Apparatus for manufacturing nonwoven fabric

Abstract

An apparatus (100) for manufacturing a nonwoven fabric is provided, comprising a plurality of different devices for manufacturing a nonwoven fabric, each device extending along a main axis (1a) and a main plane (1b) and being configured to distribute a plurality of polymeric or cellulose or viscose filaments along and parallel to one or more distribution directions (4a) transverse to the main plane (1b) via an outlet (10a) and to form a respective layer of filaments from the outlet (10a) along or parallel to a distribution plane (100a) transverse to the main axis (1a) and the main plane (1a); and comprising a conveying station (12) downstream of the outlets (10a) and comprising a calendering device (13) configured to calender the layers together, and one or more conveyors (15), each placed between a respective outlet (10a) and the calendering device (13) and configured to convey the respective layer separately from the other layers to the calendering device (13) so that the layers are laminated together only at the calendering device (13).

Description

Technical Field

[0001] The present invention relates to an apparatus for manufacturing nonwoven fabrics, which falls into the type specified in the preamble of the first claim.

[0002] Specifically, the present invention relates to an apparatus comprising at least one device including a spunbond spinneret, or a combination of spunbond and meltblown spinnerets, the spinneret being either tip-type or coaxial multi-row type, designed to distribute polymer fluid flowing from the device in the form of extruded polymer filaments to obtain a nonwoven fabric.

[0003] Furthermore, the present invention relates to an apparatus for combining extruded polymer filaments with cellulose filaments to obtain a nonwoven fabric.

[0004] Furthermore, the present invention relates to an article having continuous polymer filaments laminated therein, the filaments possibly being combined with fibrous or granular cellulose or other synthetic materials, and related methods for forming such an article, which can be used in filtration or, particularly when the granules are liquid absorbents, in absorbent hygiene products. Background Technology

[0005] As is well known, nonwoven fabric, or NWF, is an industrial product similar to woven fabric, but made through nonwoven and nonknitted processes. Therefore, in nonwoven fabric, the fibers have random patterns and no recognizable ordered structure, whereas in woven fabric, the fibers have two main and mutually orthogonal directions, commonly referred to as weft and warp yarns.

[0006] Currently, various products containing NWF are manufactured based on the manufacturing technology used, mainly depending on the intended use of the product.

[0007] Specifically, it is distinguished into high-quality NWF used for hygiene products and low-quality NWF mainly used for geotextiles.

[0008] From a technical perspective, nonwoven fabrics can be broadly classified into spunlace, spunbond, and multi-row coaxial or tipped meltblown fabrics.

[0009] Spunlace fabrics are processed to give the material isotropic resistance. Due to this property, and the possibility of production with various materials such as viscose, polyester, cotton, polyamide, and microfibers, coupled with two possible surface treatments—smooth or perforated—and a wide range of smooth or printed colors, spunlace fabrics are suitable for use in the hygiene, automotive, cosmetic, industrial, and disposable sectors.

[0010] Spunbond, typically made of polypropylene, is a widely used nonwoven fabric primarily used in agriculture, hygiene, construction, furniture, mattresses, and other related industries. With appropriate processing, a range of highly specific products can be created for each industry: fluorescent, soft calendering, mite-proof, fire-retardant, antibacterial, antistatic, UV-resistant, etc. Various surface treatments can also be applied to spunbond fabrics, such as printing, lamination, flexographic lamination, and self-adhesive.

[0011] The production apparatus for spunbond nonwoven fabrics essentially includes at least one inlet conduit for polymer material, a polymer extrusion head, a polymer distributor or diverter, and a spinneret suitable for producing the actual spunbond yarn deposited on a conveyor belt.

[0012] The aforementioned components are arranged close to each other to allow for polymer processing and NWF spunbonding distribution.

[0013] More specifically, the polymer within the distribution conduit is pushed towards the extruder head under pressure and high temperature, typically above 200°C. At this point, pressure control is generally performed, for example, via a pressure switch, to ensure the continuity of the output yarn and the precision of the deposition process.

[0014] The extruder head dispenses polymer through a distribution surface, through which the molten polymer reaches the distributor. Between the distributor or manifold and the extruder head is a filter made of steel plate, typically varying in thickness between 0.8 mm and 1.6 mm, and comprising a fine mesh, for example, with nominal sizes between 20 micrometers and 110 micrometers. Essentially, the filter is a stretched mesh.

[0015] After passing through the filter, the molten polymer enters the distributor, which guides the polymer to the spinneret, where it is extruded into filaments that constitute spunbond NWF. Specifically, the purpose of the filter is to block incompletely dissolved or large polymer particles or polymer pigments that could clog the tiny NWF extrusion orifices if they pass through and enter the spinneret.

[0016] NWF meltblown fabric is manufactured using a specific spinneret to achieve higher technical properties than previous TNT. In fact, meltblown fabric is characterized by fibers with high filtration capabilities for both liquids and gases.

[0017] The meltblown nonwoven fabric production unit consists of a box containing the meltblown fiber manufacturing equipment and all the components required for optimal process operation.

[0018] Known tip meltblown devices include extrusion heads, tip dispensers, and air knives.

[0019] Multi-row coaxial meltblown equipment provides polymer that flows out of rows of tubes by stretching it with air, which passes through the outside of the tubes coaxially and pushes the fibers downward.

[0020] In particular, the multi-row coaxial meltblown apparatus includes an assembly defining coaxial orifices arranged in a row and adapted to accommodate at least a portion of the tubes, which pass coaxially within the orifices to allow diffusion of polymer fluid while allowing air or gas to diffuse from at least a portion of the orifices.

[0021] Typically, these devices include a device called a spinning assembly, which comprises multiple different components adapted to interact with each other. A spinning assembly typically consists of a spinneret and a diffusion device including one or more components called air plates.

[0022] More specifically, the spinneret of a known multi-row coaxial spunbond and / or meltblown spunbond and / or meltblown device includes a plate comprising a first orifice adapted to receive a conduit configured to dispense polymer fluid, and a second orifice separate from the first orifice and adapted to allow air or gas to pass through, and further comprising a clamp separate from or integral with the plate, the clamp comprising a plurality of third orifices centered relative to the first orifice and connected to the second orifice in a fluid passage, adapted to receive a portion of the conduit while simultaneously allowing the air or gas to pass through.

[0023] The aforementioned existing technologies have some significant drawbacks.

[0024] Specifically, spunbond technology typically involves nozzles downstream of the spinneret, i.e., after the filaments have exited the spinneret, designed to blow airflow through the filaments to cool them. Cooling the filaments before they are deposited onto the spool is crucial, as it prevents adjacent filaments from sticking together due to heat.

[0025] However, at the same time, the airflow cannot apply too much pressure to the filaments, otherwise the filaments may deviate from their outflow trajectory, still resulting in undesirable mutual adhesion of the filaments.

[0026] In addition, because the cooling nozzles are placed to the side of the filament outflow path, the reduced pressure of the air blowing the filaments means that the central filament cannot be cooled as effectively as the filaments shielded by the side filaments, or at least cannot receive similar cooling. Therefore, the technical problems associated with accidental filament splicing remain, leading to a loss of nonwoven fabric performance.

[0027] In addition to the above, it is clear that to ensure proper cooling of the filaments, it is necessary to increase the distance between them, i.e., the spacing between the output filaments. This means that currently known spinnerets cannot include high-density orifices or distribution tubes, thus making it impossible to manufacture high-density fabric layers.

[0028] Therefore, nonwoven fabric layers made with currently known spinnerets do not have particularly high performance when stretched in different directions.

[0029] In fact, while nonwoven fabrics manufactured in this way are very strong along the main direction of the device's development, they are not so strong in the direction perpendicular to that direction.

[0030] For example, the consequences of this weakness are very significant in the manufacture of diapers and wipes.

[0031] In fact, the above-mentioned products are usually manufactured by overlapping multiple layers to form a complete layered structure of the product itself.

[0032] Specifically, traditional diapers are typically manufactured following a lamination sequence (often referred to as S, S, MB, MB, S), which includes two spunbond sheets, two meltblown sheets, and one additional spunbond sheet; wipes are similar, although they also include an intermediate section that may contain particulate matter.

[0033] In any case, the article just described has some major defects when implemented.

[0034] First, they are manufactured by laminating on the same belt, which means multiple different steps and long delivery times. Furthermore, this aspect also means higher costs, not only from the manufacturing process itself but also from the fact that the increased number of layers raises the cost of the finished product.

[0035] Furthermore, some layers are double-layered because, in particular, conventional spunbond spinnerets, as described earlier, have limitations on the density of filament delivery orifices. Therefore, it is necessary to manufacture the spunbond portion in two layers, and thus, in two separate stages and / or devices, typically multiple work chambers arranged sequentially, each equipped with a receiving chamber containing the type of spinneret required to manufacture the desired layer.

[0036] In addition, and as anticipated, it is known that certain articles may include particulate materials. Particulate materials are widely used in the absorbent structure of absorbent articles, such as for personal hygiene products like disposable diapers for children, training pants for children, or incontinence underwear for adults, which are designed to absorb and contain bodily fluids, particularly urine, or in other moisturizing products such as wipes.

[0037] These absorbent products consist of several layers that perform different functions, typically including a top layer, a bottom layer, and an absorbent core in the other layers. The absorbent core must be able to absorb and retain liquid excretions for extended periods, such as overnight diapers, and should minimize backflow to keep the wearer dry and prevent staining clothes or sheets. Modern absorbent cores typically consist of an absorbent structure composed of superabsorbent polymer (SAP) particles (also known as absorbent gelling agents (AGM)) and fibrous materials. The fibrous materials can be natural, such as cellulose fibers; modified natural, such as regenerated cellulose-based materials; or synthetic fibers, such as viscose.

[0038] It is well known that absorbent structures can be formed "online" or "in situ" on a conversion device to form a complete absorbent article; for example, see WO2022 / 120693A1, which discloses an absorbent core for an absorbent article comprising a liquid-permeable top cover layer, a bottom cover layer, and a high-fill-factor core layer between the top and bottom layers, and first and second superabsorbent polymers, which, in addition to being adhesively fixed to the cover layers, at least partially permeate into the high-fill-factor core layer. Furthermore, WO2014 / 001487 discloses particles embedded in porous fabrics and ultrasonically fixed between cover layers.

[0039] However, these methods require each production line used for article manufacturing, also known as a conversion unit, to be equipped with a suitable handling system for adding particles, as well as an unwinding and joining system for the preformed tape. Furthermore, the formation of the absorbent core may limit overall production volume.

[0040] As an alternative to online core formation, composite absorbent tapes, including granules such as superabsorbents, can be formed offline at high production volumes. These tapes can be supplied as so-called rolls to conversion units for forming articles to be packaged and / or combined with other elements to form absorbent articles, thereby advantageously simplifying conversion equipment and processes and providing production cost advantages due to high production volumes.

[0041] Generally, while offline formation of absorbent structures offers advantages over online formation, such as achieving very high production volumes with a single production unit, improvements in the economics and / or performance of the resulting absorbent structures are still needed. Furthermore, the use of adhesives in absorbent structures complicates recycling, particularly the recovery of plant waste, and may negatively impact consumer perception, leading to the perception of them as unnecessary chemicals.

[0042] Regarding a typical device of the prior art, as shown in Figure 13, another inherent drawback of the technology is that, typically, filaments are deposited on a deposition strip or pad, and in the case of multiple devices placed in succession, multiple filament layers are stacked on the deposition strip or pad.

[0043] This layering means that the layers and filaments are effectively compressed and compacted during calendering, which, especially when forming multi-layered products such as diapers, results in the inherent brittleness of individual layers and joints, leading to poor product performance. Summary of the Invention

[0044] In this context, the technical objective of the present invention is to design an apparatus for manufacturing nonwoven fabrics that can substantially overcome at least some of the aforementioned defects.

[0045] Within the scope of the stated technical task, an important objective of the present invention is to obtain an apparatus for manufacturing nonwoven fabrics to increase the density of polymer filament conveying holes within the same apparatus, preferably a spunbond type.

[0046] Therefore, another important objective of the present invention is to provide an apparatus for manufacturing nonwoven fabrics, which enables nonwoven fabric layers, which are typically manufactured using several different spinnerets, to be manufactured using a single spinneret.

[0047] Therefore, an important task of the present invention is to realize an apparatus for manufacturing nonwoven fabrics to reduce the production cost of layers used in hygiene products such as diapers, wipes or other similar products.

[0048] Furthermore, a further object of the present invention is to provide an apparatus for manufacturing nonwoven fabrics that produces layered articles by reducing the number of process steps and time required to complete the article.

[0049] In particular, a further objective of the present invention is to provide an apparatus for manufacturing nonwoven fabrics that is capable of producing high-performance layered articles in which the layers are highly durable, resistant to wear, and where the bonding between different layers is effectively performed.

[0050] Therefore, a further objective of the present invention is to provide an apparatus for manufacturing nonwoven fabrics that can combine different technologies, such as spunbond and meltblown, to obtain articles.

[0051] Furthermore, a further objective of the present invention is to provide an apparatus for manufacturing nonwoven fabrics that enables the combination of extruded polymer filaments with cellulose filaments to obtain nonwoven fabrics.

[0052] Therefore, a further object of the present invention is to manufacture an article having continuous polymer filaments laminated therein, the filaments possibly being combined with fibrous or granular cellulose or other synthetic materials, and a related method for forming such an article, which can be used in filtration or, particularly when the granules are liquid absorbents, in absorbent hygiene products.

[0053] In particular, an additional objective of the present invention is to reduce the complexity and cost of manufacturing articles.

[0054] The technical task and specified purpose are achieved by the equipment for manufacturing nonwoven fabrics as claimed in appended claim 1.

[0055] Preferred embodiments are highlighted in the dependent claims. Attached Figure Description

[0056] Referring to the accompanying drawings, the features and advantages of the present invention will be set forth below through a detailed description of preferred embodiments, wherein:

[0057] Figure 1 A cross-sectional view of an apparatus for manufacturing nonwoven fabrics according to the present invention is shown;

[0058] Figure 2 It shows Figure 1 An exploded view of the device;

[0059] Figure 3a This is a cross-sectional perspective view of the rectangular spinneret of the apparatus for manufacturing nonwoven fabrics according to the present invention;

[0060] Figure 3b This is a cross-sectional perspective view of the circular spinneret of the apparatus for manufacturing nonwoven fabrics according to the present invention;

[0061] Figure 4 A perspective view of the spinneret holder of the apparatus for manufacturing nonwoven fabrics according to the present invention is shown;

[0062] Figure 5a The diagram shows an upper view of the spinneret of the nonwoven fabric manufacturing apparatus according to the invention, from the perspective of the dispenser, including the first hole and slit of the spinneret and the second hole shown in shaded lines, wherein the slit is parallel to the main axis and continuous.

[0063] Figure 5b The diagram shows an upper view of the spinneret of the nonwoven fabric manufacturing apparatus according to the invention, from the perspective of the dispenser, including the first hole and slit of the spinneret and the second hole shown in shaded lines, wherein the slit is parallel to the main axis and staggers between the first and second portions of the spinneret along the main axis.

[0064] Figure 5c The diagram shows an upper view of the spinneret of the nonwoven fabric manufacturing apparatus according to the invention, from the perspective of the dispenser, including the first hole and slit of the spinneret and the second hole shown in shaded lines, wherein the slit is slightly inclined relative to the spindle.

[0065] Figure 5d The diagram shows the first and second holes of the spinneret of the nonwoven fabric manufacturing apparatus according to the invention, as well as the lower part of the slit shown in shaded lines, from the perspective of the collecting surface, wherein the slit is perpendicular to the main axis.

[0066] Figure 5eThe diagram shows the first and second holes of the spinneret of the nonwoven fabric manufacturing apparatus according to the invention, as well as the lower part of the slit shown in shaded lines, from the perspective of the collecting surface, wherein the slit is strongly inclined relative to the main axis.

[0067] Figure 6 The diagram shows the first and second holes of the circular spinneret of the nonwoven fabric manufacturing apparatus according to the invention, as well as the lower part of the slit shown in shaded lines, from the perspective of the collecting surface.

[0068] Figure 7 A cross-sectional view of an apparatus for manufacturing nonwoven fabrics according to the present invention is shown, wherein the apparatus for manufacturing spunbond nonwoven fabrics, the apparatus for manufacturing meltblown nonwoven fabrics, and the apparatus for manufacturing spunbond nonwoven fabrics (without an external workspace) are arranged in sequence parallel to the main plane;

[0069] Figure 8a A schematic diagram of an apparatus for manufacturing nonwoven fabrics according to the present invention is shown, wherein the conveying station includes a pair of smooth rollers;

[0070] Figure 8b A schematic diagram of an apparatus for manufacturing nonwoven fabrics according to the present invention is shown, wherein a conveying station includes a first pair of smooth rollers and a second pair of rollers located downstream of the first pair of smooth rollers, the second pair of rollers being equipped with needles on the contact surface;

[0071] Figure 8c A schematic diagram of an apparatus for manufacturing nonwoven fabrics according to the present invention is shown, wherein the conveying station includes a pair of rollers equipped with needles on the contact surface and placed close to the collecting surface;

[0072] Figure 9a A cross-sectional view of an apparatus for manufacturing nonwoven fabrics according to the present invention is shown, wherein the apparatus for manufacturing spunbond nonwoven fabrics, the apparatus for manufacturing meltblown nonwoven fabrics and the apparatus for manufacturing spunbond nonwoven fabrics are arranged in sequence parallel to the main plane in the work area, and the conveying station includes two pairs of smooth rollers.

[0073] Figure 9b A cross-sectional view of an apparatus for manufacturing nonwoven fabrics according to the present invention is shown, wherein in the working chamber parallel to the main plane are arranged a device for dispensing cellulose or viscose, a device for manufacturing spunbond nonwoven fabrics, and a device for dispensing cellulose or viscose, and the conveying station includes a pair of smooth rollers.

[0074] Figure 9c A cross-sectional view of an apparatus for manufacturing nonwoven fabrics according to the present invention is shown, wherein in the working chamber parallel to the main plane are arranged a device for dispensing cellulose or viscose, a device for manufacturing tipped meltblown nonwoven fabrics, and a device for dispensing cellulose or viscose, and the conveying station includes a pair of smooth rollers.

[0075] Figure 9dA cross-sectional view of an apparatus for manufacturing nonwoven fabrics according to the present invention is shown, wherein in the working chamber parallel to the main plane are arranged a device for dispensing cellulose or viscose, a device for manufacturing spunbond nonwoven fabrics, and a device for dispensing cellulose or viscose, and the conveying station includes a pair of rollers, one of which is smooth and the other is equipped with needles.

[0076] Figure 9e A cross-sectional view of an apparatus for manufacturing nonwoven fabrics according to the present invention is shown, wherein in the working chamber parallel to the main plane are a device for dispensing cellulose or viscose, a device for manufacturing coaxial multi-row meltblown nonwoven fabrics, and a device for dispensing cellulose or viscose, and the conveying station includes two pairs of smooth rollers.

[0077] Figure 9f A cross-sectional view of an apparatus for manufacturing nonwoven fabrics according to the present invention is shown, wherein in the workshop parallel to the main plane are arranged devices for manufacturing multiple rows of coaxial meltblown nonwoven fabrics, devices for dispensing cellulose or viscose, and devices for manufacturing multiple rows of coaxial meltblown nonwoven fabrics, wherein the meltblown devices define a dispensing direction converging relative to the dispensing plane, and the conveying station includes a pair of smooth rollers.

[0078] Figure 10 A schematic cross-sectional view of an apparatus for manufacturing nonwoven fabrics according to the present invention is shown, wherein the compaction device and the calendering device are arranged in sequence parallel to the distribution plane, and there is no strip or pad-shaped collection surface;

[0079] Figure 11 A schematic cross-sectional view of an apparatus for manufacturing nonwoven fabrics according to the present invention is shown, wherein there are multiple different devices, each having a separate conveyor at its respective outlet, in addition to a compaction device, for conveying polymer filament layers to a calendering device.

[0080] Figure 12 A schematic cross-sectional view of an apparatus for manufacturing nonwoven fabrics according to the present invention is shown, comprising multiple different devices, each having a separate conveyor at its respective outlet, in addition to a compaction device, for conveying polymer filament layers to a calendering device, and wherein at least one filament layer is conveyed to the calendering device by the device without a conveyor; and

[0081] Figure 13 depicts a schematic cross-sectional view of a prior art equipment for manufacturing nonwoven fabrics, in which a conveyor belt is evident between the calender outlet and the rolls. Detailed Implementation

[0082] In this document, when measurements, numerical values, shape, and geometric references (such as perpendicularity and parallelism) are associated with "approximately" or other similar terms (such as "almost" or "substantially"), it should be understood that measurement errors or inaccuracies due to production and / or manufacturing variations are excluded, and most importantly, that there is less than a slight deviation compared to the relevant numerical value, measurement, shape, or geometric reference. For example, if associated with a numerical value, these terms preferably indicate a deviation of no more than 10% of the numerical value itself.

[0083] Furthermore, when used, terms such as “first,” “second,” “upper,” “lower,” “primary,” and “secondary” do not necessarily identify order, priority, or relative position, but can simply be used to clearly distinguish their different components.

[0084] Unless otherwise specified, as reflected in the following discussion, terms such as “processing,” “calculating,” “determining,” and “computing” are considered to refer to the actions and / or processes of a computer or similar electronic computing device that manipulate and / or convert data represented as physical quantities (such as electronic quantities recorded in computer systems and / or memory) into other data similarly represented as physical quantities within computer systems, recording or other information storage, transmission or display devices.

[0085] Unless otherwise stated, the measurements and data reported herein should be regarded as provided in the International Standard Atmosphere ICAO (ISO 2533:1975).

[0086] Referring to the accompanying drawings, the apparatus for manufacturing nonwoven fabrics according to the present invention is generally referred to as No. 1.

[0087] The apparatus 1 for manufacturing nonwoven fabrics according to the present invention is preferably spunbond type.

[0088] Therefore, like any spunbond apparatus, apparatus 1 is at least capable of conveying polymer filaments onto the deposition surface to produce nonwoven fabrics.

[0089] It should be stated beforehand that nonwoven fabric refers to any type of fabric in which filaments are deposited in a loose manner; that is, the filaments are not classified by means of a loom or other means that can be woven into fabric, weft and warp yarns, but by being deposited on a surface and mixed into one or more layers of the article, as explained further later. Therefore, nonwoven fabric can be made not only from polyester filaments as traditionally done, but also from any natural or synthetic material, such as polypropylene, nylon, cellulose, viscose, and of course, polyester itself.

[0090] Similarly, filament refers to any filamentous element typically defined as chemical, acrylic, and synthetic fibers.

[0091] It should also be noted that while device 1 is capable of producing nonwoven fabrics, it is also more fundamentally capable of producing only one or more filaments that can be used for nonwoven fabric formation or other purposes (such as unwinding).

[0092] Preferably, the device 1 extends primarily along the main axis 1a. The main axis 1a is a virtual axis, such as the centroidal axis, along which the device 1 extends.

[0093] Furthermore, the device 1 extends along the main plane 1b. The main plane 1b may be provided, for example, by an intermediate plane, preferably parallel to the surface where the polymer filaments constituting the nonwoven fabric are deposited.

[0094] The principal axis 1a can be parallel to the principal plane 1b, and in some cases, it is coplanar with the principal plane 1b.

[0095] Furthermore, device 1 defines a vertical axis 1c.

[0096] The vertical axis 1c is preferably perpendicular to the main axis 1a. Therefore, the vertical axis 1c is also preferably perpendicular to the main plane 1b. Thus, the vertical axis 1c is preferably oriented perpendicular to the surface where the polymer filaments constituting the nonwoven fabric are deposited, and extends from upstream to downstream along the apparatus 1.

[0097] Therefore, the vertical axis 1c is essentially an extrusion shaft, along which at least a portion of the polymer fluid is conveyed to the distributor within the device 1.

[0098] Like all spunbond devices, device 1 includes at least one extrusion head 2, a distributor 3, and a spinneret 4.

[0099] Specifically, the device 1 includes an extruder 2, a distributor 3, and a spinneret 4, preferably arranged in this order along the vertical axis 1c.

[0100] Then, the polymer fluid is introduced into the extruder head 2, then into the distributor 3, and then distributed to the spinneret 4.

[0101] Preferably, the polymer fluid is selected from polypropylene, polyester, nylon, cellulose, polyester and viscose.

[0102] Extruder 2 is preferably a general-purpose extruder, also known as a coating hanger.

[0103] Preferably, the extruder head 2 is adapted to guide polymer fluid to the distributor 3. Therefore, preferably, the extruder head 2 includes at least one main channel 20.

[0104] The main channel 20 is an opening or conduit of any shape or size, and therefore can be cylindrical or square, and is compatible with other components connected to the main channel 20.

[0105] The main channel 20 is preferably adapted to allow polymer fluid to pass through the extruder head 2. Specifically, the main channel 20 is adapted to direct the polymer fluid to the distributor 3. Of course, the extruder head 2 may also include multiple main channels 20.

[0106] As described above, dispenser 3 receives polymer fluid from extruder 2, particularly polymer fluid from main channel 20, for dispensing.

[0107] Therefore, the dispenser 3 is preferably integrated with the extruder 2.

[0108] Distributor 3 is also called a breaker plate.

[0109] Therefore, distributor 3 includes at least one distribution pipe 30.

[0110] The distribution conduit 30 is connected to the fluid channel of the main channel 20 and is adapted to distribute polymer fluid. Specifically, the distributor 30 distributes the polymer fluid to the spinneret 4 to produce polymer filaments, which then continue to form a nonwoven fabric.

[0111] Both the main channel 20 and the distribution conduit 30 can define complex shapes. Furthermore, they can be separated to provide sub-channels for distributing the polymer fluid. In other words, the distributor 3 can also include multiple distribution conduits 30 arranged downstream of the main channel 20, each designed to distribute a smaller amount of polymer fluid than the main channel 20. Preferably, the distributor 3 includes multiple distribution conduits 30 such that the polymer fluid is distributed along the main plane 1b.

[0112] Distributor 3 preferably includes at least one containment chamber and a filtration device.

[0113] The receiving chamber is preferably adjacent to the extruder 2 and placed between the main channel 20 and the distribution pipe 30.

[0114] More specifically, the receiving chamber can be formed in the interface area between the dispenser 3 and the extruder 2.

[0115] Therefore, the distributor 3 may include a single receiving chamber or may have multiple adjacent receiving chambers distributed transversely to the vertical axis 1c along the distributor 3.

[0116] The filtration device is preferably housed in a containment chamber.

[0117] Therefore, the containment chamber is essentially a storage tank where a filtration device can be placed. This tank is preferably located between the main channel 20 and the distribution pipe 30, i.e., preferably within the containment chamber, to filter the polymer fluid.

[0118] In particular, the filtration device preferably includes porous elements.

[0119] Porous elements define multiple channels of non-linear and irregular dimensions.

[0120] Porous elements are structurally similar to sponges. In this sense, however, it does not mean that porous elements are soft elements that can be easily deformed. On the contrary, porous elements are preferably defined in terms of stiffness and hardness by differentiating their materials and manufacturing processes.

[0121] However, porous elements, like sponges, contain multiple pores, making the porous elements themselves essentially non-uniform and anisotropic.

[0122] In particular, preferably, the porous element is a component manufactured using sintering technology.

[0123] Due to manufacturing process considerations, porous elements preferably include multiple non-linear channels of different sizes.

[0124] The term "size" refers to all dimensions that contribute to the determination of the volume of a cavity or pore in a porous element.

[0125] More specifically, preferably, the filtration device includes a plurality of holes or cavities that define a channel when adjacent. In other words, the continuity of the holes enables a channel for the polymer fluid.

[0126] Furthermore, preferably, each pore has a porosity greater than or equal to 18 micrometers.

[0127] As described above, porous elements are preferably processed by sintering, and therefore consist of multiple sintered particles of the same material.

[0128] The particles can be any material, as long as they can withstand the passage of polymer fluids. For example, porous elements include metallic materials.

[0129] Furthermore, sintered particles can have different properties.

[0130] For example, in a first embodiment, the particles may be components that selectively have spheres or fragments.

[0131] In a second embodiment, the porous element may include filaments that are intertwined and sintered.

[0132] In a third embodiment, the porous element may include a first layer and a second layer. These layers preferably overlap each other and each include the components and filaments as described above. Specifically, preferably, the first layer and the second layer are adjacent to the extruder 2 and the dispenser 3, respectively, or they are adjacent to the dispenser 3 and the extruder 2, respectively.

[0133] In addition, single-layer sintering of granules and filaments can be provided.

[0134] The porous element can then be integrally manufactured with the dispenser 3 or, preferably, detachably disposed within the dispenser 3, particularly in the receiving chamber.

[0135] Therefore, preferably, the porous element is shaped opposite to the receiving chamber and is detachably arranged inside the receiving chamber.

[0136] Therefore, in the case of multiple receiving chambers, dispenser 3 may include multiple porous elements that can be introduced as tablets into the appropriate receiving chambers.

[0137] Advantageously, each receiving chamber is adapted to accommodate a porous element such that the porous element is spaced apart from the dispensing conduit 30. Preferably, particularly when the dispenser 3 includes a plurality of dispensing conduits 30, the receiving chambers are configured to prevent adhesion between the filter device and the dispensing conduits 30.

[0138] Therefore, generally speaking, the containment chamber is configured to keep the filter device and the distribution pipe 30 separate, thereby forming at least one separate space.

[0139] The separation space is preferably part of the free space between the porous element and the distribution channel 30, and the free space has a thickness defined along the vertical axis 1c.

[0140] Preferably, the thickness of the separation space is greater than or equal to 500 micrometers.

[0141] More preferably, the thickness of the separation space is between 500 micrometers and 8 millimeters.

[0142] Preferably, but not necessarily, the thickness of the separation space is greater than or equal to the thickness of the porous element. In a preferred embodiment, the porous element defines a thickness of at least 1.5 mm. More specifically, preferably, the porous element defines a thickness between 1.5 mm and 8 mm.

[0143] To achieve separation between the filter device and the inlet of the distribution pipe 30, the containment chamber may include a support device.

[0144] The support device is preferably designed to allow porous elements to rest on them, so that the porous elements remain in the receiving chamber and are spaced apart from the distribution pipe 30.

[0145] Therefore, the support device may include a support frame, or other spacer elements that can at least achieve separation of the space.

[0146] The spinneret 4 is preferably a separate element from the distributor 3, as in common spunbond devices. However, preferably, the spinneret 4 is at least integrated with the distributor 3.

[0147] Preferably, the spinneret 4 includes a plurality of first holes 40. Each first hole 40 preferably extends transversely to the main plane 1b.

[0148] Furthermore, each first hole 40 is preferably connected to a fluid channel of the dispensing pipe 30 and is adapted to extrude polymer fluid to produce the corresponding filament, preferably a polymer filament.

[0149] Appropriately, the first hole 40 may have a diameter that varies in size depending on its intended use.

[0150] Furthermore, the first hole 40 can be circular in shape, or it can define other shapes transversely to its own unfolding axis, i.e., defined by the cross-section of the first hole 40 of different shapes and sizes. For example, the first hole 40 can define a circular, quadrilateral, or triangular outline, have sharp or preferably chamfered corners, and also be concave or convex.

[0151] Advantageously, the spinneret 4 of the device 1 according to the invention includes at least one slit 41.

[0152] The slit 41 preferably extends parallel to the main plane 1b. Therefore, the slit 41 is adapted to allow air to pass through the spinneret 4.

[0153] The slit 41 can extend from one side of the spinneret 4 to the other. Alternatively, the slit 41 can extend only partially within the spinneret 4.

[0154] Therefore, the spinneret 4 also advantageously includes a set of second holes 42.

[0155] The second hole 42 is connected to the fluid channel of the slit 41.

[0156] Then, the second hole 42 extends parallel to the first hole 40 to allow air to flow out from the slit 41.

[0157] Therefore, the first hole 40 and the second hole 42 extend along or parallel to one or more distribution directions 4a, the polymer filament is transported along the distribution direction, and air pushes the filament outward from the device 1 along the direction.

[0158] Therefore, one or more distribution directions 4a correspond to the directions in which the polymer filaments are distributed from the spinneret 4.

[0159] The second orifice 42 is preferably distributed throughout the spinneret 4, such that the air flowing out of the spinneret 4, especially the air flowing out of the slit 41, can interact with the polymer fluid flowing out of all the first orifices 40.

[0160] Furthermore, slit 41 may be unique and extend parallel to the main plane 1b, thereby connecting it to all the fluid channels of the second hole 42.

[0161] Alternatively, the spinneret 4 may include a plurality of slits 41, each slit being connected to a corresponding set of fluid channels in the second hole 42.

[0162] In practice, preferably, the first hole 40 is arranged in a first row 40a.

[0163] The first row 40a is essentially a row of first holes 40 that are different from each other, separate, and parallel. Therefore, the slits 41 are correspondingly different from each other and separate. Furthermore, the slits 41 are parallel to the first row 40a and extend between adjacent first rows 40a.

[0164] More specifically, the slits 41 are extended in such a way that they do not interfere with the first orifice 40. Furthermore, advantageously, the spinneret 4 includes a plurality of sets of second orifices 42, each set of second orifices being connected to a corresponding fluid channel of the slit 41.

[0165] Furthermore, the spinneret 4 can be defined with a specific shape and size consistent with the structure of the device 1, for example, consistent with the structure of the dispenser.

[0166] Therefore, for example, the spinneret 4 can be defined as a rectangular shape, or more generally a quadrilateral shape, or even a circular shape such as a circle.

[0167] Therefore, the spinneret 4 can determine the specific orientation of the first row 40a, and thus also determine the specific orientation of the slit 41 relative to the main shaft 1a.

[0168] For example, in Figures 5a to 5b and Figure 6 In the first embodiment shown, the first row 40a can extend parallel to the main axis 1a.

[0169] Or, such as Figures 5c to 5e As shown, the first row 40a can extend laterally to the main axis 1a, making them perpendicular to the main axis 1a. Figure 5d ) or tilted relative to the main axis 1a ( Figure 5c and Figure 5e ).

[0170] In any embodiment, the spinneret 4 may be divided into sections or regions. For example, the spinneret 4 may include a first section 4' and a second section 4'.

[0171] If present, the first part 4' and the second part 4" include corresponding staggered first rows 40a, such that each first row 40a of the first part 4' is aligned with a corresponding slit 41 of the second part 4"; conversely, each first row 40a of the second part 4" is aligned with a corresponding slit 41 of the first part 4', as shown below. Figure 5b As shown.

[0172] The second hole 42 can also be arranged in a specific way.

[0173] For example, advantageously, one or more of the groups of second holes 42 (preferably in each group) are arranged in at least one pair of second rows 42a.

[0174] The second rows 42a are distinct, separate, and parallel to each other. Therefore, each of the second rows 42a is preferably placed near the corresponding first row 40a of two adjacent first rows 40a.

[0175] Furthermore, advantageously, the second holes 42 of each second row 42a are preferably offset relative to the first holes 40 of the adjacent first row 40a, such that they are transverse to the first row 40a and positioned between two adjacent first holes 40 of the first row 40a.

[0176] In this way, the second hole 42 allows air to flow from the spinneret 4 and surround all the filaments flowing out from the first hole 40.

[0177] Since the slit 41 is adapted to allow air to pass through, the device 1 preferably also includes a conveying device 5.

[0178] The conveying device 5 is connected to the fluid channel of the slit 41. Therefore, the conveying device 5 is configured to deliver air into the slit 41.

[0179] Therefore, the supplied air is replacement air, which allows the first orifice 40 to be cooled before the polymer fluid escapes from the spinneret 4, and thus allows the polymer fluid to be cooled at least externally.

[0180] Furthermore, since air also escapes through the second hole 42 adjacent to the first hole 40, as described above, the air not only immediately and directly cools the polymer fluid at the outlet of the spinneret 4, but also cools the polymer fluid between the first holes 40.

[0181] This technical solution has significant advantages, which will be further elaborated later.

[0182] In addition to the above description, device 1 may also include additional details.

[0183] As described above, the spinneret 4 is preferably separate from the distributor 3 and can be defined, for example, in a quadrilateral shape. Figure 3a ) or circular shape ( Figure 3b ).

[0184] Therefore, device 1 may further include support member 6.

[0185] For example in Figures 1 to 2 and Figure 4 As shown, the support member 6 (if present) is integrally formed with the distributor 3. Therefore, the support member 6 is adapted to support the spinneret 4 so that it remains integral with the distributor 3.

[0186] In this respect, preferably, the support 6 includes a receiving chamber 60.

[0187] The receiving chamber 60 is perforated and accommodates the spinneret 4 without blocking the holes 40, 42. Accordingly, preferably, the conveying device 5 includes one or more conveying pipes 50.

[0188] One or more delivery pipes 50 are preferably disposed between the extruder head 2, the distributor 3, and the support member 6. In addition, the delivery pipes 50 are connected to one or more slits 41 fluid channels, preferably one connected to all slits 41, or each connected to the same slit 41 or corresponding slits 41.

[0189] Finally, the device 1 preferably includes an extruder head 2, a distributor 3, and a support member 6, which are distinct from each other, separate, and mutually constrained in this order. Thus, the spinneret 4 is detachably constrained to the support member 6, which is confined within a receiving chamber 60 between the distributor 3 and the support member 6.

[0190] Therefore, the device 1 is able to convey filaments, preferably polymer filaments, along and parallel to the distribution direction 4a, which may be parallel to the vertical axis 1c or even inclined relative to the vertical axis 1c.

[0191] Preferably, apparatus 1 is used to manufacture nonwoven fabric. Then, preferably, filaments are deposited on a movable deposition surface, such that at least one layer of interwoven filaments is formed during deposition.

[0192] However, device 1 can be used equivalently to manufacture filament spools. In this respect, it is practically possible to plan that the spool is positioned tangent to one or more distribution directions 4a, for example, extending parallel to the main shaft 1a and rotating about an axis parallel to the main shaft 1a, such that the filaments are collected on the rotating spool.

[0193] In this way, filaments can also be used for actual weaving, using a loom that can unwind the filaments and weave them into warp and / or weft yarns.

[0194] Similarly, the present invention includes not only the new device 1.

[0195] In fact, this invention also makes it possible to manufacture new equipment.

[0196] Specifically, the present invention realizes at least one new apparatus for manufacturing nonwoven fabrics, which is generally designated as 100 with reference to the accompanying drawings.

[0197] From the outset, it is emphasized that device 100 may include device 1, or may not include device 1.

[0198] Furthermore, the device 100 can be configured according to different modes, more specifically, according to several different possible advantageous configurations.

[0199] For example, in various embodiments, the device 100 may include a work area 10, like most devices involving spunbond or meltblown apparatus.

[0200] Work chamber 10 (if present) is essentially a housing structure that typically houses a device capable of dispensing filaments, such as device 1. In the example where device 1 is located within work chamber 10, work chamber 10 includes all components of device 1, such as extruder head 2, distributor 3, spinneret 4, and possibly support 6 and conveying device 5. Alternatively, in this example, work chamber 10 may also include only spinneret 4, and possibly support 6, to accommodate the filaments in an enclosed environment.

[0201] Therefore, the work area 10 is limited to a closed volume, meaning it cannot be accessed from the outside.

[0202] In addition, device 1 includes outlet 10a.

[0203] Generally, device 1 is actually configured to convey multiple filaments selected from polymers, cellulose or viscose via outlet 10a.

[0204] Preferably, the transport is accomplished through the Venturi effect.

[0205] Therefore, the allocation is preferably carried out along and parallel to one or more allocation directions 4a that are transverse to the main plane 1b.

[0206] If workspace 10 exists, workspace 10 may include exit 10a.

[0207] The outlet 10a can correspond to a portion of the work area 10 from which the filaments distributed by the device present in the work area 10 can escape.

[0208] Since spunbond or meltblown devices, as well as other devices suitable for distributing filaments, are typically three-dimensional objects extending along a plane transverse to the distribution direction 4a, similar to the main plane 1b of device 1, the outlet 10a extends substantially along the distribution plane 100a. The distribution plane 100a is a virtual plane, preferably transverse to the main axis 1a and the main plane 1a, along which the filaments are distributed or parallel to the plane.

[0209] Therefore, the filaments flowing out from the outlet 10a are preferably formed along or parallel to the distribution plane 100a to form a filament layer.

[0210] Therefore, the outlet 10a can structurally define a distribution slit, the area of ​​which extends laterally to the distribution plane 100a.

[0211] In practice, outlet 10a preferably defines a volume shrinkage configuration that allows multiple filaments to be dispensed from device 1 (e.g., from workroom 10). Thus, the shrinkage effect allows the filaments to be dispensed, particularly by means of the Venturi effect, by forming a set of filaments at the outlet, and then, as described above, forming a filament layer along or parallel to the dispensing plane 100a.

[0212] Regardless of whether the workspace 10 exists, the device 1 preferably also includes a funnel portion 10b.

[0213] The funnel section 10b is preferably located upstream of the outlet 10a. Then, the funnel section 10b converges to guide the filament to the outlet 10a.

[0214] This means that, for example, when the device 1 includes a working chamber 10, the filaments are deposited on the wall of the funnel portion 10b of the working chamber 10 and slide independently toward the outlet 10a.

[0215] In one embodiment, the device 100 may additionally include one or more collection surfaces 11.

[0216] The collecting surface 11 can substantially correspond to the surface referred to above as the deposition or deposit surface. Therefore, the collecting surface 11 extends transversely to the dispensing plane 100a downstream of the outlet 10a. Thus, the collecting surface 11 is configured to collect the layer output from the outlet 10a for the manufacture of nonwoven articles.

[0217] As described above, device 100 may include the spunbond type device 1 as described above.

[0218] More generally, equipment 100 may include any apparatus for manufacturing nonwoven fabrics. In equipment 100, the apparatus may, but not necessarily, be housed in workshop 10.

[0219] Therefore, the device extends along the main axis 1a and the main plane 1b, which are transverse to the dispensing plane 100a. Furthermore, the device is configured to dispense at least one filament selected from polymers, cellulose, or viscose along one or more dispensing directions 4a transverse to the main plane 1b toward the outlet 10a.

[0220] In a first embodiment of the device 100, the device 100 may include a work area 10 or may not include a work area 10.

[0221] In practice, preferably, the device 100 includes at least one device as previously described and a conveying station 12.

[0222] Therefore, in summary, the device is configured to dispense multiple polymer or cellulose or viscose filaments of any type along the main axis 1a and the main plane 1b, preferably but not necessarily, via the Venturi effect (especially if the working chamber 10 is also present) through the outlet 10a along and parallel to one or more dispensing directions 4a transverse to the main plane 1b, and to form a filament layer from the outlet 10a along or parallel to the dispensing plane 100a.

[0223] On the other hand, the conveyor station 12 is preferably located downstream of the outlet 10a.

[0224] The conveyor station 12 is essentially adapted to convey the filament layer outside the apparatus. Therefore, for example, the device 100 may include a winding machine 16.

[0225] The winding machine 16 (if present) can be configured to allow layers to be wound on itself to form a roll. Therefore, the conveyor station 12 can be configured to convey layers output from the outlet 10a to the winding machine 16.

[0226] Of course, the path between the conveyor station 12 and the winding machine 16 can be facilitated by the presence of additional components. In fact, the device 100 may also include a conveyor 17.

[0227] Conveying devices 17 (if present) are configured to guide layers from conveyor station 12 to winding machine 16. For example, they may include one or more secondary rolling elements, such as those adapted to hold the sliding belt by a vacuum system.

[0228] Advantageously, generally speaking, the conveying station 12 includes at least a calendering unit 13.

[0229] The calendering apparatus 13 is an apparatus that enables the layer to be calendered. Calendering is an industrial process in which the layer slides within a gap, such as between two rolling rollers, to compress and stretch the layer by reducing its local thickness.

[0230] Therefore, the calendering unit 13 is advantageously spaced from the outlet 10a at a collection distance between 0 and 5 meters. The collection distance can also be less, for example, between 0.1 meters and 3 meters, more specifically, preferably 0.5 meters and 1.5 meters, and more suitablely 1 meter.

[0231] In this embodiment, the conveyor station 12 preferably does not have a collection surface, such as a strip or pad-shaped collection surface 11 located upstream of the calendering unit 13. This means that, as Figure 10 As clearly shown, device 100 allows the layer to be conveyed from the apparatus so that the layer is directly calendered into calendering apparatus 13 without being pre-deposited on a strip or pad-shaped collection surface.

[0232] Avoiding filament deposition increases the strength of the nonwoven layer. In addition, it allows the manufacture of nonwoven products to be made without stacking various uncompressed layers on the deposition surface, but rather by combining them appropriately only after calendering.

[0233] Of course, it may also include additional components to further improve the device.

[0234] For example, the conveying station 12 may also include a compaction device 14.

[0235] A compaction device 14 (if present) is placed between the outlet 10a and the calendering unit 13. The compaction device 14 is then configured to compress the layer so that the filaments of the layer are interlaced and welded before the layer is conveyed to the calendering unit 13.

[0236] Therefore, preferably, the compaction device 14 applies greater pressure to the filament layer than the calendering device 13.

[0237] Therefore, the calendering device 13 and / or the compaction device 14 may include additional details.

[0238] For example, the calendering apparatus 13 may include a pair of first rolls 13a.

[0239] The first roller 13a (if present) preferably rotates in the opposite direction. Furthermore, the first roller 13a extends parallel to the main plane 1b. Thus, they rotate about their respective axes of rotation oriented relative to the main shaft 1a and are configured to convey the layer away from the outlet 10a under pressure.

[0240] Of course, the first roller 13a can be fixed or selectively pivoted relative to the main shaft 1a.

[0241] More specifically, the first roller 13a includes a first contact surface 130.

[0242] The first contact surface 130 is the portion of the first roller 13a adapted to contact the filament flowing out from the outlet 10a.

[0243] Therefore, the first contact surface 130 can be smooth.

[0244] Alternatively, the first contact surface 130 may include one or more knurlings. The knurlings (if present) are configured to pick up the filament from the outlet 10a along the dispensing plane 100a when the filament contacts the first contact surface 130. Furthermore, the knurlings (if present) are also configured to release the filament in an orderly manner when the layer is released from the first contact surface 130.

[0245] In a particularly advantageous embodiment of the device 100, the first contact surface 130 preferably includes a plurality of first pins 131.

[0246] The first needle 131 (if present) is radially distributed along and around the axis of rotation. In addition, the first needle 131 protrudes from the first contact surface 130.

[0247] Therefore, given the configuration, the first needle 131 is configured to pierce the nonwoven layer conveyed from the outlet 10a to form distributed perforations on the layer. Advantageously, at the perforations, the filaments will interweave and seal each other.

[0248] Similarly, the compaction device may include a pair of second rollers 14a.

[0249] The second roller 14a (if present) preferably rotates in the opposite direction. Furthermore, the second roller 14a extends parallel to the main plane 1b. Therefore, they rotate about their respective axes of rotation oriented relative to the main shaft 1a and are configured to convey the layer away from the outlet 10a under pressure.

[0250] Of course, the second roller 14a can be fixed or selectively pivoted relative to the main shaft 1a.

[0251] More specifically, the second roller 14a includes a second contact surface 140.

[0252] The second contact surface 140 is the portion of the second roller 14a adapted to contact the filament flowing out from the outlet 10a.

[0253] Therefore, the second contact surface 140 can be smooth.

[0254] Alternatively, the second contact surface 140 may include one or more knurlings. The knurlings (if present) are configured to pick up the filament from the outlet 10a along the dispensing plane 100a when the filament contacts the second contact surface 140. Furthermore, the knurlings (if present) are also configured to release the filament in an orderly manner when the layer is released from the second contact surface 140.

[0255] In a particularly advantageous embodiment of the device 100, the second contact surface 140 preferably includes a plurality of second pins 141.

[0256] The second needle 141 (if present) is radially distributed along and around the axis of rotation. In addition, the second needle 141 protrudes from the second contact surface 140.

[0257] Therefore, given the configuration, the second needle 141 is configured to pierce the nonwoven layer conveyed from the outlet 10a to form distributed perforations on the layer. Advantageously, at the perforations, the filaments will interweave and seal with each other.

[0258] The calendering device 13 and the compaction device 14 can also be arranged according to a specific configuration; in fact, preferably, the calendering device 13 and the compaction device 14 are placed sequentially along the distribution plane 100a so as to transport the layer along the distribution plane 100a.

[0259] The above-described configuration of the apparatus 100 according to the present invention realizes a new method for manufacturing nonwoven fabric articles.

[0260] This method is of course implemented by device 100.

[0261] Therefore, the method preferably includes at least one conveying stage.

[0262] During the conveying stage, preferably, the layer is conveyed from the outlet 10a to the calendering unit 13 without pre-depositing the layer on the strip or pad-shaped collection surface.

[0263] More specifically, advantageously, during the transport phase, the layers can also be compacted and may be perforated to form distributed perforations on the layers, where the filaments will interweave and seal each other.

[0264] Therefore, the method preferably also includes a calendering stage.

[0265] During the calendering stage, the layer is calendered using calendering device 13.

[0266] Of course, the present invention also includes nonwoven fabric articles manufactured by the above method.

[0267] The implementation of the above-described device 100 can also be modified.

[0268] In fact, in the second embodiment, the device 100 preferably includes a plurality of different devices and conveying stations 12.

[0269] As previously described, each device extends along a main axis 1a and a main plane 1b transverse to the dispensing plane 100a. Furthermore, the device is configured to dispense at least one filament selected from polymers, cellulose, or viscose along one or more dispensing directions 4a transverse to the main plane 1b toward the outlet 10a. Additionally, the device may or may not be equipped with a working chamber 10. Since the devices are preferably different, they are preferably not arranged within the same working chamber 10.

[0270] Therefore, the conveying station 12 preferably includes a calendering device 13. The calendering device 13 may or may not include the above-described detailed components, that is, it may or may not include the first roller 13a, the first contact surface 130, and the first needle 131.

[0271] Advantageously, in this second embodiment, the conveyor station 12 also includes one or more conveyors 15.

[0272] One or more conveyors 15 are each positioned between a corresponding outlet 10a and the calendering unit 13. Thus, for example, as... Figure 12As shown, device 100 may include a conveyor 15 placed between the outlet 10a of one device and the calendering unit 13, while there is no conveyor 15 between the outlet 10a of the other device and the calendering unit 13. Alternatively, as... Figure 11 As shown, the equipment 100 can be equipped with a conveyor 15 for each outlet 10a of the corresponding device upstream of the calendering unit 13.

[0273] Advantageously, one or more conveyors 15 are each configured to convey a corresponding layer separately from the other layers to the calendering unit 13. In particular, they are configured such that the layers are stacked together only at the calendering unit 13.

[0274] Therefore, in this second embodiment, it is designed to use the same calendering apparatus 13 to calender multiple different filament layers dispensed from their respective outlets 10a by different apparatuses, thereby avoiding delamination of different layers on the same surface before calendering 13.

[0275] To further improve the performance of the product flowing out of the calendering unit 13, the product may be conveyed to the winding machine 16 via the conveying device 17, and the equipment 100 may also include a compaction device 14.

[0276] A compaction device 14 (if present) is placed downstream of one or more outlets 10a. Thus, each compaction device 14 (if present) is positioned between an outlet 10a and a calendering device 13. They are then configured to compress a single layer to interweave and seal the filaments before conveying the layer to the calendering device 13.

[0277] More specifically, advantageously, one or more conveyors 15 are placed between the compaction unit 14 and the calendering unit 13 so that the compacted layer can be conveyed.

[0278] The compaction device 14 may also include the details described above, namely, a second roller 14a, a second contact surface 140, and a second needle 141.

[0279] On the other hand, from a structural perspective, one or more conveyors 15 may each include a collection surface 11. As described above, the collection surface 11 extends transversely to the distribution plane 100a downstream of the outlet 10a to collect the layer flowing out of the outlet 10a. The collection surface 11 is then configured to convey the layer to the calendering unit 13. For example, the collection surface 11 may be made of a moving belt or pad. Alternatively, one or more conveyors 15 may be made of chutes or rollers or other elements that allow for the determination of a path through which the layer reaches the calendering unit 13 separately from other layers.

[0280] In addition, one or more conveyors 15 can be uniquely positioned relative to the calendering unit 13.

[0281] Preferably, the calendering unit 13 is positioned at an interval relative to at least one of the one or more conveyors 15. Furthermore, at least one of the one or more conveyors 15 is positioned to be suspended above the calendering unit 13.

[0282] Furthermore, the configuration of the apparatus 100 according to the present invention also enables a new method for manufacturing nonwoven fabric articles.

[0283] This method is of course implemented by device 100.

[0284] Therefore, the method advantageously includes at least one transport stage.

[0285] During the conveying stage, preferably, each layer is conveyed separately from the other layers from the outlet 10a to the calendering unit 13. Thus, due to the preferred different paths defined by the conveyor 15, the different layers are stacked together only at the calendering unit 13.

[0286] More specifically, advantageously, during the transport phase, the layer can also be compacted by the compaction device 14 and may also be perforated to form distributed perforations on the layer so that the filaments interweave and seal at the perforations.

[0287] Therefore, the method preferably also includes a calendering stage.

[0288] During the calendering stage, the layers are calendered together using calendering apparatus 13.

[0289] Of course, the present invention also includes nonwoven fabric articles manufactured by the above method.

[0290] In another embodiment of the invention, the device 100 preferably includes a work area 10 and additional devices in the work area 10.

[0291] Preferably, the work area 10 includes at least two devices arranged side-by-side parallel to the main plane 1b. Furthermore, of these two devices, preferably only one is spunbond or meltblown type.

[0292] Therefore, under a given configuration, at least two different types of filaments fed by the device are simultaneously mixed at the outlet 10a of the working chamber 10.

[0293] In this way, different types of filaments form the same layer at the output of the workroom 10.

[0294] This is very important because, typically in common equipment, different filaments are not mixed before leaving the work chamber 10, but are stacked on the collection surface 11 through multiple consecutive work chambers equipped with a single arrangement of equipment.

[0295] In a particularly advantageous embodiment, preferably, the work area 10 includes at least three devices distributed parallel to the main plane 1b, such that at least three types of filaments (of which at least two are of different types) are mixed simultaneously in the work area 10.

[0296] Therefore, the equipment in the work area 10 can be configured in different ways.

[0297] First, one or more distribution directions 4a of each device are either parallel to the distribution plane 100a or may converge to the distribution plane 100a. This means, for example, in a device 100 with three devices, they may include a central device with distribution directions 4a parallel to or aligned with the distribution plane 100a, and side devices with distribution directions 4a converging toward the distribution plane 100a and thus incident on and inclined to the distribution direction 4a of the central device.

[0298] Of course, since the device can convey multiple filaments, and the conveying can be linear or tapered, each device can define a dispensing cone, such as... Figures 9a to 9f As shown, the distribution direction 4a is restricted within the distribution cone.

[0299] In addition, the device can be configured with specific types of features.

[0300] For example, in Figure 7 and Figure 9a In the illustrated embodiment, the work area 10 may include a spunbond unit, a meltblown unit, and a spunbond unit arranged in that order. This configuration allows for the simultaneous mixing of filaments to obtain an SMS-type layer, which is particularly advantageous for diaper manufacturing.

[0301] Or, in Figures 9b to 9e In the illustrated embodiment, the work area 10 may include a cellulose or viscose dispensing device, a spunbond or meltblown device, and a cellulose or viscose dispensing device arranged in that order.

[0302] Similar to common meltblown and spunbond devices, cellulose or viscose dispensing devices are already known and therefore will not be described in detail here.

[0303] The above configuration allows for the simultaneous mixing of filaments to obtain the absorbent layer, which is particularly advantageous for manufacturing wet wipes or similar products.

[0304] Or again, in Figure 9f In the illustrated embodiment, the work area 10 may include a meltblown or spunbond device, a cellulose or viscose dispensing device, and a meltblown or spunbond device arranged in that order.

[0305] If there are one or more meltblown units in workshop 10, one of them can be a tip-type ( Figure 9a ) or multi-row coaxial type ( Figures 9e to 9f ).

[0306] Furthermore, in the case of one or more spunbond devices in the workroom 10, they are preferably, but not necessarily, configured as the device 1 according to the invention.

[0307] The above-described configuration of the apparatus 100 according to the present invention realizes a new method for manufacturing nonwoven fabric articles.

[0308] This method is of course implemented by device 100.

[0309] Therefore, the method preferably includes at least one mixing stage.

[0310] During the mixing stage, preferably, at least two different types of filaments dispensed from the device at the outlet 10a of the working chamber 10 are mixed simultaneously.

[0311] As mentioned above, filaments can also be mixed in three quantities simultaneously.

[0312] The method then includes a dispensing stage. In the dispensing stage, a monolayer made of mixed filaments of different types is dispensed from the workroom 10 through outlet 10a.

[0313] Therefore, the method includes a deposition stage. In the deposition stage, the layer is collected on a collection surface 11 or on a roll. Thus, layers deposited in this manner are capable of creating nonwoven articles with significantly improved mechanical properties.

[0314] Of course, the present invention also includes articles manufactured by the above method.

[0315] The device 100 according to the present invention can also be configured in different ways.

[0316] For example, device 100 may include a work area 10 as described, a collection surface 11, and a device configured to dispense at least one filament selected from polymers, cellulose, or viscose along one or more dispensing directions 4a transverse to the main plane 1b toward an outlet 10a.

[0317] All of these features have been described in detail above.

[0318] However, in a further embodiment of the invention, the device 100 may also include a conveyor station 12.

[0319] In this configuration, the conveyor station 12 is preferably placed between the work area 10 and the collection surface 11. In particular, in a preferred embodiment, the conveyor station 12 is also placed next to the outlet 10a in order to advantageously close the outlet 10a.

[0320] Alternatively, in an alternative embodiment, or even in combination with the foregoing embodiments, the conveying station 12 is placed next to the collection surface 11.

[0321] Therefore, the conveying station 12 includes at least one rolling element 12a.

[0322] The rolling element 12 preferably extends parallel to the main plane 1b. Therefore, the rolling element 12 preferably rotates about an oriented axis of rotation, for example, parallel to, perpendicular to, or inclined relative to the main axis 1a. Thus, advantageously, the rolling element 12a is configured to convey the filaments of the filament layer onto the collecting surface 11 in an orderly manner, particularly by orienting the filaments perpendicular to or parallel to the collecting surface 11.

[0323] Of course, the rolling element 12a can be fixed or selectively pivoted relative to the spindle 1a.

[0324] In addition, the rolling element 12a may include a first roller 13a or a second roller 14a, or may be composed of a first roller 13a or a second roller 14a.

[0325] More specifically, the rolling element 12a includes an additional contact surface 120. The additional contact surface 120 may also include a first contact surface 130 and a second contact surface 140, or be composed of the first contact surface 130 and the second contact surface 140.

[0326] The additional contact surface 120 is the portion of the second rolling element 12a adapted to contact the filament flowing out from the outlet of the work chamber 10.

[0327] Therefore, the additional contact surface 120 can be smooth.

[0328] Alternatively, the additional contact surface 120 may include one or more knurlings. The knurlings (if present) are configured to pick up the filament from the outlet 10a along the dispensing plane 100a when the filament contacts the additional contact surface 120. Furthermore, the knurlings (if present) are also configured to release the filament in an orderly manner when the layer is released from the additional contact surface 120.

[0329] In a particularly advantageous embodiment of device 100, the additional contact surface 120 preferably includes a plurality of additional pins 121. The additional pins 121 may also correspond to a first pin 131 or a second pin 141.

[0330] Additional needles 121 (if present) are radially distributed along and around the axis of rotation. In addition, additional needles 121 protrude from additional contact surface 120.

[0331] Therefore, given the configuration, the additional needle 121 is configured to pierce the nonwoven layer conveyed from the outlet 10a to form distributed perforations on the layer. Advantageously, at the perforations, the filaments will interweave and seal with each other.

[0332] The conveyor station 12 of the equipment 100 can also be configured in different ways.

[0333] For example, in Figures 8a to 8b and Figures 9a to 9f In the first embodiment shown, the conveying station 12 preferably includes at least one pair of rolling elements 12a that rotate in opposite directions. Furthermore, the rolling elements 12a are configured such that the layer passes between the rolling elements 12a before being deposited on the collection surface 11.

[0334] In another embodiment, such as Figure 8b , Figure 9a and Figure 9e As shown, the conveyor station 12 may include two pairs of rolling elements 12a.

[0335] Furthermore, the pair of rolling elements 12a may include the same additional contact surface 120. Alternatively, as in... Figure 9d In one embodiment, a pair of rolling elements 12a may include different additional contact surfaces 120, in particular, for example, one is smooth and the other includes a needle, or even one is smooth and the other is knurled, or one is knurled and the other includes a needle.

[0336] In embodiments with a single rolling element 12a, particularly if the rolling element 12a is as follows: Figure 8c If the rolling element 12a is placed close to the collecting surface 11, it preferably includes an additional contact surface 120 equipped with an additional needle 121.

[0337] Finally, the aforementioned equipment 100 may also include a calendering apparatus 13.

[0338] The calendering unit 13 (if present) is located downstream of the conveyor station 12.

[0339] Then, the calendering apparatus 13 interacts with the nonwoven fabric layer on the collection surface 11 to produce nonwoven fabric articles.

[0340] The above-described configuration of the apparatus 100 according to the present invention realizes a new method for manufacturing nonwoven fabric articles.

[0341] This method is of course implemented by device 100.

[0342] Therefore, the method preferably includes at least one allocation stage.

[0343] During the dispensing stage, preferably, a filament layer selected from polymers, cellulose, or viscose is dispensed from outlet 10a along dispensing plane 100a.

[0344] The method further preferably includes a transport phase.

[0345] During the conveying stage, the layered filaments are conveyed in an orderly manner to the collection surface 11 via the conveying station 12, wherein the filaments are oriented perpendicular to or parallel to the collection surface 11.

[0346] More specifically, advantageously, during the transport phase, the layer is also perforated to form distributed perforations on the layer, allowing the filaments to interweave and seal at the perforations.

[0347] The method then further includes a deposition stage. In the deposition stage, preferably, a layer is deposited on the collection surface 11 to obtain the article.

[0348] If a calender 13 is also present, the method further includes a calendering stage in which the layers are calendered downstream of the conveyor station 12 to obtain the product.

[0349] Of course, the present invention also includes nonwoven fabric articles manufactured by the above method.

[0350] The apparatus 1 for manufacturing nonwoven fabrics, the equipment 100 for manufacturing nonwoven fabrics, the method for manufacturing nonwoven fabric articles, and the nonwoven fabric articles according to the present invention have significant advantages.

[0351] In practice, existing spunbond devices typically cannot include spinnerets that are too wide. This is because air is only delivered to the filaments at the spinneret outlet and sides, and cannot reach the center of the fibers. This causes uncooled fibers to stick together or not crystallize when dripping from the spinneret, thus seriously damaging product quality.

[0352] In contrast, device 1 also allows the filaments to be cooled inside the spinneret 4, achieving more effective and efficient fiber cooling, and most importantly, more uniform cooling.

[0353] Therefore, compared with the prior art, device 1 allows for an increase in the number of fibers extruded from spinneret 4, thereby significantly increasing the kilograms of filament produced;

[0354] In addition, considering that in existing spunbond devices, cooling air reaches the filament from the side and should theoretically be able to reach the center of the spinneret, the layout of the polymer fluid outlet holes must always have holes that are staggered and spaced far enough apart so that air can reach the center.

[0355] In contrast, device 1 allows the filament to be cooled from above, thus allowing multiple extrusion orifices, and possibly even multiple spinnerets 4, to work alongside different extrusion technologies, such as spunbond and meltblown spinnerets, to simultaneously form a single layer on the same device 1.

[0356] Regarding equipment 100, which typically uses known technology, if the intention is to produce nonwoven fabric for diaper production, it is necessary to laminate five layers of nonwoven fabric together and then calender all five layers together. This requires five different devices in the machine, each equipped with at least three devices with spunbond spinnerets and one with meltblown spinnerets. As you can imagine, this increases the cost of the product. Laminating and calendering more layers of nonwoven fabric together will inevitably lead to a reduction in the mechanical quality of the final product.

[0357] In contrast, using the device 100 according to the invention, two or three devices can be arranged side by side, whether combined into one unit or with separate component settings, and can work simultaneously with several different types of spinnerets. Thus, the devices in the same workroom 10 have the potential of three device heads of the prior art, thereby significantly reducing the costs of investment, maintenance, and electricity and air consumption.

[0358] Furthermore, the simultaneous blending of different types of filaments (such as SMS type) before leaving the workshop greatly improves the quality of the product and significantly alters its technical-mechanical and aesthetic properties.

[0359] Furthermore, if there is a cellulose or viscose dispensing device equipped with a corresponding conveyor or editor from which cellulose and / or viscose or other materials flow; and if there is a polymer filament dispensing device that encounters the mixed cellulose and / or viscose as they flow out, then device 100 makes it possible to manufacture a single-layer fabric composed of a portion of polymer fibers and a portion of cellulose and / or viscose, cotton or other materials.

[0360] Finally, while known equipment only allows the manufacture of articles with good mechanical strength in one direction, equipment 100 allows the filaments to be oriented via conveyor station 12, so that they can be deposited on collection surface 11 not only in one direction but also in different directions, for example, at an angle to the feed direction of collection surface 11. This different positioning of the filaments before passing through the calender allows the mechanical strength of the formed layer to be enhanced in both directions.

[0361] Furthermore, the conveying station 12, having at least one of its rolling elements 12a including an additional needle 121, allows the filaments to be oriented while perforating the layers formed by the filaments to partially seal them together before passing through the calender. This allows the articles thus manufactured to have additional mechanical strength on both sides.

[0362] Finally, the device 100 conveys filament layers that are not deposited on the collection surface, and the conveying of different types of filaments is carried out along a separation path, so that the individually compacted layers can be calendered without depositing on other layers, allowing the production of nonwoven products with better performance and greater durability, with stronger layers and stronger seals between different layers, thereby increasing the performance of the products, especially when they are used to manufacture diapers or wipes.

[0363] This invention can be modified to create different versions that fall within the scope of the inventive concept defined by the claims.

[0364] In this case, all details can be replaced by equivalent components, and any material, shape, and size can be used.

Claims

1. An apparatus (100) for manufacturing nonwoven fabrics, the apparatus (100) comprising a plurality of different devices for manufacturing nonwoven fabrics, each device extending along a main axis (1a) and a main plane (1b) and configured to dispense a plurality of polymer or cellulose or viscose filaments via an outlet (10a) along and parallel to one or more dispensing directions (4a) transverse to the main plane (1b), and to form a corresponding layer of filaments from the outlet (10a) along or parallel to a dispensing plane (100a) transverse to the main axis (1a) and the main plane (1a); Its features are, The device (100) also includes: - A conveyor station (12), located downstream of the outlet (10a), and comprising: - A calendering apparatus (13) configured to calender the layers together, and - One or more conveyors (15), each conveyor (15) is placed between the respective outlet (10a) and the calendering device (13) and is configured to convey the respective layer separately from the other layers to the calendering device (13) such that the layers are stacked together only at the calendering device (13).

2. The device (100) according to claim 1, wherein the conveying station (12) includes a compaction device (14) disposed downstream of one or more of the outlets (10a), each compaction device being located between the outlet (10a) and the calendering device (13) and configured to compress the layer before the layer is conveyed to the calendering device (13) so that the filaments of the layer interweave and seal with each other.

3. The device (100) according to the preceding claims, wherein one or more conveyors (15) are located between the compaction device (14) and the calendering device (13).

4. The apparatus (100) according to any of the preceding claims, wherein each of the one or more conveyors (15) includes a collection surface (11) extending transversely to the distribution plane (100a) downstream of the outlet (10a) to collect the layer flowing out from the outlet (10a) and convey the layer to the calendering apparatus (13).

5. The apparatus (100) according to any of the preceding claims, wherein the calendering unit (13) is spaced apart from at least one of the one or more conveyors (15), and at least one of the one or more conveyors (15) extends cantileveredly from the calendering unit (13).

6. The apparatus (100) according to any of the preceding claims, wherein the calendering device (13) comprises at least a pair of counter-rotating first rollers (13a), the first rollers (13a) extending parallel to the main plane (1b) and rotating about respective rotation axes oriented relative to the main shaft (1a), and configured to convey the layer away from the outlet (10a) under pressure.

7. The device (100) according to the preceding claim, wherein one or more of the rollers (13a) include a first contact surface (130), the first contact surface (130) being smooth or including one or more knurled surfaces, the first contact surface (130) being configured to draw the layer from the outlet (10a) when the filament contacts the first contact surface (130), and to release the filament in an orderly manner when the layer is released from the first contact surface (130).

8. The device (100) according to the preceding claim, wherein the first contact surface (130) includes a plurality of first needles (131) radially distributed along and around the axis of rotation, protruding from the first contact surface (130) and configured to pierce a layer of the nonwoven fabric dispensed from the outlet (10a) to form distributed perforations in the layer, such that the filaments interweave and seal at the perforations.

9. The apparatus (100) according to any of the preceding claims, wherein the compaction device (14) comprises at least a pair of counter-rotating second rollers (14a), the second rollers (14a) extending parallel to the main plane (1b) and rotating about respective rotation axes oriented relative to the main shaft (1a), and configured to convey the layer from the outlet (10a) toward the calendering device (13) under pressure.

10. A method of manufacturing a nonwoven article using the apparatus (100) according to any of the preceding claims, comprising dispensing a plurality of layers of polymer or cellulose or viscose type filaments from the outlet (10a) along the respective dispensing plane (100a); Its features are, Also includes: - Each of the layers is separately conveyed from the outlet (10a) to the calendering apparatus (13), such that the layers are stacked together only at the calendering apparatus (13), and - The layer is rolled using the rolling apparatus (13).

11. A nonwoven article manufactured by the method according to claim 10.

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