in both the x and y directions. , the
I operating distance (ie, distance from laser head nozzle to fabric surface), density requirements (holes / inches<sup>2</sup>) for a given fabric, and the number of passes to subject the fabric to optical radiation.
Figure 7 illustrates images of a perforated fabric in accordance with one or more aspects of the present invention. Image 702 illustrates the through holes drilled in an 'ercassa'
<img file="MX337965B_D0033.tif" />
fabric, as seen from the top surface (ie, laser side) of the fabric. Image 704 illustrates the drilled through holes, as seen from the bottom surface (ie, opposite side) of the fabric. The perforation criteria were to achieve the through holes that have a larger aperture area on the laser side or top surface relative to the opposite side or bottom surface of the fabric. Images 702 and 704 show larger openings (Figure 702) on the laser side or upper surface in relation to the openings on the lower surface (Figure 704). These through holes can also be drilled using a CO laser.<sub>2 </sub>that can be programmed or operated to generate optical pulses of a predefined pulse width for a predefined period of time. Various other parameters associated with the through hole drilling process may include for example, but are not limited to setting the laser output energy (Watts), the drilling speed, the incremental movement in both the x and y directions, the operating distance (ie, distance from laser head nozzle to fabric surface), density requirements (holes / inches<sup>2</sup>) for a given fabric, and the number of passes to subject the fabric to optical radiation. As illustrated in Figure 7, the shape of the through holes is
<img file="MX337965B_D0034.tif" />
substantially oval in shape compared to through holes shown in Figure 6. Different factors and / or parameters (eg, drilling speed) can contribute to differences in through hole shape and through hole open areas (%) that correspond to both next to the laser as well as the opposite side of the fabric.
Figures 8A-G illustrate images of a perforated laminate fabric in accordance with one aspect of the present invention. Fabric laminated in accordance with this embodiment may include two or more layers bonded using a suitable lamination technique. A CO2 laser can be operated for example in a tone pulse mode, supplying an output power of for example around 600W. Since the fabric that was pierced was a laminate, the through holes were generated after multiple passes of the incident optical radiation.
Figures 8A-G are microscopic images showing the penetration depth of incident optical radiation with each pass, from the I<sup>to</sup> passed until 7<sup>to </sup>pass. These images also show the raised edges created during the drilling processes. Examples of these raised edges (ie, top surface) are depicted at 804 (Figure 8A), 806 (Figure 8B), and 808 (Figure 8G). With each pass, the images in Figures 8A-G illustrate some increases in the openings over ζ
λ;
Or both the upper surface and the lower surface of the through hole. For example, the image associated with Figure 8D shows an opening in the upper surface having a diameter of approximately 3.2mm on the upper surface and a diameter of approximately 1.4mm on the lower surface of the through hole after the 4<sup>to </sup>pass. However, after 7<sup>to</sup> past, as illustrated in Figure 8G, the top surface opening has been increased to a diameter of approximately 3.3mm on the upper surface and a diameter of approximately 2.5mm on the lower surface of the through hole. These plotted results show that 5 passes were required to generate a through hole. However, it will be appreciated, that the number of passes to generate a through gap varies according to many factors such as, but not limited to, laminate material, laminate thickness, type of laser device, laser operating or operating parameters, etc. .
Figure 9 illustrates the images of both the upper surface 902 and the lower surface 904 of the drilled through holes corresponding to Figure 8G (ie, after 7<sup>to</sup> pass). As shown in Figure 9, after 7<sup>to</sup> Past the shape of the upper and lower openings the through holes are substantially rectangular in shape.
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Figure 10 depicts various gap patterns from experimental trials to generate through gaps in accordance with yet another aspect of the present invention. In some cases, through holes of increased size may be desired. For example, the size of the impact of the laser beam can be a limiting factor. To overcome this restriction and generate larger through holes, the laser device is effectively used as a bur rather than a drill. To create this cutting action, the laser head can be balanced (ie, Sway or Vobulation) according to a different frequency (eg, Sway or Vobulation frequency) and resistance criteria (eg, Sway or Vobulation rate) in order to to establish larger through holes.
For example, images 1010 and 1012 depicted in Figure 10 correspond to through holes that are generated based on different operating parameters such as, but not limited to, drilling speed, roll frequency, roll index, output energy. laser, etc. Accordingly, the shape of the surface openings 1014 for the through holes corresponding to the image 1010 is substantially round, while the shape of the surface openings 1016 for the through holes associated with the image 1012 is substantially rectangular. One factor among others, which affects the way
<img file="MX337965B_D0035.tif" />
surface openings can be the _____ scan speed (ie, mm / s) of the laser as the incident radiation moves from one position to the next to generate a subsequent through hole in the fabric.
In another embodiment, a fabric structure that may or may not have a base support substrate comprises a sheet contacting surface that has a series of flat areas and depressions, and a branched hollow structure adapted to impart texture to a fabric, towel or non-woven product. Figure 2B shows the cross section of the surface of a fabric structure 10 with a branched gap or opening 11 comprising a plurality of small holes 10a and 10b on the side 12 of the sheet that are inclined in such a way that they merge into a larger hole 10c on the opposite side 14 of the surface. As illustrated, the branched opening 11 may also be formed to include raised edges or edges 16 adjacent the circumference of the holes 10a and 10b. Although not shown in Figure 2B, the raised edges or edges may also be formed adjacent the circumference of the larger gap 10c on the opposite side 14 of the fabric structure. Although holes 10a and 10b are shown melting into gap 10c, a branched gap structure can be envisioned having three or more holes that merge into a larger gap, whereby the raised edges
<img file="MX337965B_D0036.tif" />
* · * - * ·. ·. ·, «. iNS'TnMEXICANO ΙΑ. ι. /, i ',' ','. '/ íE!? AD A.'SUSTIUAL can be formed adjacent in either Ί £ ϊηΕθ! 5 ~ “13β' the smaller lateral holes of the sheet and the opposite lateral recesses bigger. Also, the raised edges can cover the fabric either partially or completely.
Such a structure allows for a high number of small voids in a fabric structure while also allowing low long-term elongation in the MD machine direction while allowing high flexural stiffness in the transverse CD machine direction. Such a structure can also be adapted in such a way that for example, it allows holes in the fabric structure that are smaller in diameter than the thickness of the substrate without, for example, resulting in holes plugged due to contamination.
A fabric structure having the described branched structure surface is contemplated for nonwoven applications. For example, a coarse structure on the upper surface and smaller holes on the opposite lower or machine side surface can for example capture, shape and / or orient the fibers arranged on the fabric structure in a desired pattern and create a textured non-woven product. As previously described, the described recesses can be straight (cylindrical) or conical. For example, conical holes of different patterns can be designed such that ^ ΐίΐτBii are larger and well distributed over a web or lateral surface of the sheet, while the holes on the opposite lateral surface of the machine can be aligned. substantially along the MD, thereby providing for example increased drainage. Branched voids can be created by any number of drilling methods or combinations thereof, including laser drilling, drilling, or mechanical stamping (eg, thermal or ultrasonic). For example, gaps can be created by combining laser drilling with stamping.
It is taken into account as mentioned above that normally the webs that make nonwovens do not impart structure to the nonwovens made therein. The structure pertains to variations in the basis weights and / or the density of nonwovens that are greater than those that occur in the ordinary process of manufacturing nonwovens and due to ordinary variations. However, the structure can also be referred to as the texture or pattern on the non-woven product. Such structured nonwovens are usually soft and bulky with high absorbency. Such bands comprise a surface pattern structure and may have a reinforcing structure. Structured nonwovens can be softer, more absorbent
MEXICAN INSTITUTE OF THE rKONfDAD
INDUSTRIAL
<img file="MX337965B_D0037.tif" />
and be of a lower basis weight than unstructured nonwovens.
An industrial fabric generally has two sides: one side in contact with the sheet or web and one side of the machine or roller. The former is so named because it is the side of the fabric that faces the newly formed nonwoven web. The latter is so named because it is the side of the fabric that passes through and is in contact with the rollers on the machine.
Figure 11 is a perspective view of a band or sleeve 1110 formed in accordance with an exemplary embodiment of the invention. According to this embodiment, the band or sheath 1110 has an inner surface 1112 and an outer surface 1214 and is formed by spirally winding a tape of polymeric material 1116 produced using one of the various methods and systems described above. The band can be produced using the method described in US Pat. No. 5,360,656 to Rexfelt et al., Commonly owned, the full contents of which are incorporated herein by reference. Tape of material 1116 may be spirally wound in a plurality of contiguous and mutually adjacent turns, substantially in the longitudinal direction around the length of web 1110 by virtue of the helical shape in which web 1110 is constructed.
<img file="MX337965B_D0038.tif" />
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An exemplary method by which web 1110 can be manufactured is illustrated in Figure 12. Apparatus 1220 includes a first process roll 1222 and a second process roll 1224, each of which is rotated about its longitudinal axis. The first process roll 1222 and the second process roll 1224 are parallel to each other, and are separated by a distance that determines the total length of web 1110 to be manufactured therein, as measured longitudinally around them. Provided on the side of the first process roll 1222 is a supply reel (not shown in the figures) installed rotatably about an axis and movable parallel to the process rolls 1222 and 1224. Rollers 1222 and 1224 can be adjusted so that the length of the fabric wound on them is approximately the desired length of the final fabric. The supply reel accommodates a wound supply of material tape 1116 which has, for example, a width of 10 mm or more. The supply reel is initially positioned, for example, at the left end of the first process roller 1222, before continuously moving to the right or the other side at a predetermined speed.
To start the manufacture of the web 1110, the start of the material web 1116 is extended in a tight condition from the first process roll 1222 to the second process roll 1224, air & e ^ or ^ agT second process roll 1224 and from Return<sup>r</sup>'' 'aT''priiner process roll 1222 forming a first turn of a closed helix 1226. To close the first turn of the closed helix 1226, the start of the material belt 1116 is attached to the end of the first turn thereof at 1228. As will be discussed below, adjacent turns of spirally wound tape of material 1116 are bonded together by mechanical, thermal and / or adhesive means.
Therefore, subsequent closed helix turns 1226 are produced by rotating the first process roll 1222 and the second process roll 1224 in a common direction as indicated by the arrows in Figure 12, while feeding the material belt 1116 on the first process roll 1222. At the same time, the material web 1116 that was recently wound on the first process roll 1222 is continuously attached to the one already on the first process roll 1222 and the second process roll 1224 by for example mechanical means. and / or adhesives or any other suitable for producing additional closed helix turns 1226.
This process continues until the closed helix 1226 has a desired width, as measured axially along the first process roll 1222 or the second process roll 1224. At that point, the web of material is cut.
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1116 not yet rolled onto the first process roll 1222 •. * ». · V. '. T,<sub>t</sub>l i.<sub>t</sub>..i, -y. / -<sub>t</sub> » -.
and the second process roll 1224, and the closed helix 1226 produced therefrom is preferably trimmed to make the fabric edges parallel and to a desired width, and then removed from the first process roll 1222 and the second process roll. process 1224 to provide band 1110 of the present invention.
One method of sewing or holding adjacent tapes of material together, in accordance with one embodiment of the invention, is to ultrasonically weld edge-to-edge of adjacent tapes while simultaneously providing lateral pressure to keep the edges in contact with each other. For example, one part of the welding device may hold a tape, preferably the tape that has already been wound into a spiral, down against a support roll while the other part of the device pushes the other tape, preferably the tape that does not it is wound up against the tape that is held down.
The application of ultrasonic capillary welding results in a particularly strong joint. By contrast, ultrasonic welding in either a time mode or an energy mode, which is also known as conventional ultrasonic welding, results in a joint that can be described as brittle. Therefore, it can
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It can be concluded that a joint formed through ultrasonic capillary welding is preferred over conventional ultrasonic welding.
Another exemplary method of holding adjacent tapes together in accordance with one embodiment of the invention is to apply an adhesive to the ends of the adjacent tapes and bond them. It should be noted that a filler material can be used to fill the spaces or portions where the tapes do not contact each other.
Another method of holding adjacent tapes of material together, in accordance with one embodiment of the invention, is to weld the adjacent tapes using a laser welding technique. An advantage of laser welding over ultrasonic welding is that laser welding can be carried out at speeds in the range of 100 meters per minute while ultrasonic welding has a maximum speed of about 10 meters per minute. Adding a light absorbing or ink absorbing dye to the edges of the ribbons can also help to focus the thermal effect of the laser. The absorbents can be black ink or near IR dyes that are not visible to the human eye, such as those used by Clearweld for example. The abutting edges of the tapes can be prepared to improve resistance to separation in use. The edges can be tapered at an angle or formed in other ways such as shown in US Pat.
Co-owned Hansen No. 6,630,223, the disclosure of which is incorporated herein by reference.
The present methods and systems for producing web 1110 are highly versatile and adaptable for the production of industrial fabrics or webs of a variety of longitudinal and transverse dimensions. That is, the manufacturer, in practicing the present invention, no longer needs to produce an endless fabric or flat weave and sewn fabric of an appropriate length and width for a given position on a nonwovens machine. Rather, the manufacturer only needs to separate the first process roll 1222 and the second process roll 1224 by the appropriate distance, to determine the approximate length of the web 1110, and wrap the material tape 1116 over the first process roll 1222. and the second process roll 1124 until the closed helix 1226 has reached the approximate width desired.
Furthermore, because web 1110 is produced by spirally winding a tape of material 1116, and is not a woven fabric, the outer surface 1112 of web 1110 is smooth and continuous, and lacks knots that prevent the surfaces of a woven fabric are perfectly uniform. Preferably, the tape of material can be a tape of thermoplastic material, such as, for example, a film or 'T-' vi χ l γΤ & ^
IN3TíTOTOMEX! C *, N3
FROM THE PROPERTY »V» 1 ± 3S?
INDUSTRIAL metal tape, and can be made of any polymeric material, preferably Polyester (PET). However, other materials such as other polyesters (eg, polyethylene naphthalate (PEN)) or polyphenylene sulfide (PPS) can also be used. Polyamides or polyether ether ketones (PEER) can also be used.
With respect to a laminate with two or more layers, each layer can be the same or be formed of different materials. The metallic film or tape material can be uniaxially or biaxially oriented with sufficient modulus and stability in both MD and CD to function as intended. Furthermore, the metallic film or tape may contain reinforcing fibers in MD or CD or in both MD and CD, or in any random direction. The reinforcing fibers can be included through an extrusion or stretch extrusion process wherein the fibers can be extruded or stretch extruded together with the material that forms the metal film or tape. The reinforcing fibers can be formed from a high modulus material, such as for example aramids including but not limited to Kevlar® and Nomex®, and can provide extra strength, modulus, tear resistance and / or cracking to the film or tape. metallic.
Alternatively, the web of material may be a web of nonwoven material formed from a low melt fiber, such as for example polyamides, which can be carded α ¡·· / ύ />.
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INSTITUTE
ÍKDUi-y-tlAL needles ü Others - - measures by passing the tape of a roller pressure and consolidating by punching with suitable and that material can be fused through for example hot creating by this a uniform surface on one or both sides of the material tape. The non-woven material can also comprise a mixture of different materials, such as for example a combination of low melting and high melting fibers, eg 90% of a low melting polyamide 6 in combination with 10% PA6,6 or any other combination selected to impart a desired characteristic. Alternatively, a portion of the nonwoven may comprise bicomponent fibers, such as for example sheath-core type fibers, which may have the low-melt material on the outside and the functional material on the inside. The tape of material can also be covered eg using a polyurethane resin to further provide eg homogeneity to the fabric. Coating can improve sheet release and / or the structural integrity of the tape of material. The aforementioned structures can then be drilled in a manner as described heretofore.
Figure 13A illustrates a top side image of fabric, web, or sheath 1302 having through holes drilled in a substantially diagonal pattern, according to
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INDySTKInl With an alternative embodiment of the present invention, for example, the through holes 1304 are drilled according to a diagonal 1306 with respect to the cross-machine direction (L) of the fabric, web or sleeve. Similarly, Figure 13B illustrates a bottom side image of fabric 1302 having through holes drilled according to the substantially diagonal pattern. As illustrated, through holes 1304 are drilled according to diagonal 1306. Illustrated exemplary images of fabric 1302 comprise a perforated fabric having a length of for example 15m, where the size of the upper side holes are for example about 1.5mm (CD) x 1.2mm (MD), and the Bottom side hole sizes are about 0.65mm x 0.5mm. The distance between, for example, the holes in the CD direction is approximately 1,695mm, and the distance between the holes in the MD is approximately 1.18mm.
Similarly, Figures 14A-C illustrate exemplary images of fabrics, bands, or sleeves having through holes drilled in various patterns in accordance with various aspects of the present invention. For example, fabric 1402 comprises through holes drilled in a manner that gives the appearance of a square diamond pattern 1403. A magnified image of region 1404a within fabric 1402 is depicted at 1404b. Dotted areas 1405 have been added to the ampl-if-Lsada-X4Q4ba image to provide improved visual perception of the drilled through hole pattern. Similarly, another magnified image corresponding to region 1406a within fabric 1402 is depicted at 1406b. Dotted area 1407 has also been added to magnified image 1406b to provide enhanced visual perception of the drilled through hole pattern.
According to another example, fabric 1410 comprises through holes drilled in a manner that also gives the appearance of a square diamond pattern 1411. An enlarged image of region 1412a within fabric 1410 is depicted at 1412b. Dotted guide lines 1413 have been added to magnified image 1412b to provide improved visual perception of the drilled through hole pattern. Similarly, another magnified image corresponding to region 1414a within fabric 1410 is depicted at 1414b. Dotted guide lines 1415 have also been added to magnified image 1414b to provide enhanced visual perception of the drilled through hole pattern.
According to yet another example, fabric 1418 comprises through holes drilled in accordance with another pattern 1419. An enlarged image of region 1420a within fabric 1418 is depicted at 1420b. The lines
<img file="MX337965B_D0040.tif" />
. : <sup>1</sup> 'JTO Μ EXICANO Vt <Í27 ·, ·; 0
OF THE Í-SOPIEDXD VteJÍSSá IND'JSTiÜAL Dotted Guide 1422 have been added to the
1420b to provide improved visual perception of the drilled through hole pattern. In summary, the voids or through holes formed in the fabrics, bands or sleeves of the present invention can be separated by a flat surface area, which can take any geometric shape of a desired size. Although geometric shapes such as diamonds and squares are depicted in the present figures, these shapes are only exemplary and the hole pattern can be modified to form virtually any shape for flat areas, such as for example parallelograms, triangles, circles, rectangles. , floral, hexagonal or polygonal.
The inventive fabric, as noted above, can be used as a process web or sheath used in air blast, melt blown, spun bond or hydroentangled processes. The inventive fabric, band, or sleeve may include one or more additional layers on top or under the substrate formed using the tapes of material, solely to provide functionality and not reinforcement. For example, the additional layers used can be of any of the woven or non-woven materials, arrays of MD and / or CD yarns, spirally wound tapes of woven material having a width less than the width of the fabric, fibrous webs, films or
<img file="MX337965B_D0041.tif" />
a combination thereof, and can be attached to the substrate using any suitable technique known to one of ordinary skill in the art. Thermal bonding and chemical bonding lamination are just a few examples.
Although a preferred embodiment of the present invention and modifications thereof have been described in detail herein, it should be understood that this invention is not limited to this precise embodiment and modifications, and that other modifications and variations may be made by one skilled in the art. subject matter without departing from the spirit and scope of the invention as defined by the appended claims.
Contents18
63 sheets
Sheet 1 Sheet 2 Sheet 3 Sheet 4 Sheet 5 Sheet 6 Sheet 7 Sheet 8 Sheet 9 Sheet 10 Sheet 11 Sheet 12 Sheet 13 Sheet 14 Sheet 15 Sheet 16 Sheet 17 Sheet 18 Sheet 19 Sheet 20 Sheet 21 Sheet 22 Sheet 23 Sheet 24 Sheet 25 Sheet 26 Sheet 27 Sheet 28 Sheet 29 Sheet 30 Sheet 31 Sheet 32 Sheet 33 Sheet 34 Sheet 35 Sheet 36 Sheet 37 Sheet 38 Sheet 39 Sheet 40 Sheet 41 Sheet 42 Sheet 43 Sheet 44 Sheet 45 Sheet 46 Sheet 47 Sheet 48 Sheet 49 Sheet 50 Sheet 51 Sheet 52 Sheet 53 Sheet 54 Sheet 55 Sheet 56 Sheet 57 Sheet 58 Sheet 59 Sheet 60 Sheet 61 Sheet 62 Sheet 63
210 members in 17 offices
Priority claims9
| Document | Office | Kind | Date |
|---|---|---|---|
| 14789409 | United States of America | P | |
| 14789409 | United States of America | P | |
| 61147894 | United States of America | – | |
| 2010022247 | United States of America | W | |
| 2010022247 | United States of America | W | |
| 61147894 | – | – | – |
| US1022247 | – | – | – |
| US20090147894P | – | – | – |
| WO2010US22247 | – | – | – |
Members210
| Document | Office | Kind | |
|---|---|---|---|
| CA2736765A1 | Canada | A1 | |
| CA2736770A1 | Canada | A1 | |
| CA2751352A1 | Canada | A1 | |
| WO2010030298A1 | World Intellectual Property Organization (WIPO) | A1 | |
| WO2010030547A1 | World Intellectual Property Organization (WIPO) | A1 | |
| WO2010030570A1 | World Intellectual Property Organization (WIPO) | A1 | |
| CA2746424A1 | Canada | A1 | |
| CA2746845A1 | Canada | A1 | |
| WO2010068765A1 | World Intellectual Property Organization (WIPO) | A1 | |
| WO2010068778A1 | World Intellectual Property Organization (WIPO) | A1 | |
| CA2750821A1 | Canada | A1 | |
| CA2753350A1 | Canada | A1 | |
| CA2986973A1 | Canada | A1 | |
| WO2010088280A1 | World Intellectual Property Organization (WIPO) | A1 | |
| WO2010088283A1 | World Intellectual Property Organization (WIPO) | A1 | |
| TW201029615A | Taiwan Province of China | A | |
| TW201030203A | Taiwan Province of China | A | |
| TW201033427A | Taiwan Province of China | A | |
| TW201033428A | Taiwan Province of China | A | |
| US2010230064A1 | United States of America | A1 | |
| US2010236034A1 | United States of America | A1 | |
| US2010236740A1 | United States of America | A1 | |
| US2010239814A1 | United States of America | A1 | |
| TW201037126A | Taiwan Province of China | A | |
| TW201040345A | Taiwan Province of China | A | |
| WO2010030570A9 | World Intellectual Property Organization (WIPO) | A9 | |
| TW201043750A | Taiwan Province of China | A | |
| MX2011002620A | Mexico | A | |
| MX2011002621A | Mexico | A | |
| MX2011002622A | Mexico | A | |
| KR20110057229A | Republic of Korea | A | |
| EP2334859A1 | European Patent Office (EPO) | A1 | |
| EP2334860A1 | European Patent Office (EPO) | A1 | |
| EP2334869A1 | European Patent Office (EPO) | A1 | |
| KR20110069807A | Republic of Korea | A | |
| AU2009324581A1 | Australia | A1 | |
| AU2009324607A1 | Australia | A1 | |
| KR20110086798A | Republic of Korea | A | |
| CN102209813A | China | A | |
| KR20110110168A | Republic of Korea | A | |
| KR20110112332A | Republic of Korea | A | |
| EP2376690A1 | European Patent Office (EPO) | A1 | |
| EP2376691A1 | European Patent Office (EPO) | A1 | |
| MX2011007972A | Mexico | A | |
| MX2011007973A | Mexico | A | |
| US2011272112A1 | United States of America | A1 | |
| KR20110125225A | Republic of Korea | A | |
| KR20110126643A | Republic of Korea | A | |
| MX2011006227A | Mexico | A | |
| MX2011006228A | Mexico | A | |
| CN102264970A | China | A | |
| CN102264971A | China | A | |
| EP2391754A1 | European Patent Office (EPO) | A1 | |
| EP2391768A1 | European Patent Office (EPO) | A1 | |
| CN102317524A | China | A | |
| CN102317525A | China | A | |
| CN102333917A | China | A | |
| JP2012502200A | Japan | A | |
| JP2012502201A | Japan | A | |
| JP2012502202A | Japan | A | |
| US2012021171A1 | United States of America | A1 | |
| US2012027997A1 | United States of America | A1 | |
| CN102439211A | China | A | |
| JP2012512334A | Japan | A | |
| JP2012512335A | Japan | A | |
| JP2012516396A | Japan | A | |
| JP2012516397A | Japan | A | |
| RU2011108942A | Russian Federation | A | |
| RU2011108945A | Russian Federation | A | |
| RU2011108946A | Russian Federation | A | |
| RU2011124023A | Russian Federation | A | |
| RU2011124025A | Russian Federation | A | |
| US8388812B2 | United States of America | B2 | |
| RU2011131140A | Russian Federation | A | |
| RU2011131143A | Russian Federation | A | |
| US8394239B2 | United States of America | B2 | |
| US2013081772A1 | United States of America | A1 | |
| US2013086781A1 | United States of America | A1 | |
| US8454800B2 | United States of America | B2 | |
| US2013264318A1 | United States of America | A1 | |
| CA2872784A1 | Canada | A1 | |
| CA2872925A1 | Canada | A1 | |
| WO2013170038A1 | World Intellectual Property Organization (WIPO) | A1 | |
| WO2013170042A1 | World Intellectual Property Organization (WIPO) | A1 | |
| TW201400663A | Taiwan Province of China | A | |
| TW201400718A | Taiwan Province of China | A | |
| RU2507334C2 | Russian Federation | C2 | |
| US8728280B2 | United States of America | B2 | |
| RU2519879C2 | Russian Federation | C2 | |
| RU2519923C2 | Russian Federation | C2 | |
| US8758569B2 | United States of America | B2 | |
| RU2520935C2 | Russian Federation | C2 | |
| US8764943B2 | United States of America | B2 | |
| US8801903B2 | United States of America | B2 | |
| RU2526681C2 | Russian Federation | C2 | |
| US8822009B2 | United States of America | B2 | |
| JP5596688B2 | Japan | B2 | |
| JP5600123B2 | Japan | B2 | |
| RU2530370C2 | Russian Federation | C2 | |
| RU2530371C2 | Russian Federation | C2 |
1 legal event, as the office reported them to INPADOC
Events
| Event | Code | |
|---|---|---|
| Grant or registrationFG | FG |
Numbers
- Publication
- 337965
- Publication, DOCDB
- 337965
- Publication, EPODOC
- MX337965
- Application
- 2011007973
- Application, DOCDB
- 2011007973
- Application, EPODOC
- MX20110007973
Titles
- Spanish
- TELA INDUSTRIAL PARA LA PRODUCCION DE PRODUCTOS NO TEJIDOS Y METODO PARA SU FABRICACION.
Classification
- CPC, 32
- B32B3/266
- D04H13/00
- D21G9/00
- B32B5/26
- D04H1/44
- D04H1/46
- D04H5/02
- D21F1/0036
- D21F1/0063
- D21F11/14
- B23K26/384
- B32B5/022
- B32B5/08
- B32B5/22
- B32B2255/02
- B32B2255/26
- B32B2262/02
- B32B2262/0253
- B32B2262/0261
- B32B2262/0269
- B32B2262/0276
- B32B2262/12
- B32B2262/14
- B32B2307/50
- B32B2307/726
- B32B2413/00
- Y10T428/24281
- Y10T428/24273
- Y10T83/0481
- D04H3/10
- D04H1/70
- D04H1/54
- IPC, 4
- D04H1 44
- B32B5 26
- D04H1 46
- D04H5 02