EP2302121B1 - Felt body production method - Google Patents

Description

The invention relates to a method for the production of spatial objects made of felt or felt-like materials and a device for producing such products.

From the US 4,714,647 For example, an apparatus and a method for producing a felt belt are known. For this purpose, a circulating around two rollers porous band is provided, above which a plurality of spinning beams are provided. These give off molten plastic in fibrous form. By vacuum this is deposited on the porous moving under the nozzle bar moving band. The forming fiber layer is peeled off as a batt. The result is a planar structure.

A similar process for the production of meltblown nonwovens is known from DE 199 56 368 A1 and from the US 3,825,379 known, which also provide information about the construction of appropriate melt blown heads. The fiber stream generated by the meltblown heads is passed to a collector drum and then removed from this as a belt. The result is a planar fleece. From the DE 10 2004 030 393 A1 is a method for producing knopped nonwovens known. For this purpose, a batt is placed on a sieve drum with a hole structure. When solidifying by means of water jets form the desired nubs on the nonwoven fabric through the existing holes.

In addition, the describes WO 01/53587 A1 the production of spatially shaped nonwovens by forming an initially planar web in a corresponding molding device.

Out EP 1323857 A2 is a method for producing spunbonded fabrics according to the "melt-blown" known. In this case, filaments are produced via an extruder and deposited on nozzles via dies. The shapes determine the three-dimensional shape of the nonwoven body to be produced. After depositing the filaments they are connected by thermobonding. Such a procedure is also off JP-A-49-100374 known. Spunbonding is also in WO 00/29656 A1 described. There, the filaments are ejected via nozzles onto a rotating drum whose lateral surface corresponds to the desired three-dimensional shape of the nonwoven body. By a negative pressure, the filaments are adapted to the drum contour. A processing of natural fibers is not possible in this way.

It is an object of the invention to provide a cost-effective method for producing three-dimensionally shaped objects from disordered fibers, in particular brassiere cups.

It is another object of the invention to provide a suitable device suitable for carrying out the method.

• Bei dem erfindungsgemäßen Verfahren wird zur Aufnahme eines Faserflors oder Faservlieses ein Träger bereitgestellt, der eine dem herzustellenden Gegenstand entsprechende Form aufweist. Auf diesem Träger werden Fasern ungeordnet abgelegt. Es entsteht ein noch wenig oder nicht verfestigter Körper, der dann durch ein in Strahlen auf das Wirrfaservlies (16) einwirkendes Fluid zu einem Vlies- oder Filzkörper verfestigt wird. Damit ist für die dreidimensionale Gestaltgebung kein Zusatzarbeitsgang erforderlich. Bereits beim Ablegen der zum Beispiel extrudierten Fasern auf dem Träger wird die dreidimensionale Form gebildet. Die "dreidimensionale Form" ist in zumindest zwei verschiedenen Richtungen gekrümmt. Der Träger kann dazu entsprechende konvexe oder konkave Formen aufweisen. Im Fall der Herstellung von Büstenhaltern hat der Träger die Innenform oder die Außenform des später gewünschten Körbchens.

These objects are achieved with the method according to claim 1 and the device according to claim 7:

• In the method according to the invention, a carrier is provided for receiving a batt or nonwoven fabric, which has a shape corresponding to the article to be produced. On this carrier fibers are deposited disorderly. The result is a little or not solidified body, which is then solidified by a in blasting on the random fiber fleece (16) acting fluid to a nonwoven or felt body. Thus, no additional operation is required for the three-dimensional design. Already when depositing the example extruded fibers on the carrier, the three-dimensional shape is formed. The "three-dimensional shape" is curved in at least two different directions. The carrier may have corresponding convex or concave shapes for this purpose. In the case of brassieres, the wearer has the inner shape or outer shape of the later desired basket.

The carrier may have a porous or sieve-like structure. By a pressure difference on the carrier, the fibers can be stored specifically on this. To generate the pressure difference, a negative pressure can be used under the carrier. Also, over-extrusion of fibers may assist in depositing the fibers on the backing. By subtracting the resulting band with the corresponding shapes in one direction so creates a already three-dimensional shapes exhibiting cloth with the desired basket or other shapes. The cloth can then be solidified by further processing steps, for example thermal bonding, impregnation, hydroentanglement or the like.

Preferably, a first solidification of the batt can already be carried out on the carrier. For this purpose, for example, a water jet nozzle bar may be arranged in the vicinity of a spinneret, which carries out a first preconsolidation and fixation of the fibers, before further fixing, for example in the form of a thermobonding process and / or a hydroentanglement takes place.

It can further be provided that the baskets or other 3D shapes are cut out of the produced solidified cloth by suitable measures, for example by a punching process or by a laser cutting process. Also, a further processing, for example, by printing, hemming, packaging, etc. join.

The solidification of the batt by water jets is preferred. Additionally or alternatively, the solidification may, however, also be effected by other informal media, such as, for example, gas jets, blasting of an organic fluid, heat, an adhesive or another adhesive or solvent. This applies both to the preconsolidation of the fibrous web on the carrier and also to a solidification subsequent to the removal of the not yet completely consolidated felt cloth or nonwoven fabric from the carrier.

The presented method allows the combination of different fiber materials in the three-dimensional felt body. According to the invention, fibers of different materials will be deposited one after the other on the carrier. Layers of different fibers thus form in the batt, which then form interconnected layers with different properties in the finished fabric or felt body. For example, structural solid fiber layers and fibers that provide comfort can be combined with each other.

It is also possible to use bicomponent fibers which, for example, have a core of a first material and a sheath of a second material. When bra cups As a rule, it is desirable that they have a certain elasticity. For this purpose, the extruded fibers are for example generated so that the individual fiber curls and thereby causes a elasticity effect. The crimped or uncrimped fiber may be made of an elastomer. A bicomponent fiber may be made by having one component as the strength component and being centered, for example, as a core. An outer component can envelop the soul and determine the degree of softness of the fiber.

If a fiber multilayer structure is desired, for example for making brassiere baskets, and if the inside of the basket is located on the side facing the wearer, for example, first the soft fibers are laid down by a first spinning beam. In a second spin beam then the fibers are applied, which make up the elastic support of the structure. A third spin beam may be provided to apply fibers that may be printed in a later operation, for example. On the other hand, when the carrier is placed on the outside of the basket, the filing order of the fibers is reversed.

• Figur 1 Spinnbalken und einen dreidimensionalen Träger zur Erzeugung eines dreidimensionalen Faserflors, in schematisierter Darstellung,
• Figur 2 die Herstellung des Faserflors in der Vorrichtung nach Figur 1, in schematisierter Darstellung,
• Figur 3 die Verfestigung des Faserflors, in einer schematisierten Darstellung,
• Figur 4 einen vergrößerten Ausschnitt aus dem erzeugten räumlichen geformten Vlies,
• Figur 5 eine alternative Möglichkeit zur Verfestigung des Faserflors, in schematisierter Darstellung,
• Figur 6 die Herstellung eines Faserflors auf einem der gewünschten Außenform eines Büstenhaltermaterials entsprechenden Träger.

In the drawings, embodiments of the invention are illustrated. Show it:

• FIG. 1 Spinning beam and a three-dimensional support for producing a three-dimensional fiber batt, in a schematic representation,
• FIG. 2 the production of the batt in the device according to FIG. 1 in a schematic representation,
• FIG. 3 the solidification of the batt, in a schematic representation,
• FIG. 4 an enlarged section of the produced spatially shaped fleece,
• FIG. 5 an alternative possibility for solidification of the batt, in a schematic representation,
• FIG. 6 the production of a batt on a the desired outer shape of a bra material corresponding carrier.

In FIG. 1 a fiber-laying device 1 is schematically illustrated, which serves for the production of spatial, ie three-dimensionally shaped nonwovens. The fiber-laying device 1 includes a carrier 2, which has at least one, but preferably several, 3D-forms 3, 4. For example, these 3D shapes 3,4 are approximately hemispherical or otherwise formed three-dimensional shapes. For example, the 3D molds 3, 4 may have a shape corresponding to the cup of a brassiere to make bras. The 3D shapes can be elevations or depressions. At least in places, they have a surface which is curved at the same point both in the carrier longitudinal direction and in the transverse direction of the carrier.

The carrier 2 is preferably made of a porous or sieve-like material. It can be designed as an endless belt, for example wrapped around two or more rollers, on which the 3D molds 3, 4 are provided. In that regard, is in FIG. 1 only a section of the carrier 2 shown. The optionally driven rollers around which the carrier 2 is looped are not further illustrated.

To the fiber-laying device 1 may also include one or more nozzle bars 5, 6, 7, which are each occupied by a series of melt-blowing nozzles 8, 9, 10. These serve to extrude fibers from molten plastic in order to apply them to the carrier 2. While the nozzle bars 5, 6, 7 are preferably arranged in a stationary manner, the carrier 2, which is preferably in the form of an endless belt, is preferably located in the in FIG FIG. 1 represented by an arrow 11 carrier longitudinal direction transverse to the nozzle bar 5, 6, 7 moved under this past.

Optionally, at the end of the row formed by the nozzle bars 5, 6, 7 or between adjacent nozzle bars 5, 6, a web stabilizing device 12, for example in the form of a nozzle strip, may be arranged. This may be adapted to direct a water jet curtain on the carrier 2.

Alternatively, one or more of the meltblowing dies 8, 9, 10 may be replaced by means adapted to apply prefabricated fibers, for example natural fibers, to the carrier 2. Further, the nozzle bars 5, 6, 7 may be formed similar or different. They may be adapted to apply fibers of the same or different plastics to the carrier 2. In addition, one or more of the nozzle strips 5, 6, 7 may be configured to produce fibers composed of different components, for example fibers having a core of a first material and a sheath of a second material.

With the out FIG. 1 schematically apparent fiber laying device, a three-dimensional Faserflor can be produced, as in FIG. 2 is indicated. The carrier 2 moving in the direction of the arrow 11 passes under the nozzle bars 5, 6, 7. Thus, first of all, the fibers 13 discharged from the melt-blowing nozzle 8, then the fibers 14 discharged from the melt-blowing nozzle 9 and then the fibers 15 discharged from the Schmalzblasdüse 10 strike the carrier 2 or the already underlying fiber layer. It forms on the here approximately hemispherical 3D shapes 3, 4 a batt 16. This can be completely loose. If the web stabilizer 12 is provided and operated, the batt 16 is at least partially solidified. The attachment of the fibers 13, 14, 15 to the carrier 2 can be promoted by an outgoing of the melt-blowing nozzles 8, 9, 10 air flow and optionally by a negative pressure, which may be applied to the underside of the carrier 2. The batt 16 can be constructed in layers. For example, the fibers 13 may consist of a fluffy, skin-friendly material. For example, the fibers 14 may be comprised of a predominantly elastic, supportive, and supportive material, while the fibers 15 may be comprised of any of the foregoing materials, or may include a third material, such as a printable, dyeable, dyed, or otherwise provided material for the outer surface of a brassiere ,

The possibly pre-consolidated fiber web is continuously removed from the moving support 2 on one side and fed to a solidifying device 17, as it is FIG. 3 evident. This may consist of a series of nozzles 18 to 24 which direct, for example, fine jets of water or jets of other gaseous or liquid fluid onto the batt 16. The nozzles 18 to 24 may optionally be arranged on only one side of the batt 16 or on both sides thereof. The rays acting on the batt 16 are in FIG. 3 illustrated schematically. They serve to produce a consolidated felt-like nonwoven or a nonwoven body 25 from the relatively loose fibrous web 16 while retaining the three-dimensional shape originally predetermined by the carrier 2.

In the present embodiment, the nozzles 18 to 24 have a mutually parallel alignment. But it is also possible to align the nozzles 23 to 24 in adaptation to the spatial shape of the desired felt body. Further is it, as in FIG. 5 indicated, it is possible to hold the batt 16 to solidify on a suitable, for example sieve-like carrier 26.

FIG. 4 illustrates a section of a thus obtained nonwoven body 25. The nonwoven body 25 is, as can be seen, multi-layered, here two-layered constructed. It consists of a first fiber layer 26, for example consisting of soft crimped fibers and an outer second fiber layer 27, consisting of fibers of a different material. The two fiber layers 26, 27 are intimately interconnected and entangled or solidified. They follow the form originally given by the carrier 2. From the nonwoven body 25 produced in this way, the desired 3D felt bodies, for example garments, for example brassiere blanks, can be cut out. These can then be supplied to further processing steps in which they are, for example, trimmed, printed and / or assembled.

The method has been explained above on a support 2, which defines the hollow shape, ie the inside of the felt body to be produced. As in FIG. 6 however, the support 2 'may be arranged so as to define the convex outer shape of the body to be manufactured. Again, one or more nozzle bars 5, 6, 7 are provided with meltblowing dies 8, 9, 10 or other means for delivering fibers. At an appropriate location, for example between the nozzle bars 6, 7 or also at one end of the row formed by the nozzle bars 5, 6, 7, the optional web bonding device 12 is provided. In addition, further such web stabilizing devices can be provided between the other nozzle bars 5, 6. The fibers 13, 14, 15 are, as described above, on the Carrier 2 'applied and form a relatively loose possibly pre-consolidated fibrous web 16. This can be made of a single material or, as it is preferred and in FIG. 6 is shown to be multi-layered. The pre-consolidated fiber web can then be fed to a solidifying device 17 again as in FIG. 3 already shown.

Instead of the illustrated Wasserstrahlverfestigungsverfahrens or in addition to the same, other processing steps can be made, such as thermal bonding, impregnation or the like.

In the method according to the invention for the production of spatial objects from a fleece or felt, fibers are deposited on a mold, which is preferably permeable to air. The fibers can be attracted to them by vacuum under the mold. The mold preferably has a plurality of spatial structures that determine the shape of the forming batt and at least approximately correspond to the desired final shape. By subsequently solidifying the thus obtained formed batt, a spatially three-dimensional felt article is achieved. In this method subsequent deformation steps are superfluous or reduced to a low level, so that the material to be produced undergoes no significant delay.

reference numeral

1

Fiber laying device

2

carrier

3, 4

3D shapes

5, 6, 7

nozzle beam

8, 9, 10

meltblowing

11

direction

12

Fleece solidification means

13, 14, 15

fibers

16

Fibrous, nonwoven

17

solidifying device

18-24

jet

25

fleece body

26, 27

fiber layer

Claims (10)

1. Method for the production of three-dimensional articles from felt, in particular brassiere cups, with the following steps:

   providing a support (2) with at least one 3D form (3, 4),

   producing the random fibre nonwoven (16) at least from fibres (13) of a first material and fibres (14) of a second material,

   generating the random fibre nonwoven (16) by random laying of the fibres (13) of the first material and subsequent random laying of the fibres (14) of the second material one after the other onto the 3D form (3, 4),

   bonding the preformed random fibre nonwoven (16) to a three-dimensional nonwoven body (25) by means of a fluid acting on the random fibre nonwoven in jets.
2. Method according to claim 1, characterised in that the random fibre nonwoven (16) is removed from the support (2) for bonding and is then bonded.
3. Method according to claim 1, characterised in that the random fibre nonwoven (16) is pre-bonded on the 3D form (3, 4) before removal.
4. Method according to claim 3, characterised in that a fluid acting on the random fibre nonwoven (16) in jets, heat, an adhesive and/or solvent is used for the pre-bonding.
5. Method according to claim 1, characterised in that the random fibre nonwoven (16) contains composite fibres, which are respectively composed of two different materials.
6. Method according to claim 1, characterised in that parts are cut out of the nonwoven body (25) after bonding of the random fibre nonwoven (16).
7. Device for the production of three-dimensional articles from felt, in particular brassiere cups:

   with a support (2) with at least one 3D form (3, 4),

   with at least one fibre delivery device (5, 6, 7) for applying an unbonded random fibre nonwoven (16) to the 3D form (3, 4) by randomly laying fibres (13, 14) thereon,

   wherein the fibre delivery device (5, 6, 7) [has?] devices (5, 6) for the discharge of fibres (13, 14) composed of two different materials, which randomly lay fibres (13) of a first material and then fibres (14) of a second material one after the other on the 3D form (3, 4),

   with at least one bonding device (17) for bonding the preformed random fibre nonwoven (16) to a three-dimensional nonwoven body (25), which directs jets of a fluid onto the random fibre nonwoven (16).
8. Device according to claim 7 characterised in that the fibre delivery device (5, 6, 7) comprises at least one nozzle bar (5).
9. Device according to claim 7, characterised in that the 3D form (3, 4) is arranged to lie opposite a pre-bonding device (12).
10. Device according to claim 7, characterised in that the pre-bonding device (12) has at least one nozzle bar, which directs jets of a fluid onto the random fibre nonwoven (16).

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