Method and apparatus for producing nonwoven fabric material from fibers

Abstract

A method for producing a nonwoven material from fibers, comprising: at least one meltblown spinneret producing endless filaments from a thermoplastic resin; and at least one defibrator producing short pulp fibers. In the defibrator, at least one short fiber air stream is formed from the short pulp fibers, which is guided through an outlet channel and flows out of the outlet channel toward an air-permeable delivery sheave belt with an initial volume flow rate V1 and a flow direction S1. The endless filaments flow from the at least one meltblown spinneret as a filament air stream toward the short fiber air stream with an initial volume flow rate V2. The filament air stream and the short fiber air stream are guided together in a contact area above the delivery sheave belt and delivered as an endless filament short fiber mixture onto the delivery sheave belt in the delivery area to form a nonwoven material or a nonwoven web. In the delivery area of ​​the fibers or the endless filament short fiber mixture, air or process air is sucked through the delivery sieve belt from below with a volume flow rate V4, which is greater than the sum of the volume flows V1 and V2.

Description

[Technical Field]

[0001] The present invention relates to a method for producing a nonwoven fabric material from fibers, wherein an endless filament is produced from a thermoplastic resin by at least one meltblown spinneret, preferably at least two meltblown spinnerets, and further, pulp short fibers are produced by at least one defibration device, in which at least one short fiber airflow is formed from the pulp short fibers in the defibration device, the endless filament flows as a filament airflow from at least one meltblown spinneret, and the endless filament and pulp short fibers are fed onto a feeding sieve-like belt in a feeding area to form a nonwoven fabric material or a nonwoven web. The present invention further relates to an apparatus for producing a nonwoven fabric material from fibers. The term fiber means both endless filaments and short fibers within the scope of the present invention. An endless filament is based on the length of its nearly endless short fibers and differs from short fibers having extremely short lengths, for example, from 0.1 mm to 60 mm. A nonwoven fabric material comprising at least an endless filament or melt-blown endless filament and short fibers or pulp short fibers can be produced by the method or apparatus according to the present invention. [Background technology]

[0002] The methods and apparatus described at the beginning are basically known in various forms in practice. Nonwoven fabrics containing pulp short fibers are excellent in their extremely high liquid absorbency. These pulp short fiber-based nonwoven fabrics are used, exemplarily, in liquid-absorbing cloths, such as wiping cloths. The liquid may be water or aqueous liquids in particular. However, it has been found that in the manufacture of nonwoven fabrics containing pulp short fibers, there is a trade-off between the high liquid absorbency of the nonwoven fabric and sufficient stability or strength. It is known that a mixture of endless filaments and pulp short fibers is used in the nonwoven fabric to stabilize or mechanically stabilize the nonwoven fabric. In this case, the endless filaments are essentially important for the strength or stability of the nonwoven fabric, while the pulp short fibers ensure the liquid absorbency of the resulting product. However, in such nonwoven fabrics consisting of endless filaments and pulp short fibers, there is still a need for improvement regarding the optimal compromise between liquid absorbency and mechanical strength. Furthermore, it has been found that, in practically known methods, a uniform distribution of endless filaments and pulp short fibers in the final product remains undesirable. There is a need for improvement in this respect as well, because if the endless filaments and pulp short fibers are distributed very uniformly, a satisfactory compromise between the mechanical strength and liquid absorbency of the nonwoven material can be achieved even if the proportion of endless filaments is relatively small. [Overview of the project] [Problems that the invention aims to solve]

[0003] In contrast, the fundamental technical problem of the present invention is to provide a method, as described above, that can produce a nonwoven fabric material comprising endless filaments or melt-blown endless filaments and short fibers or pulp short fibers, which is excellent in finding the optimal compromise between strength or stability and liquid absorbency, and in particular exhibits high uniformity in the distribution of endless filaments and pulp short fibers. Furthermore, a fundamental technical problem of the present invention is to provide an apparatus for producing such a nonwoven fabric material. [Means for solving the problem]

[0004] To solve this technical problem, the present invention provides a method for producing a nonwoven fabric material from fibers, comprising: producing an endless filament from a thermoplastic resin using at least one meltblown spinneret, preferably at least two meltblown spinnerets; further producing pulp short fibers using at least one defibration device, wherein at least one short fiber airflow is formed from the pulp short fibers in the defibration device, the short fiber airflow is guided through an outlet channel, advances from the outlet channel, and flows toward a permeable discharge sieve-like belt with an initial volumetric flow rate V1 and flow direction S1. The endless filament flows from at least one meltblown spinneret as a filament airflow, with an initial volumetric flow rate V2, toward the short fiber airflow. The filament airflow and the short fiber airflow are guided together in a contact area above the delivery sieve-like belt, and are fed onto the delivery sieve-like belt in the delivery area as an endless filament short fiber mixture, forming a nonwoven fabric material or nonwoven web. In the delivery region for fibers or endless filament short fiber mixtures, air or process air is drawn in from below through a delivery sieve-like belt at a volumetric flow rate V4, where the volumetric flow rate V4 is greater than the sum of the volumetric flow rates V1 and V2.

[0005] Within the scope of the method according to the present invention, a molten-fluid plastic filament is produced by a meltblown spinneret or a plurality of meltblown spinnerets and extruded by a high-speed blown air stream. The blown air also, for purposeful purposes, advances from the meltblown spinneret, and in this case, the blown air is preferably warm or high-temperature blown air. In this case, a filament air stream consisting of the produced endless filament and blown air flows from at least one or a plurality of meltblown spinnerets toward a short-fiber air stream. The configuration of one or more meltblown spinnerets, particularly with respect to the advancement of the molten-fluid plastic filament and blown air, will be described in more detail later.

[0006] According to the present invention, the endless filament is made from a thermoplastic resin. Within the scope of the method according to the present invention, the endless filament is preferably made from at least one polyolefin. The at least one polyolefin is preferably polypropylene and / or polyethylene, and preferably polypropylene. In principle, the endless filament may be made from polyester, for example polyethylene terephthalate, or other thermoplastic resins such as polyamide or mixtures of the aforementioned thermoplastic materials. The endless filament or meltblown endless filament is recommended to have an average filament diameter in the range of 0.2 μm to 15 μm, preferably 0.5 μm to 12 μm, and preferably 0.5 μm to 10 μm.

[0007] Within the scope of the present invention, the term "pulp" specifically refers to fibrous materials based on cellulose or crystalline fiber. For purposes, solid pulp is used within the scope of the methods according to the present invention. The term "solid pulp" specifically refers to dry materials based on cellulose or crystalline fiber. Particularly preferably, within the scope of the present invention, a web made of solid pulp is used and defibrated into pulp short fibers by at least one defibration device. The pulp used within the scope of the methods according to the present invention is preferably prepared. The pulp short fibers produced by at least one defibration device have, for purposes, a length or average length of 0.05 mm to 5 mm, preferably 0.1 mm to 4 mm, and particularly preferably 0.1 mm to 3 mm.

[0008] According to a preferred embodiment of the present invention, the defibration device is a sawmill. According to the present invention, in the defibration device, a short fiber airflow is formed from pulp short fibers, the short fiber airflow is guided through an outlet channel, advances from the outlet channel at an initial volumetric flow rate V1, and flows toward a permeable discharge sieve-like belt in the flow direction S1. The outlet channel is, for the purposes of this invention, part of the defibration device or connected to the defibration device. Within the scope of the present invention, the initial volumetric flow rate V1 means the volumetric flow rate of the short fiber air mixture immediately after it advances from the outlet channel.

[0009] According to a preferred embodiment of the present invention, the breathable sheave-shaped belt for dispensing is a continuously movable breathable sheave-shaped belt, particularly a sheave-shaped belt that circulates endlessly.

[0010] According to the present invention, the fabricated endless filament flows from at least one meltblown spinneret as a filament airflow towards a short-fiber airflow at an initial volumetric flow rate V2. In this case, the initial volumetric flow rate V2 refers specifically to the volumetric flow rate of the filament airflow located immediately below the meltblown spinneret after the blown air has been applied to the endless filament.

[0011] According to the present invention, in the delivery area of the fiber or endless filament staple fiber mixture or at least in the delivery area, air or process air is sucked through the delivery sieve-shaped belt. For this purpose, expediently, at least one suction device or suction fan is arranged below the delivery sieve-shaped belt, particularly below the delivery area. According to the present invention, the volume flow rate V4 sucked through the delivery sieve-shaped belt is greater than the sum of the volume flow rates V1 and V2, so V4 > (V1 + V2) holds. According to a particularly preferred embodiment of the method according to the present invention, the volume flow rate V4 corresponds to 1.05 to 30 times, preferably 5 to 25 times, suitably 10 to 20 times the sum of the volume flow rates V1 and V2.

[0012] According to a particularly preferred embodiment of the present invention, at least two meltblown spinnerets, particularly two meltblown spinnerets, are provided. The endless filament preferably flows as a second filament air flow in the direction of the short fiber air flow with an initial volume flow rate V3 from the second meltblown spinneret. The initial volume flow rate V3 in this case particularly means the volume flow rate present immediately below the meltblown spinneret or the second meltblown spinneret after blowing air onto the endless filament. Particularly preferably in this case, the volume flow rate V4 is greater than the sum of the volume flow rates V1, V2, and V3, so particularly V4 > (V1 + V2 + V3) holds. According to a particularly preferred embodiment of the method according to the present invention, the volume flow rate V4 corresponds to 1.05 to 30 times, preferably 5 to 25 times, suitably 10 to 20 times the sum of the volume flow rates V1, V2, and V3.

[0013] It is recognized that the filament air flow flows on the upstream side of the short fiber air flow in the feed direction F of the delivery sieve-shaped belt, and the second filament air flow preferably flows on the downstream side of the short fiber air flow in the feed direction F of the delivery seal-shaped belt.

[0014] Within the scope of the present invention, the filament airflow flows in its flow direction S2 at an angle α1 with respect to the flow direction S1 of the short fiber airflow, at least partially or in part. Purposefully, the second filament airflow flows in its flow direction S3 at an angle α2 with respect to the flow direction S1 of the short fiber airflow, at least partially or in part. A particularly preferred embodiment of the present invention is characterized in that angles α1 and / or angles α2 are greater than 10°, particularly preferably greater than 20°, and especially preferably greater than 25°. Thus, within the scope of the present invention, the two filament airflows flow toward the short fiber airflow. The fact that one or more filament airflows flow at an angle α1 or α2 with respect to the flow direction S1 of the short fiber airflow in its flow direction S2 or S3 means, within the scope of the present invention, in particular, that the flow vector of the filament airflow extends at an angle α1 or α2 with respect to the flow direction S1 or flow vector of the short fiber airflow, at least partially or in part. Within the scope of this invention, the terms flow direction and flow vector refer, in particular, to the average flow direction or flow vector of each flow.

[0015] Within the scope of the present invention, particularly preferably, at least one filament airflow, particularly multiple filament airflows, flow at an angle α1 or α2 with respect to the flow direction S1 of the short fiber airflow, at least in the contact region or just before the contact region, in their flow direction S2 or S3. In this case, angles α1 and α2 refer particularly to the inclination angle at which the filament airflow contacts the short fiber airflow in the contact region. According to a preferred embodiment of the present invention, at least one filament airflow, particularly two filament airflows, flow at an angle α1 or α2 with respect to the flow direction S1 of the short fiber airflow, in their flow direction, along the overall flow path, particularly straight or essentially straight, from their respective meltblown spinneret to the contact region. In this case, particularly preferably, at least one filament airflow or multiple filament airflows and / or short fiber airflows flow from the meltblown spinneret or outlet channel toward the contact region without any guide means.

[0016] As already mentioned above, the angle α1 and / or the angle α2 are greater than 10°, particularly preferably greater than 20°. It has been demonstrated that the angle α1 and / or the angle α2 are greater than 25°, preferably greater than 30°, suitably greater than 35°, for example greater than 40°. It is recommended that the angle α1 and / or the angle α2 have values in the range from 10° to 75°, preferably from 20° to 70°, particularly preferably from 25° to 65°, especially preferably from 30° to 65°, for example from 35° to 60°. Within the scope of the present invention, the angle α1 and the angle α2 have the same value, so that the two fiber air flows abut symmetrically on both sides in the contact area, particularly on both sides with respect to the short fiber air flow or the central short fiber air flow. Moreover, in principle, the angle α1 and the angle α2 may have different values.

[0017] According to a preferred embodiment of the method according to the present invention, the short fiber air flow flows from the outlet channel or the end of the outlet channel in its flow direction S1 perpendicular or substantially perpendicular to the sheave belt surface of the delivery sheave belt. Therefore, the flow direction S1 of the short fiber air flow is directed particularly perpendicular or substantially perpendicular to the sheave belt surface of the breathable delivery sheave belt. This means, within the scope of the present invention, in particular that the flow vector of the short fiber air flow extends perpendicular or substantially perpendicular to the planar extension of the sheave belt surface.

[0018] It is within the scope of the present invention that secondary air is sucked in in the space between the short fiber air flow and the filament air flow and / or in the space between the short fiber air flow and the second filament air flow. In this case, the secondary air is sucked in particularly at a volume flow rate V sek and V sek is, expediently, the total volume flow rate of the entire secondary air being sucked in. In this case, preferably, V4≧(V1 + V2 + V sek ) and / or V4≧(V1 + V2 + V3 + V sek ) holds. V4 is the sum of the volume flow rates V1, V2, V sek and / or the volume flow rates V1, V2, V3, V sekIt is recommended that the total amount be between 1 and 30 times, preferably between 5 and 25 times, and more preferably between 10 and 20 times. Within the scope of the present invention, the term secondary air means air that is drawn in by the flow motion of the filament airflow and / or short fiber airflow, and does not correspond to the blown air from the meltblown spinneret and the air that enters the outlet channel together with the pulp short fibers. Within the scope of the present invention, the blown air from the meltblown spinneret and the air that enters the outlet channel together with the pulp short fibers are specifically referred to as primary air. In addition, within the scope of the present invention, the term air includes gaseous or fluid mixtures similar to air.

[0019] Purposefully, the short-fiber airflow is accelerated in the outlet channel, particularly by a fan in the defibration device. Therefore, according to a preferred embodiment, the defibration device has a fan that supplies air to the defibration device. It is within the scope of the present invention that the airflow for forming the short-fiber airflow is formed in the defibration device by the defibration process and / or by a fan. According to one preferred embodiment of the present invention, the defibration device is a saw mill. In this case, the airflow for forming the short-fiber airflow is preferably formed by the grinding process in the saw mill and / or by a fan in the saw mill. According to a more preferred embodiment, the short-fiber airflow accelerated in the outlet channel exits the outlet channel at an initial volumetric flow rate V1.

[0020] According to one particularly preferred embodiment of the present invention, at least one meltblown spinneret has a plurality of spinneret openings arranged in a row and preferably two air inlet gaps that extend parallel to the row of spinneret openings on both sides and are inclined toward the spinneret openings, through which blown air enters. Purposefully, at least two, particularly two, meltblown spinnerets are configured in this way. When one or more meltblown spinnerets have a plurality of spinneret openings arranged in a row, within the scope of the present invention, it particularly means that the meltblown spinneret has only a single row of spinneret openings. Such a meltblown spinneret is also called a single-row spinneret. Purposefully, one or more meltblown spinnerets each have at least two, particularly two, air inlet gaps, the air inlet gaps extending parallel to the row of spinneret openings on both sides. Extending parallel to each other on both sides of the air intake gap means, within the scope of the present invention, in particular, that the longitudinally extended portion of the air intake gap extends parallel to the longitudinally extended portion of the row of die openings. Furthermore, the air intake gap is preferably inclined toward the die opening or toward the row of die openings. This achieves, in particular, that the blown air or planar blown airflow advancing from the air intake gap is applied to the curtain of extruded endless filaments from the side or from the opposite side at an inflow angle. The inflow angle of the blown air with respect to the flow direction of the formed endless filaments is preferably less than 30°, and more preferably less than 20°. Preferably, the blown air is applied uniformly or symmetrically to the endless filaments arriving from two air intake gaps of one or more meltblown spinnerets. Furthermore, in principle, the two air inlet gaps of the meltblown spinneret also allow for non-uniform or asymmetrical action on the endless filament with respect to the temperature and / or volumetric flow rate of the blown air.

[0021] According to another preferred embodiment of the present invention, at least one meltblown spinneret has a plurality of spinneret openings arranged in a plurality of rows, in which case preferably each spinneret opening is assigned one air inlet opening or its own air inlet opening from which blown air enters. Such a meltblown spinneret having a plurality of rows of spinneret openings for the entry of molten, fluid plastic filaments is also referred to as a multi-row spinneret. It is within the scope of the present invention that at least two, in particular two, meltblown spinnerets are configured in this manner. It is within the scope of the present invention that each spinneret opening of a meltblown spinneret has one air inlet opening or its own air inlet opening, in particular that the corresponding air inlet opening is directly assigned to or assignable to the spinneret opening. It is within the scope of the present invention that the air inlet openings of a meltblown spinneret surround each spinneret opening and are arranged in particular coaxially with respect to the spinneret opening. In this case, for the purpose of the process, the blown air enters from an air inlet allocated to the nozzle opening, either parallel to the molten plastic or coaxial with the molten plastic filament, and surrounds the resulting filament to cover it.

[0022] According to another preferred embodiment of the present invention, at least one meltblown spinneret has a plurality of advance openings arranged in a plurality of rows of die openings and air inlet openings, wherein the advance openings or die openings and air inlet openings are preferably spaced apart from each other and arranged in a regular and / or irregular pattern, wherein preferably at least 90% of the air inlet openings, in particular each air inlet opening, are assigned at least two die openings, and / or preferably at least 90% of the die openings, in particular each die opening, are assigned at least two air inlet openings. It is within the scope of the present invention that at least two, in particular two meltblown spinnerets are configured in this way. This embodiment of the present invention is characterized in that each die opening from which a plastic molten material or molten-flowable plastic filament advances does not have its own air inlet opening directly assigned. Rather preferably, each die opening is assigned at least two air inlet openings. Blowing air advances from these air inlet openings, within the scope of this embodiment. Preferably, the die openings are configured such that only the polymer molten material advances from them, and the polymer molten material advances from the die openings without blown air that is directly assigned to each die opening or advances coaxially with respect to the die openings. For the purposes of this embodiment, only blown air advances from the air inlet openings. Within the scope of this preferred embodiment, some of the advance openings of the meltblown spinneret are configured in the form of die openings, and some or another of the advance openings are configured in the form of air inlet openings. Within the scope of this embodiment, it is preferable that the spacing between directly adjacent meltblown spinneret advance openings is the same or essentially the same in at least one die direction of the entire dieneret. More preferably, the proportion of die openings to the total number of advance openings is 10% to 50%, preferably 12% to 45%, and preferably 15% to 40%.

[0023] In a more preferred embodiment of the present invention, when at least two, particularly two, meltblown spindles are provided, preferably the two meltblown spindles or all of the meltblown spindles are identically configured with respect to the spindle opening and the air inlet opening or air inlet gap. Moreover, basically, at least two different meltblown spindles may be combined within the scope of the method according to the present invention. In other respects, preferably the advance opening of the meltblown spindle, particularly the spindle opening and / or air inlet opening, is formed in a round or circular shape.

[0024] The present invention provides a method for producing a nonwoven fabric consisting of endless filaments and pulp short fibers, particularly by the ratio of the sum of the initial volumetric flow rates of the short fiber airflow and one or more filament airflows to the volumetric flow rate drawn in through a delivery sieve-like belt, wherein the nonwoven fabric is excellent in its extremely high uniformity of distribution between endless filaments and pulp short fibers, and in particular in its optimal compromise between the stability or strength of the nonwoven material and its liquid absorbency. In this case, particularly advantageous results are obtained when one or more filament airflows flow at an angle to the flow direction of the short fiber airflow, and especially preferably two filament airflows flow symmetrically, inclined on both sides with respect to the central short fiber airflow. The endless filament short fiber mixture delivered onto the delivery sieve-like belt is, for the purposes of the purpose, the base material of endless filaments embedded with pulp short fibers.

[0025] According to a preferred embodiment of the present invention, water is sprayed onto an endless filament of at least one filament airflow, preferably multiple filament airflows, between the meltblown spinneret and the feed sieve-like belt, particularly on the side of the filament airflow opposite to the short-fiber airflow. Preferably, one or one water nozzle is provided for spraying water onto the endless filament, and the water nozzle is positioned particularly on the side of each filament airflow opposite to the short-fiber airflow. Thus, purposefully, at least one or more water nozzles are located outside the filament airflow. It is within the scope of the invention that the water nozzles are assigned to each meltblown spinneret and preferably positioned below the meltblown spinneret in the filament flow direction, particularly immediately below. Thus, the endless filament is sprayed with water after it has emerged from the meltblown spinneret, particularly immediately after it has emerged. This allows for proper cooling of the fabricated endless filament.

[0026] Preferably, the short-fiber airflow enters the outlet channel at a rate of 0.0138 kg to 0.0833 kg, preferably 0.0222 kg to 0.0694 kg, and preferably 0.0277 kg to 0.05 kg of pulp short fibers per kg of air. It is recommended that the short-fiber airflow enters the outlet channel at a rate of pulp short fibers exceeding 0.0138 kg, preferably exceeding 0.0222 kg, and preferably exceeding 0.0277 kg per kg of air. Purposefully, the rate of pulp short fibers per kg of air can be controlled in an open-loop and / or closed-loop manner by the speed of the defibration device, and in particular, by the draw-in speed of the defibration device.

[0027] More preferably, at least one or more filament airflows advance from the meltblown spindle at a rate of 0.002 kg to 0.5 kg, preferably 0.01 kg to 0.25 kg, preferably 0.015 kg to 0.12 kg, and particularly preferably 0.018 kg to 0.1 kg of endless filaments per kg of air. It is recommended that at least one, preferably more than one filament airflow, advance from the meltblown spindle at a rate of (each) greater than 0.002 kg, preferably greater than 0.01 kg, preferably greater than 0.015 kg, and particularly preferably greater than 0.018 kg of endless filaments per kg of air. It is also within the scope of the present invention that filament airflows, particularly two filament airflows, advance from the meltblown spindle at the same rate of endless filaments per kg of air. According to an alternative embodiment of the method according to the present invention, filament airflow, particularly two filament airflows, advances endless filaments from the meltblown spinneret at different rates per kilogram of air. The rate at which the filament airflow advances endless filaments from the meltblown spinneret per kilogram of air can be adjusted, according to a recommended embodiment of the present invention, by the mass flow rate of the thermoplastic resin and / or by closed-loop and / or open-loop control of the blown air advancing from the air inlet gap or air inlet opening of the meltblown spinneret. According to a particularly preferred embodiment of the present invention, the rate at which endless filaments are present in the extruded nonwoven material is 10% to 35% by weight, preferably 15% to 30% by weight, and more preferably 20% to 28% by weight.

[0028] As already mentioned above, according to an advantageous embodiment of the present invention, the short-fiber airflow is accelerated in the outlet channel by a fan in the defibration device. Preferably in this regard, the air drawn in by the fan in the defibration device is regulated. Particularly preferably, the regulated air drawn in by the fan has a relative air humidity of more than 65% at 28°C.

[0029] It is within the scope of the present invention that the outlet channel is height-adjustable relative to the surface of the sheave-shaped belt of the delivery sheave-shaped belt. Purposefully, the distance a between the end of the outlet channel and the surface of the sheave-shaped belt is 200 mm to 1000 mm, preferably 300 mm to 750 mm, more preferably 400 mm to 600 mm, and particularly preferably 460 mm to 530 mm. Therefore, the outlet channel or the end of the outlet channel is height-adjustable within this range relative to the surface of the sheave-shaped belt of the delivery sheave-shaped belt. Particularly preferably, the amount of secondary air drawn in can be controlled in a closed loop and / or open loop by adjusting the height of the outlet channel relative to the surface of the sheave-shaped belt of the delivery sheave-shaped belt. Within the scope of the method according to the present invention, the height of the outlet channel is V4 ≥ (V1 + V2 + V sek ) and / or V4 ≥ (V1 + V2 + V3 + V sekIt is recommended that the following conditions be met: In this case, the amount of secondary air drawn in means the amount of secondary air drawn in between the short fiber airflow and at least one, preferably two, filament airflows. The term outlet channel end means, within the scope of the present invention, the end of the outlet channel, particularly the end of the outlet channel closer to the delivery sieve-like belt. Preferably, the wall of the outlet channel is configured such that, in the region of the outlet channel end, the outlet channel end is formed to be constant, diffuse, or converge in the inner cross-section. This can affect the subsequent mixing of the endless filaments and pulp short fibers in the contact area. The distance a between the outlet channel end and the sieve-like belt surface is measured, within the scope of the present invention, particularly perpendicular to the sieve-like belt surface. The ability to control the amount of secondary air drawn in in a closed-loop and / or open-loop manner allows for an effect on the flow characteristics that makes the function more reliable, particularly with respect to secondary air supply. The height adjustment or height adjustment performance of the outlet channel or the end of the outlet channel allows for adjustment or control of the position of the contact area, particularly in combination with angles α1 and / or α2, within the scope of the present invention. This allows for advantageous influence on the mixing of the endless filament and the pulp short fibers, particularly in combination with the configuration of the outlet channel wall in the region of the outlet channel end, preferably with a constant configuration of the outlet channel wall in the region of the outlet channel end, in the inner cross-section.

[0030] According to the present invention, filament airflows, preferably multiple or two filament airflows and a short-fiber airflow, are guided together above a delivery sieve-like belt in a contact area. In this contact area, mixing of the filament airflows and short-fiber airflows preferably occurs. According to a preferred embodiment of the present invention, the endless filament short-fiber mixture flows from the contact area to the delivery sieve-like belt as a uniform or essentially uniform mixture. The flow characteristics according to the present invention and preferably the guidance of the short-fiber airflows and filament airflows together at a predetermined angle allow for optimal mixing and distribution of pulp short fibers and endless filaments within the scope of the present invention, so that a uniform or essentially uniform endless filament short-fiber mixture flows from the contact area to the delivery sieve-like belt and is delivered to form a woven material or nonwoven web. It is advantageous that the endless filament short-fiber mixture flows from the contact area to the delivery sieve-like belt or delivery area perpendicular or substantially perpendicular to the surface of the sieve-like belt with respect to its flow direction.

[0031] Within the scope of the present invention, a short-fiber airflow guides or conveys pulp short fibers at a rate of at least 50 kg / h / m, particularly at least 75 kg / h / m, preferably at least 100 kg / h / m, and particularly preferably at least 200 kg / h / m, with respect to the width of the delivery sieve-like belt. Within the scope of the present invention, the width of the delivery sieve-like belt means, in particular, the maximum width of the delivery sieve-like belt in the longitudinally extending portion of the delivery sieve-like belt or in the transverse, particularly perpendicular, portion of the delivery sieve-like belt with respect to the conveying direction. Within the scope of the present invention, at least two, particularly at least three, and preferably at least four defibration devices, preferably together with accompanying fans and / or outlet channels, can be arranged along the width of the delivery sieve-like belt. In this way, even a delivery sieve-like belt with a width of at least 1 m, particularly at least 2 m, preferably at least 3 m, and preferably at least 4 m, can be supplied with particularly uniform pulp short fibers or a short-fiber airflow across the entire width of the delivery sieve-like belt.

[0032] A particularly preferred embodiment of the method according to the invention is that the non-woven material or non-woven web is solidified by at least one calendar, wherein preferably an embossing pattern is processed into the non-woven material or non-woven web by at least one calendar. It is recommended to perform the solidification "inline" by at least one calendar. This means, within the scope of the present invention, in particular that the solidification by at least one calendar is carried out following the delivery of the endless filament staple fiber mixture and a non-woven material or non-woven web is produced. According to an alternative and preferred embodiment of the method according to the invention, the solidification of the non-woven material or non-woven web by at least one calendar is carried out "offline". This means, within the scope of the present invention, in particular that the non-woven material or non-woven web is taken off the delivery sheave-shaped belt and wound up after being delivered onto the delivery sheave-shaped belt, and is fed out again at a later point and supplied to at least one calendar.

[0033] It is recommended that at least one calendar has at least one calendar roller pair, through which the non-woven material or non-woven web is preferably pressed and guided. Expediently, one of the calendar rollers of the calendar is a smooth roller with a smooth outer surface and / or one of the calendar rollers of the calendar has an embossing pattern on its outer surface. According to a preferred embodiment of the present invention, the calendar or the calendar roller pair is temperature-controlled. The temperature of the calendar roller is preferably lower than the melting point of the thermoplastic resin of the endless filament within the scope of the present invention. Preferably, the calendar roller temperature is between 50 °C and 150 °C within the scope of the method according to the invention. It is also within the scope of the present invention that the linear pressure of one or more calendar rollers is between 10 daN / cm and 120 daN / cm.

[0034] Particularly preferably, the embossing pattern is formed without interruption, and the basic geometric shape of the embossing pattern is from 20 mm 2 to 50 mm 2 and preferably 25 mm2 From 45mm 2 Preferably 30 mm 2 From 40mm 2 Particularly preferred is 32.5 mm 2 37.5mm 2 The press surface has a range of dimensions. Within the scope of the present invention, the basic geometric pattern means, in particular, a geometric shape based on the repeating elements of the embossed pattern. Naturally, in this regard, the basic geometric pattern or repeating elements are preferably the same size or essentially the same size, so that the resulting embossed pattern is a regular embossed pattern. Within the scope of the present invention, an uninterrupted embossed pattern is a honeycomb structure, and its basic geometric pattern or repeating elements are purposefully hexagonal or regular hexagonal. In this case, the embossed pattern preferably consists of a plurality of adjacent regular hexagons of the same size, where the inner surfaces of the hexagons preferably form the non-pressed portions of the embossed area.

[0035] According to another preferred embodiment of the present invention, the embossed pattern is formed from a plurality of elements, preferably dots and / or lines, which have interrupted portions and are not connected to one another, in this case the elements are purposefully 2 mm 2 Smaller than, preferably 1.5 mm 2 Smaller than, preferably 1.1 mm 2 Smaller than, particularly preferably 0.55 mm 2 Each has a smaller press surface. Within the scope of the present invention, it is also possible to combine an uninterrupted embossed pattern with an embossed pattern having interrupted portions.

[0036] Advantageously, the height of the basic geometric pattern shapes or elements of the embossed pattern is 0.3 mm to 2.0 mm, preferably 0.4 mm to 1.8 mm, and more preferably 0.5 mm to 1.6 mm. In this case, the height of the basic geometric pattern shapes means the difference in height between the pressed and unpressed areas of the embossed pattern, or the average difference in height. Furthermore, the proportion of the pressed surface of the embossed pattern on the entire surface of the nonwoven material or nonwoven web is 2.5% to 25%, preferably 5% to 15%, and more preferably 5.25% to 12.5%, which is within the scope of the present invention.

[0037] In addition, naturally, with respect to the aforementioned forms of the embossed pattern, the corresponding rollers of a pair of calendar rollers having an embossed pattern have complementary embossed patterns on their outer surfaces. The calendar or calendar roller has, in particular, a press surface portion or press surface of 2.5% to 25%, preferably 5% to 15%, and more preferably 5.25% to 12.5%.

[0038] To solve the technical problems, the present invention further teaches an apparatus for producing a nonwoven material from fibers by the method described above, in which the apparatus comprises at least one meltblown spinneret, preferably at least two meltblown spinnerets, for producing endless filaments from a thermoplastic resin, and further comprises at least one defibration device for producing pulp staples and an outlet channel for guiding the pulp staples or a stream of staple air, and the apparatus comprises at least one permeable feed sieve-like belt for feeding the pulp staples and endless filaments as an endless filament staple mixture to form a nonwoven material or a nonwoven web, and is provided with at least one suction device, by which air or process air can be drawn through the feed sieve-like belt into the fiber or endless filament staple mixture feeding area.

[0039] According to a preferred embodiment, the apparatus has at least two, particularly two, meltblown spinnerets. Preferably, the first meltblown spinneret is positioned upstream of the outlet channel in the feeding direction of the feed sieve-like belt, and the second meltblown spinneret is positioned downstream of the outlet channel in the feeding direction of the feed sieve-like belt. It is within the scope of the present invention that at least one meltblown spinneret, preferably at least two or two meltblown spinnerets, are positioned at an angle to the outlet channel. The angle of inclination between the meltblown spinneret and the outlet channel is purposefully at least 10°, preferably at least 20°, and preferably at least 25° (each). More preferably, the angle of inclination between the meltblown spinneret and the outlet channel is at least 30°, particularly preferably at least 35°, for example at least 40° (each). Preferably, the inclination angle between at least one meltblown spinneret and the outlet channel, preferably between two meltblown spinnerets and the outlet channel, is 10° to 75°, preferably 20° to 70°, particularly preferably 25° to 65°, and especially preferably 30° to 65° (each). In this way, the filament airflow from the meltblown spinneret may flow toward the short fiber airflow at an angle α1 or α2 with respect to the flow direction S1 of the short fiber airflow toward the delivery sieve-like belt. Preferably, the inclination angles between the meltblown spinneret and the outlet channel are adjustable or configurable.

[0040] Preferably, the outlet channel is configured to be height-adjustable relative to the sheave surface of the delivery sheave belt. It has been demonstrated that the distance a between the end of the outlet channel and the surface of the sheave belt can be adjusted in the range of 200 mm to 1000 mm, preferably 300 mm to 750 mm, preferably 400 mm to 600 mm, and particularly preferably 460 mm to 530 mm.

[0041] According to a preferred embodiment of the apparatus according to the present invention, the defibration apparatus has at least one fan that accelerates pulp short fibers or a short fiber airflow in an outlet channel.

[0042] The present invention further teaches a nonwoven material comprising an endless filament short fiber mixture produced according to the method and / or using the apparatus described above. The nonwoven material preferably has a thickness in the range of 0.1 mm to 3 mm, preferably 0.2 mm to 2 mm, and more preferably 0.3 mm to 1.5 mm. Within the range of the present invention, the thickness of the nonwoven material means the maximum thickness of the nonwoven material particularly transversely, particularly perpendicular or substantially perpendicular to the planar extension of the nonwoven material, especially after a predetermined solidification step or calendering step.

[0043] The present invention is based on the understanding that the method according to the present invention enables the production of a nonwoven fabric material consisting of endless filaments and pulp staples that satisfies all requirements not only in terms of stability and strength but also in terms of liquid absorbency. In this respect, the means according to the present invention allows for an optimal compromise between the strength and liquid absorbency of the nonwoven fabric material. The flow characteristics according to the present invention and the suitably predetermined arrangement of one or more meltblown spinnerets and outlet channels for pulp staples enable optimal mixing of endless filaments and pulp staples, resulting in a nonwoven fabric material with an extremely uniform distribution of endless filaments and pulp staples. In this way, a nonwoven fabric material that satisfies all requirements can be provided with a relatively small proportion of endless filaments. Furthermore, the means according to the present invention are not very complicated, and therefore the method according to the present invention is highly economical. This also applies to the apparatus according to the present invention.

[0044] The present invention will be described in detail below based on drawings that merely illustrate one embodiment. [Brief explanation of the drawing]

[0045] [Figure 1] A longitudinal cross-sectional view of the apparatus according to the present invention for carrying out the method according to the present invention is shown. [Figure 2]This shows a bottom view of the meltblown spinneret according to the present invention in the first embodiment. [Figure 3] Figure 2 shows a vertical cross-sectional view of the object. [Figure 4] A bottom view of the meltblown spinneret according to the present invention, which is a second embodiment, is shown. [Figure 5] A bottom view of the meltblown spinneret of the third embodiment is shown. [Figure 6A] A partial plan view of the nonwoven fabric material according to the present invention, having an embossed pattern, is shown. [Figure 6B] Figure 6A shows a cross-sectional view along the line A-A. [Modes for carrying out the invention]

[0046] Figure 1 shows an apparatus for producing a nonwoven material 1 from fibers according to the present invention. An endless filament made of a thermoplastic resin is produced by passing it through two meltblown spinnerets 2 and 3. Within the scope of the present invention, in embodiments, the thermoplastic resin may be polypropylene. As can be seen in Figure 1, pulp short fibers are produced from pulp, preferably and in embodiments from solid pulp 19, by at least one defibration device 4. The defibration device 4 is purposefully and in embodiments, a sawmill. In the defibration device 4, according to the present invention, at least one short fiber airflow 5 is generated from the pulp short fibers. The short fiber airflow 5 is accelerated in an outlet channel 6, preferably and in embodiments, by a fan 7 of the defibration device 4. The fan 7 supplies air to the defibration device 4, purposefully and in embodiments. The airflow for generating the short fiber airflow 5 is generated within the scope of the present invention, in embodiments, based on a grinding process in the defibration device 4 or sawmill and by the fan 7.

[0047] According to the present invention, the accelerated short-fiber airflow 5 enters the outlet channel 6 at an initial volumetric flow rate V1. The initial volumetric flow rate V1, within the scope of the present invention, specifically refers to the volumetric flow rate of the short-fiber airflow 5 immediately after it enters the outlet channel 6. The short-fiber airflow 5 flows toward the permeable discharge sheave-shaped belt 8 in a flow direction S1 that is perpendicular or substantially perpendicular to the surface of the sheave-shaped belt 8. The permeable discharge sheave-shaped belt 8 is configured, for the purpose and in the embodiment, as an endlessly circulating discharge sheave-shaped belt 8.

[0048] The endless filament produced by the meltblown spinnerets 2 and 3 flows, in purpose and in examples, from the meltblown spinnerets 2 and 3 to the short fiber airflow 5 as a filament airflow 9 and 10 having an initial volumetric flow rate V2 or V3. The initial volumetric flow rate V2 or V3 refers, in particular, to the volumetric flow rate of the filament airflow 9 and 10 that exists after blown air is added to the endless filament immediately below the meltblown spinnerets 2 and 3.

[0049] Within the scope of the present invention, in the embodiments, the first filament airflow 9 flows upstream of the short fiber airflow 5 when viewed in the feeding direction F of the delivery sheave-shaped belt 8. The filament airflow 9 flows at an angle α1 with respect to its flow direction S2 relative to the flow direction S1 of the short fiber airflow 5. The second filament airflow 10 flows downstream of the short fiber airflow 5 when viewed in the feeding direction F of the delivery sheave-shaped belt 8. This second filament airflow 10 flows at an angle α2 with respect to its flow direction S3 relative to the flow direction S1 of the short fiber airflow 5. Therefore, the filament airflows 9 and 10 preferably, and in the embodiments, flow into the short fiber airflow 5 from both sides of the central short fiber airflow 5 at angles α1 and α2. Within the scope of the present invention, angles α1 and α2 are preferably greater than 20°, and particularly preferably greater than 25°. In the illustrated embodiments, angles α1 and α2 may each be about 30°. Preferably, within the scope of the examples, angles α1 and α2 have the same value or essentially the same value.

[0050] In purpose and in the embodiments, the filament airflows 9 and 10 and the short fiber airflow 5 are guided together in a contact area 11 above a delivery sieve-like belt 8 and are delivered as an endless filament short fiber mixture 12 onto the delivery sieve-like belt 8 in a delivery area 13 to form a nonwoven material 1 or a nonwoven web. Preferably and in the embodiments, the filament airflows 9 and 10 flow at an angle α1 or α2 with respect to the flow direction S1 of the short fiber airflow 5 in or immediately before the contact area 11 with respect to their flow direction S2 or S3. In this case, angles α1 and α2, within the scope of the present invention and in the embodiments, in particular, mean the angle of inclination at which the filament airflows 9 and 10 contact the short fiber airflow 5 in the contact area 11. Preferably and in the embodiment, both filament airflows 9 and 10 flow along all the flow paths from their respective meltblown spinnerets 2 and 3 to the contact area 11 at an angle α1 or α2 with respect to their flow direction S2 or S3 relative to the flow direction S1 of the short fiber airflow 5. Preferably and in the embodiment, in this case, the filament airflows 9 and 10 flow straight or essentially straight. Preferably and in the embodiment shown in Figure 1, the filament airflows 9 and 10 flow symmetrically toward the short fiber airflow 5 and contact the short fiber airflow 5 symmetrically in the contact area 11. Both filament airflows 9 and 10 and the short fiber airflow 5 flow, preferably and in the embodiment, toward the contact area 11 from the meltblown spinnerets 2 and 3 or the outlet channel 6 without any guide means.

[0051] Preferably and in the embodiment, secondary air is drawn in the space between the filament airflows 9, 10 and the short fiber airflow 5. In this case, the secondary air is drawn in particularly by volumetric flow rate V sek It was sucked in, and at that time, V sekThis is, in a purposeful sense, the total volumetric flow rate of the secondary air drawn in as a whole. Furthermore, according to the present invention, in the delivery region 13 of the fiber or endless filament short fiber mixture 12, or at least in this delivery region 13, air or process air is drawn in from below through the delivery sieve-like belt 8 at a volumetric flow rate V4. For this purpose, in embodiments within the scope of the present invention, a suction device 16 or suction fan is provided below the delivery sieve-like belt 8, particularly below the delivery region 13. Preferably, the volumetric flow rate V4 is greater than the sum of the volumetric flow rates V1, V2 and V3. More preferably, the volumetric flow rate V4 is greater than the sum of the volumetric flow rates V1, V2, V3 and V sek It is greater than or equal to the sum of [the specified values].

[0052] According to a preferred embodiment of the present invention, the meltblown spinnerets 2 and 3 each have a plurality of spinneret openings 17 arranged in a row, and a molten-flowable plastic filament is preferably extruded from the spinneret openings 17 within the scope of the method according to the present invention. Preferably, two air inlet gaps 18 extend parallel to each other on both sides of the row of spinneret openings 17. This can be seen in Figures 2 and 3. Preferably, blown air enters from the air inlet gaps 18. The plastic filament extruded from the spinneret openings 17 is purposefully pushed into the blown airflow. Within the scope of the present invention, in the embodiment shown in Figures 2 and 3, the meltblown spinnerets 2 and 3 have a single row of spinneret openings 17, and in that case, they are configured as a single-row spinneret. Within the scope of the present invention, the fact that the air intake gap 18 extends parallel to the rows of die openings 17 on both sides means, in particular, that the longitudinal extension of the air intake gap 18 extends parallel to the longitudinal extension of the rows of die openings 17 (Figure 2). Preferably, within the scope of the embodiments shown in Figures 2 and 3, the air intake gap 18 is inclined toward the die openings 17 or toward the rows of die openings 17. In this case, the blown air or planar blown airflow advancing from the air intake gap 18 is applied to the extruded endless filament at an inflow angle (Figure 3), in this case from the side.

[0053] Figure 4 shows a bottom view of another preferred embodiment of the meltblown spinnerets 2, 3. In the preferred embodiment of the meltblown spinnerets 2, 3 shown in Figure 4, there are multiple spinneret openings 17 arranged in multiple rows, in which case each spinneret opening 17 is assigned one air inlet opening 21 or its own one air inlet opening 21, through which blown air enters. Such a meltblown spinneret having multiple rows of spinneret openings 17 for the entry of molten, fluid plastic filaments is also referred to as a multi-row spinneret. Preferably and in the embodiment shown in Figure 4, each air inlet opening 21 is assigned directly to a concrete spinneret opening 17. Preferably and in the embodiment shown in Figure 4, the air inlet openings 21 coaxially surround each spinneret opening 17. In this manner, blown air flows out from the air inlet openings 21 assigned to each nozzle opening 17, parallel and coaxially with respect to the molten plastic or the molten, fluid plastic filament.

[0054] Another preferred embodiment of the meltblown spinnerets 2, 3 is shown in Figure 5. According to this preferred embodiment, the meltblown spinneret 2 or a plurality of meltblown spinnerets 2, 3 has a plurality of advancing openings arranged in double rows, in the form of spinneret openings 17 (shown as unfilled circles in Figure 5) and air inlet openings 21 (shown as filled circles in Figure 5). For the purpose and in the embodiment, the advancing openings or spinneret openings 17 and the air inlet openings 21 are spaced apart from each other in a regular pattern. In this case, at least two air inlet openings 21 are assigned to each spinneret opening 17. This means, in particular, that at least two air inlet openings 21 are located directly adjacent to each spinneret opening 17. Furthermore, preferably and in the embodiment, at least two spinneret openings 17 are located directly adjacent to each air inlet opening 21. Only blown air advances from the air inlet openings 21, within the scope of the preferred embodiment shown in Figure 5. Preferably, the die opening 17 is configured such that only the polymer molten material advances from there, and the polymer molten material advances from the die opening 17 without blown air that is directly assigned to each die opening 17 or advances coaxially with respect to the die opening 17. Purposefully, in the embodiment shown in Figure 5, a portion of the advance openings of the meltblown spinneret 2 or a plurality of meltblown spinnerets 2, 3 are formed in the form of die openings 17, and a portion or another portion of the advance openings are formed in the form of air inlet openings 21. Within the scope of this embodiment, in the embodiment, the spacing between directly adjacent advance openings of the meltblown spinnerets 2, 3 in the longitudinal and transverse directions is the same or substantially the same for the entire spinnerets 2, 3.

[0055] Within the scope of the present invention, in the embodiments, water is sprayed onto the filament airflows 9 and 10 between the meltblown spinnerets 2 and 3 and the feed sieve-like belt 8, on the side of the filament airflows 9 and 10 opposite to the short fiber airflow 5. For this purpose, water nozzles 20 are provided for each, which are purposefully and in the embodiments positioned on the side of each filament airflow 9 and 10 opposite to the short fiber airflow 5. Thus, the water nozzles 20 are preferably and in the embodiments positioned outside the filament airflows 9 and 10, and particularly preferably below or immediately below the meltblown spinnerets 2 and 3 in the filament flow direction.

[0056] The amount of secondary air drawn in can be controlled in an open loop and / or closed loop, preferably by adjusting the height of the outlet channel 6 or the outlet channel end 14 relative to the surface of the sheave-shaped belt 8, within the scope of the method according to the present invention or by the apparatus according to the present invention. Preferably, the height of the outlet channel 6 is V4 ≥ (V1 + V2 + V sek ) and / or V4 ≥ (V1 + V2 + V3 + V sek The outlet channel 6 is adjusted so that the following conditions are met. The outlet channel 6 is preferably configured to be height-adjustable relative to the surface of the sheave-like belt 8 for delivery. The distance a between the outlet channel end 14 and the surface of the sheave-like belt is purposefully 200 mm to 1000 mm, preferably 300 mm to 750 mm. Within the scope of the present invention, the distance a is measured perpendicular to the surface of the sheave-like belt between the outlet channel end 14 and the surface of the sheave-like belt. In the region of the outlet channel end 14, the wall portion of the outlet channel 6 is preferably, and in embodiments, configured such that the outlet channel end 14 is formed by diffusion in the inner cross-section. The height adjustability or height adjustment of the outlet channel 6 and the configuration of the wall portion of the outlet channel 6 or the outlet channel end 14, in combination with the selection of angles α1 and α2, within the scope of the present invention, can be used to adjust or control the state of the contact area 11. This can also be advantageously influenced in the mixing of endless filaments and pulp short fibers.

[0057] Preferably, the endless filament short fiber mixture 12 flows from the contact area 11 to the delivery sieve-like belt 8 as a uniform or essentially uniform mixture. The uniform endless filament short fiber mixture 12 is then, for purpose, delivered onto the delivery sieve-like belt 8 in the delivery area 13 to form a nonwoven material 1 or a nonwoven web. Preferably, and in the embodiment shown in Figure 1, the endless filament short fiber mixture 12 flows from the contact area 11 to the delivery sieve-like belt 8 or to the delivery area 13 perpendicular or substantially perpendicular to the surface of the sieve-like belt with respect to its flow direction.

[0058] The nonwoven material 1 is solidified "inline" by at least one calender 15 according to a preferred embodiment of the method according to the present invention and in the embodiment. In the embodiment, at least one calender 15 has at least one pair of calender rollers, and the nonwoven material 1 is guided through the pair of calender rollers, preferably under pressure. More preferably, an embossed pattern is processed onto the nonwoven material 1 or nonwoven web by at least one calender 15. For this purpose, at least one of the calender rollers of the calender 15 may have an embossed pattern on its outer surface.

[0059] Figure 6A shows a partial plan view of a nonwoven fabric material according to the present invention having an embossed pattern. Figure 6B shows a cross-sectional view of the object according to Figure 6A along line AA. Preferably, and in the embodiment according to Figure 6A, the embossed pattern is formed without interruption. Since the basic geometric shape or repeating element of the embossed pattern is preferably a regular hexagon, the embossed pattern preferably, and in the embodiment, consists of a plurality of adjacent regular hexagons of equal size, and is formed in such a way as a particularly honeycomb-like embossed pattern. In Figure 6B, it can be seen that the inner surfaces of the hexagons, for purpose, form the unpressed portions of the embossed pattern.

[0060] The height h of the basic geometric shapes or elements of the embossed pattern is preferably between 0.3 mm and 2.0 mm. In the embodiments shown in Figures 6A and 6B, the height of the basic geometric shapes or regular hexagons may be approximately 1.5 mm. In this case, the height h of the basic geometric shapes refers to the difference in height between the pressed surface and the non-pressed area of ​​the embossed pattern, or the average height difference. Furthermore, within the scope of the present invention, the proportion of the pressed surface of the embossed pattern on the entire surface of the nonwoven material is between 2.5% and 25%, preferably between 5% and 15%. In addition, naturally, the roller corresponding to the roller with the embossed pattern in the calendar roller pair has a complementary embossed pattern on its outer surface. This application relates to the invention described in the claims, but also includes the following other embodiments. 1. A method for producing a nonwoven fabric material (1) from fibers, An endless filament is produced from a thermoplastic resin by at least one meltblown spinneret (2), preferably at least two meltblown spinnerets (2, 3), and further, short pulp fibers are produced by at least one defibration device (4), in which case at least one short fiber airflow (5) is formed from the short pulp fibers in the defibration device (4), the short fiber airflow (5) is guided through an outlet channel (6), and proceeds out of the outlet channel (6) toward a permeable discharge sieve-shaped belt (8) with an initial volumetric flow rate V1 and flow direction S1. The endless filament flows from at least one meltblown spinneret (2) as a filament airflow (9) towards the short fiber airflow (5) at an initial volumetric flow rate V2. The filament airflow (9) and the short fiber airflow (5) are guided together in a contact area (11) above the delivery sieve-shaped belt (8), and are fed onto the delivery sieve-shaped belt in the delivery area (13) as an endless filament short fiber mixture (12), forming a nonwoven fabric material (1) or a nonwoven fabric web. A method wherein, in the delivery region (13) of fibers or an endless filament short fiber mixture (12), air or process air is drawn in from below through the delivery sieve-like belt (8) at a volumetric flow rate V4, wherein the volumetric flow rate V4 is greater than the sum of the volumetric flow rates V1 and V2. 2. The method of (1) described above, wherein at least two meltblown spinnerets (2, 3) are provided, and the endless filament flows from the second meltblown spinneret (3) as a second filament airflow (10) toward the short fiber airflow (5) at an initial volumetric flow rate V3, wherein preferably the volumetric flow rate V4 is greater than the sum of the volumetric flow rates V1, V2, and V3, and particularly preferably the filament airflow (9) flows upstream of the short fiber airflow (5) in the feeding direction (F) of the delivery sieve-shaped belt (8), and the second filament airflow (10) flows downstream of the short fiber airflow (5) in the feeding direction of the delivery sieve-shaped belt (8). 3. The filament airflow (9) flows in the flow direction S2 at least partially or partially at an angle α1 with respect to the flow direction S1 of the short fiber airflow (5), preferably the second filament airflow (10) flows in the flow direction S3 at least partially or partially at a predetermined angle α2 with respect to the flow direction S1 of the short fiber airflow (5), wherein preferably the angles α1 and / or α2 are greater than 10°, particularly preferably greater than 20°, and especially preferably greater than 25°, according to method 1 or 2 above. 4. The short-fiber airflow (5) flows from the outlet channel (6) or the end of the outlet channel (14) in the flow direction S1 perpendicular or substantially perpendicular to the surface of the sheave-shaped belt (8) of the delivery sheave-shaped belt, in any one of the methods described in 1 to 3 above. 5. One of the methods 1 to 4 above, wherein secondary air is drawn in in the space between the short fiber airflow (5) and the filament airflow (9), and / or in the space between the short fiber airflow (5) and the second filament airflow (10). 6. The short fiber airflow (5) is accelerated in the outlet channel (6), and in particular by the fan (7) of the defibration device (4), in any one of the methods described in 1 to 5 above. 7. At least one of the meltblown spinnerets (2, 3) has a plurality of spinneret openings (17) arranged in a row and preferably two air inlet gaps (18) that extend parallel to the row of spinneret openings (17) on both sides and are inclined toward the spinneret openings (17), and blown air advances from the air inlet gaps (18), any one of the methods 1 to 6 above. 8. At least one of the meltblown spinnerets (2, 3) has a plurality of spinneret openings (17) arranged in a double row, preferably one air inlet opening (21) or its own air inlet opening (21) assigned to each spinneret opening (17), through which blown air enters, in any one of the methods 1 to 6 above. 9. At least one of the meltblown spinnerets (2, 3) has a plurality of advance openings and air inlet openings (21) in the form of spinneret openings (17) arranged in double rows, wherein the advance openings or the spinneret openings (17) and the air inlet openings (21) are preferably spaced apart from each other and arranged in a regular and / or irregular pattern, preferably each air inlet opening (21) is assigned to at least two of the spinneret openings (17) and / or each spinneret opening (17) is assigned to at least two of the air inlet openings (21), any one of the methods 1 to 6 above. 10. One of the methods 1 to 9 above, wherein water is sprayed onto an endless filament of at least one filament airflow (9), preferably multiple filament airflows (9, 10), between the meltblown spinneret (2, 3) and the feed sieve-like belt (8), particularly on the side of the filament airflows (9, 10) opposite to the short fiber airflow (5). 11. The short fiber airflow (5) advances from the outlet channel (6) at a rate of 0.0138 kg to 0.0833 kg, preferably 0.0222 kg to 0.0694 kg, and more preferably 0.0277 kg to 0.05 kg of pulp short fibers per 1 kg of air, in any one of the methods 1 to 10 described above. 12. One of the methods 1 to 11 above, wherein at least one filament airflow (9) or a plurality of filament airflows (9, 10) advance from the meltblown spinneret (2, 3) at a rate of 0.002 kg to 0.5 kg, preferably 0.01 kg to 0.25 kg, more preferably 0.015 kg to 0.12 kg, and most preferably 0.018 kg to 0.1 kg of endless filaments per 1 kg of air. 13. The outlet channel (6) is height-adjustable relative to the surface of the sheave-shaped belt (8) of the delivery sheave-shaped belt, and the distance (a) between the outlet channel end (14) and the surface of the sheave-shaped belt is particularly 200 mm to 1000 mm, preferably 300 mm to 750 mm, more preferably 400 mm to 600 mm, and most preferably 460 mm to 530 mm, and for the purpose of controlling the amount of secondary air drawn in, the amount of secondary air drawn in can be controlled in a closed loop and / or open loop by adjusting the height of the outlet channel (6) relative to the surface of the sheave-shaped belt (8) of the delivery sheave-shaped belt, any one of the methods 1 to 12 above. 14. The short fiber airflow (5) guides and / or conveys pulp short fibers in any one of the methods 1 to 13 described above, with respect to the width (b) of the delivery sieve-like belt (8) at least 50 kg / h / m, particularly at least 75 kg / h / m, preferably at least 100 kg / h / m, and particularly preferably at least 200 kg / h / m. 15. The nonwoven material (1) or nonwoven web is solidified by at least one calender (15), and in the process, an embossed pattern is processed onto the nonwoven material (1) or nonwoven web by at least one of the calenders (15), in any one of the methods 1 to 14 described above. 16. The embossed pattern is formed without interruption, and the basic geometric shape of the embossed pattern is 20mm. 2 From 50mm 2 Preferably 25 mm 2 From 45mm 2 Preferably 30 mm 2 From 40mm 2 Particularly preferred is 32.5 mm 2 37.5mm 2 The 15 methods described above, having a pressing surface within the range of [specify range]. 17. The embossed pattern is formed from multiple elements, preferably dots and / or lines, that are interrupted and not connected to one another, and the elements are purposefully 2 mm 2 Smaller than, preferably 1.5 mm 2 Smaller than, preferably 1.1 mm 2 Smaller than, particularly preferably 0.55 mm 2 The apparatus 15 or 16 described above, each having a smaller pressing surface than the above. 18. In an apparatus for manufacturing a nonwoven fabric material from fibers by any one of the methods described in 1 to 17 above, The apparatus comprises at least one meltblown spinneret (2), preferably at least two meltblown spinnerets (2, 3) for producing an endless filament from a thermoplastic resin. Furthermore, the apparatus is provided with at least one defibration device (4) for producing pulp short fibers and an outlet channel (6) for guiding the pulp short fibers or short fiber airflow (5). The apparatus includes at least one breathable, sheave-like feeding belt (8) for feeding pulp short fibers and endless filaments as an endless filament short fiber mixture (12) to form a nonwoven material (1) or a nonwoven web. An apparatus comprising at least one suction device (16) which allows air or process air to be drawn into a delivery area (13) of fibers or an endless filament short fiber mixture (12) through the delivery sieve-like belt (8). 19. The apparatus of 18, wherein the apparatus has at least two meltblown spinnerets (2, 3), the first meltblown spinneret (2) is positioned upstream of the outlet channel (6) in the feeding direction of the feed sieve-like belt (8), and the second meltblown spinneret (3) is positioned downstream of the outlet channel (6) in the feeding direction of the feed sieve-like belt (8). 20. A nonwoven fabric material (1) produced from an endless filament short fiber mixture (12) according to one of the methods 1 to 17 described above.

Claims

1. A method for producing a nonwoven fabric material (1) from fibers, An endless filament is produced from a thermoplastic resin using at least one meltblown spinneret (2, 3), and further, short pulp fibers are produced using at least one defibration device (4), during which at least one short fiber airflow (5) is formed from the short pulp fibers in the defibration device (4), the short fiber airflow (5) is guided through an outlet channel (6), and proceeds out of the outlet channel (6) toward a permeable discharge sieve-shaped belt (8) with an initial volumetric flow rate V1 and flow direction S1. The endless filament flows from at least one meltblown spinneret (2, 3) as a filament airflow (9) towards the short fiber airflow (5) at an initial volumetric flow rate V2. The filament airflow (9) and the short fiber airflow (5) are guided together in a contact area (11) above the delivery sieve-shaped belt (8), and are fed onto the delivery sieve-shaped belt in the delivery area (13) as an endless filament short fiber mixture (12), forming a nonwoven fabric material (1) or a nonwoven fabric web. In the delivery region (13) of the fiber or endless filament short fiber mixture (12), air or process air is drawn in from below through the delivery sieve-shaped belt (8) at a volumetric flow rate V4, and at that time, the volumetric flow rate V4 is greater than the sum of the volumetric flow rates V1 and V2. The outlet channel (6) is height-adjustable relative to the surface of the sheave-shaped belt (8) for delivery, and the distance (a) between the end of the outlet channel (14) and the surface of the sheave-shaped belt is from 200 mm to 1000 mm. method.

2. The method according to claim 1, wherein at least two meltblown spinnerets (2, 3) are provided, and the endless filament flows from the second meltblown spinneret (3) as a second filament airflow (10) toward the short fiber airflow (5) at an initial volumetric flow rate V3, wherein the volumetric flow rate V4 is greater than the sum of the volumetric flow rates V1, V2, and V3.

3. The method according to claim 1, wherein the filament airflow (9) flows at an angle α1 with respect to the flow direction S1 of the short fiber airflow (5) in the flow direction S2, at least partially or in part.

4. The method according to any one of claims 1 to 3, wherein the short fiber airflow (5) flows from the outlet channel (6) or the end of the outlet channel (14) perpendicular or substantially perpendicular to the surface of the sheave-shaped belt (8) of the delivery sheave-shaped belt in the flow direction S1.

5. The method according to any one of claims 1 to 3, wherein secondary air is drawn in in the space between the short fiber airflow (5) and the filament airflow (9), and / or in the space between the short fiber airflow (5) and the second filament airflow (10).

6. The method according to any one of claims 1 to 3, wherein the short fiber airflow (5) is accelerated in the outlet channel (6).

7. The method according to any one of claims 1 to 3, wherein at least one of the meltblown spinnerets (2, 3) has a plurality of spinneret openings (17) arranged in a row and two air inlet gaps (18) that extend parallel to the row of spinneret openings (17) on both sides and are inclined toward the spinneret openings (17), and blown air advances from the air inlet gaps (18).

8. The method according to any one of claims 1 to 3, wherein at least one of the meltblown spinnerets (2, 3) has a plurality of spinneret openings (17) arranged in a double row, and each of the spinneret openings (17) is assigned one air inlet opening (21) or its own air inlet opening (21), through which blown air enters.

9. The method according to any one of claims 1 to 3, wherein at least one of the meltblown spinnerets (2, 3) has a plurality of advance openings and air inlet openings (21) in the form of spinneret openings (17) arranged in double rows, and the advance openings or the spinneret openings (17) and the air inlet openings (21) are spaced apart from each other and arranged in a regular and / or irregular pattern.

10. The method according to any one of claims 1 to 3, wherein water is sprayed onto an endless filament of at least one filament airflow (9, 10) between the meltblown spinneret (2, 3) and the feed sieve-like belt (8).

11. The method according to any one of claims 1 to 3, wherein the short-fiber airflow (5) advances from the outlet channel (6) at a rate of 0.0138 kg to 0.0833 kg of pulp short fibers per 1 kg of air.

12. The method according to any one of claims 1 to 3, wherein at least one filament airflow (9) or a plurality of filament airflows (9, 10) advance from the meltblown spinneret (2, 3) at a rate of 0.002 kg to 0.5 kg of endless filament per kg of air.

13. The method according to any one of claims 1 to 3, wherein the short fiber airflow (5) guides and / or conveys at least 50 kg / h / m of pulp short fibers with respect to the width (b) of the delivery sieve-shaped belt (8).

14. The method according to any one of claims 1 to 3, wherein a nonwoven material (1) or a nonwoven web is solidified by at least one calender (15), and in the process, an embossed pattern is processed onto the nonwoven material (1) or nonwoven web by at least one of the calenders (15).

15. The embossed pattern is formed without interruption, and the basic geometric shape of the embossed pattern is 20 mm. ２ The method according to claim 14, having a press surface in the range of 50 mm².

16. The embossed pattern is formed from multiple elements that are interrupted and not connected to each other, and the elements are 2 mm ２ The method according to claim 14, wherein each has a press surface smaller than the specified size.

17. An apparatus for producing a nonwoven fabric material from fibers by the method described in any one of claims 1 to 3, The apparatus comprises at least one meltblown spinneret (2, 3) for producing an endless filament from a thermoplastic resin. Furthermore, the apparatus is provided with at least one defibration device (4) for producing pulp short fibers and an outlet channel (6) for guiding the pulp short fibers or short fiber airflow (5). The apparatus includes at least one breathable feeding sieve-like belt (8) for feeding pulp short fibers and endless filaments as an endless filament short fiber mixture (12) to form a nonwoven material (1) or a nonwoven web. At least one suction device (16) is provided, and the suction device (16) allows air or process air to be drawn into the delivery area (13) of the fiber or endless filament short fiber mixture (12) through the delivery sieve-shaped belt (8). The outlet channel (6) is height-adjustable relative to the surface of the sheave-shaped belt (8) for delivery, and the distance (a) between the outlet channel end (14) and the surface of the sheave-shaped belt is from 200 mm to 1000 mm, in the apparatus.

18. The apparatus according to claim 17, wherein the apparatus has at least two meltblown spinnerets (2, 3), the first meltblown spinneret (2) is positioned upstream of the outlet channel (6) in the feeding direction of the feed sieve-like belt (8), and the second meltblown spinneret (3) is positioned downstream of the outlet channel (6) in the feeding direction of the feed sieve-like belt (8).

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