Installation, method, and roller for consolidating a textile material web

Abstract

The invention relates to an installation and a method for consolidating a nonwoven fabric (10), having at least one rotatable roller (1) with a plurality of needles (3) which are arranged over the circumference of the surface of the roller (1) and over the working width, having at least one stitch plate (21) which is spaced from the roller (1), extends over the working width of the roller (1), and has elongated holes (21a) through which the needles (3) of the roller (1) can pass over an angle of rotation of the roller (1). The installation is designed to consolidate a nonwoven fabric (10) between the roller (1) and the stitch plate (21). The invention further relates to a roller for use in the installation for consolidating a nonwoven fabric.

Description

[0001] Internal file number P230903W01

[0002] Title: Plant, process and roller for consolidating a textile web

[0003] Description

[0004] The invention relates to a system, a method and a roller for consolidating a textile web according to the preambles of claims 1, 10 and 16.

[0005] Fiber bonding processes are categorized as mechanical, chemical, and thermal. In the nonwovens sector, the most well-known methods are hydroentanglement, thermal bonding, and needling. This is particularly relevant for heavy nonwovens with a basis weight of 100 g / m². 2 up to 600g / m² 2Fiber sheets, often prefabricated in several layers, are classic intermediate products for needling. Depending on the needle penetration depth, the fibers of the outer layers should have a fiber length of at least 20 mm. Current needling processes consolidate fiber laminations by using a reciprocating motion to insert and withdraw needles vertically into the fiber lamination lying on a needle plate. The needle first penetrates the stripper, then the fiber material, and at least partially enters the holes in the needle plate. As the needles are withdrawn, the fiber material is retained by a stripper plate. When the material is pierced, fibers become entangled in the needle notches and are pulled upwards or downwards. The resulting entanglement within the lamination leads to higher fiber-to-fiber friction and thus to greater strength of the finished product.

[0006] The speed of the process is limited by the combination of the maximum number of strokes per minute or unit of time and the maximum possible feed per stroke. While the needles are embedded in the fiber pile, the fiber can only be transported a limited amount. The movement of the fiber pile exerts a bending force on the needles. If the feed per stroke is too great, the needles bend so much that they either break or no longer engage the holes in the needle plate. This leads to damage to the needle plate (e.g., grooves where fibers catch and spin) and / or damage to the needles, even to the point of snapping. Processes that use an elliptical stroke improve upon this deficiency, but are also limited in speed and require complex drive trains to achieve the elliptical movement of the needle bars. So-called circular needle machines also operate with a stroke motion. Internal reference P230903W01

[0007] Needle drilling machines are designed to withstand high piercing forces and are therefore very robust. This robust construction is particularly relevant when needling materials weighing less than 100 g / m². 2 This is unnecessary and therefore causes unnecessarily high costs. The lifting motion creates special requirements that result in higher costs during the design of a plant compared to other compaction methods, e.g., the condition of the ground on which the machines stand, the vibrations that would be introduced into the ground without countermeasures, or the noise generated by the lifting movements.

[0008] According to the prior art, it is known to perforate nonwovens using decorated rollers. DE 2015243 A1 discloses a perforation of a nonwoven using a decorated roller, in which a gas stream is directed onto the opening to be formed from the opposite side of the nonwoven, contrary to the insertion direction of the needles. This is intended to prevent fibers from breaking out of the surface of the nonwoven. The counterforce for fixing the nonwoven is applied by a rotating perforated drum, which prevents the nonwoven from shifting during perforation.

[0009] The EP 1092054 B1 also creates a hole structure using a decorated roller, whereby the perforated nonwoven fabric is subsequently consolidated by thermal treatment using calender rollers. The counterforce to fix the nonwoven fabric is applied by a circumferential perforated band, which can be supported from the underside to prevent the nonwoven fabric from shifting during perforation.

[0010] A disadvantage is that the methods described here are not suitable for consolidating a nonwoven fabric without damaging its structure, i.e., without perforation. The needles used are also unsuitable for interlocking the fibers.

[0011] Accordingly, the invention aims to enable the needling of a textile web at a high production speed. A quick replacement of the needles should also be possible.

[0012] The invention solves the stated problem by means of a system, a method, and a roller having the features specified in claims 1, 10, and 16. Advantageous embodiments of the invention are defined in the dependent claims.

[0013] The textile web is described below as a nonwoven fabric, which is processed either pre-bonded or unbonded as a woven pile. Internal reference number P230903W01

[0014] The roller needling process described below eliminates the aforementioned shortcomings by largely avoiding bending forces on the needles and eliminating the need for a reciprocating motion. The needles used to consolidate the nonwoven fabric are arranged on the rollers, for example, as an endless strand of wire or as a multitude of overlapping rings. The roller with the needles and the nonwoven fabric move together at the same speed. During the needling process, the nonwoven fabric to be consolidated is transported by the needling roller. Thus, the transport speed is no longer determined by the maximum feed per stroke or the stroke frequency. The nonwoven fabric can be consolidated by several rollers, which can be individually positioned side-by-side or one above the other in any desired arrangement, depending on the desired material flow from roller to roller.This also allows for a delay between the individual rollers.

[0015] The apparatus according to the invention for consolidating a nonwoven fabric comprises at least one rotatably designed roller with a plurality of needles arranged on the surface of the roller around its circumference and across its working width. The apparatus also comprises at least one needle plate or needle roller spaced apart from the roller, extending across the working width of the roller and having elongated holes through which the needles of the roller can pass over an angle of rotation of the roller. The apparatus is designed to consolidate a nonwoven fabric between the roller and the needle plate. In contrast to the prior art, this apparatus does not perforate the nonwoven fabric, but rather entangles the fibers together through the piercing needles, thereby creating the consolidation. The needle plate is stationary and does not rotate. Alternatively, a rotatable needle roller can be used, to which the needles are assigned an arrangement in stationary rows.The constant rotation of the roller, which corresponds to the transport speed of the nonwoven fabric around its circumference, allows for high productivity in bonding the fabric. As the roller rotates, the needles pierce the nonwoven and simultaneously enter a corresponding elongated hole in the needle plate. Unlike traditional needling methods, there is no intermittent movement; instead, the roller and nonwoven fabric move uniformly at a constant speed. Alternatively, a stationary brush or a rotating brush roller can be used, where the needles do not need to be arranged in rows or lanes.

[0016] By means of a guide element positioned in front of the roller in the material transport direction, the nonwoven fabric can be introduced into the gap between the roller and the needle plate. The guide element can be designed and positioned such that initial compaction of the nonwoven fabric occurs between the guide element and the needle plate. Further compaction of the nonwoven fabric can occur between the roller and the needle plate. By means of another guide element positioned behind the roller in the material transport direction (Internal File Reference P230903W01), the nonwoven fabric can be guided in such a way that the needles are pulled out of the nonwoven fabric by the continued rotation of the roller.

[0017] In the material transport direction behind the roller, a stripping element can be arranged, designed to pull or strip the roller needles from the nonwoven fabric. The nonwoven fabric can be guided and transported further on the upper side of the stripping element, with the roller needles passing through outwardly open elongated slots, which are designed as a comb structure, and exiting the nonwoven. This is particularly advantageous for multi-stage consolidation of the nonwoven fabric on the same roller, as the nonwoven then travels a longer distance than the circumference of the rotating roller. This prevents re-piercing at the same point in the nonwoven, thus allowing for modification of the surface of the consolidated nonwoven.

[0018] Space-saving, multi-stage bonding of the nonwoven fabric can be achieved by arranging an additional needle plate and a further stripper element on an offset circumference of the roller. The nonwoven fabric is guided over a larger portion of the roller's circumference and can be bonded multiple times. The number of bonding stages that can be achieved depends, among other things, on the roller's diameter and the method used to re-feed the nonwoven fabric onto the roller.

[0019] The single or multiple bonding of the nonwoven fabric on a first roller can be followed by further bonding on a second roller with another needle plate. This results in a very compact system in which the rollers with the needle plates and scrapers can be arranged side by side and / or one above the other to save space, with the nonwoven fabric running in a meandering pattern around the rollers and being needled from both sides. Different roller speeds can also be used to control the degree of distortion.

[0020] The stripper element has elongated slots open on one side, which correspond to the needles of the roller. A comb-like structure is created in the profile, over which the nonwoven fabric is conveyed, while the needles are simultaneously pulled out of the fabric by the rotation of the roller. This requires that the needles are arranged in rows or lanes.

[0021] Alternatively, the stripping element can be designed as a comb or brush roller, which can be stationary (i.e., non-rotatable) or rotatable. The use of a brush roller allows for a random or spiral arrangement of the needles, which are not arranged in rows or lanes.

[0022] The inventive method for consolidating a nonwoven fabric comprises at least one rotatably designed roller with a plurality of needles which are located on the surface of the Internal file number P230903W01

[0023] The rollers are arranged around the circumference and across the working width. The incoming nonwoven fabric is consolidated between at least one needle plate or roller spaced apart from the main roller. The needles of the roller penetrate the nonwoven fabric and, after a rotational angle of the roller, exit it again. The peripheral speed of the roller during consolidation corresponds to the transport speed of the nonwoven fabric. This achieves a continuous transport speed during consolidation, where the needles no longer enter and exit the nonwoven fabric through a perpendicular impact motion, but rather through a continuous rotational movement of the roller.

[0024] The nonwoven fabric is fed into the gap between the roller and the needle plate by means of a guide element, with optional compaction of the nonwoven fabric between the guide element and the needle plate. By positioning the guide element behind the roller in the material transport direction, the nonwoven fabric is guided in such a way that the needles of the roller emerge from the nonwoven fabric via the rotational movement.

[0025] The needles are stripped from the nonwoven fabric by means of a stripping element that has open elongated holes, a comb structure, or a brush structure. The needles rotate through the elongated holes, the comb structure, or the brush while the nonwoven fabric is transported further over the stripping element.

[0026] The nonwoven fabric can be bonded multiple times on a single roller by arranging several needle plates and stripper elements around the roller's circumference. Guiding the nonwoven fabric over the stripper elements creates a path difference between the needles and the fabric, preventing the fabric from being punctured in the same spot repeatedly. To achieve a high puncture density and, if desired, to puncture from both the top and bottom, the nonwoven is guided not just over one roller, but over several. This allows the puncture density to be scaled with the number of rollers. When using multiple rollers, distortion between them is possible due to their different rotational speeds. As the bond strength increases, the nonwoven fabric can be deflected more sharply, allowing it to pass through multiple puncture stations per roller. For this, the nonwoven is guided alternately under a needle plate and then over a stripper element.Besides the number of rollers, the diameter of the rollers is another way to scale the needling performance. A larger diameter allows for more needle plates and stripping elements to be placed on them.

[0027] The roller according to the invention for consolidating a nonwoven fabric comprises a set of needles arranged and attached to the circumference of the roller. The set is either wound around the roller as a wire, or slid onto the roller as rings and fixed in place, or arranged and attached to the roller as a needle assembly. This allows for quick replacement of the sets as a complete unit by simply sliding them onto the roller (Internal File No. P230903W01). Unlike a conventional needle-bonding machine, this allows for very rapid needle changes for different fiber types and nonwoven thicknesses to be consolidated.

[0028] The needles can have cylindrical, pyramidal, or stepped cross-sections, featuring notches at regular or irregular intervals along their height and circumference. The angle of the needles to the surface can also be varied, allowing for greater penetration depth. The type of needles influences the desired strength and the external appearance of the nonwoven fabric.

[0029] The needles of the assembly can be spaced apart across the working width of the roller, with the spacing achieved by a widened assembly base or by spacers. This allows tensile forces acting on the assembly to be absorbed and simultaneously influences the needle pattern.

[0030] Advantageously, the needle rings have a groove or tongue on their inner diameter that interlocks with the surface of the roller. This prevents random arrangement of the needle rings on the roller by specifying a precise positioning according to which the arrangement of the needles on each needle ring is aligned.

[0031] A joining point allows the set rings to be manufactured as split or open rings, which simplifies both production and assembly. At the joining point, the open set rings are joined together to form a closed circumference.

[0032] Internal file number P230903W01

[0033] Further measures improving the invention are described in more detail below together with the description of several embodiments of the invention with reference to the figures.

[0034] They show:

[0035] Figure 1a shows a schematic representation of a roller with a trim in the form of an endless wire;

[0036] Figure 1b shows a schematic representation of a roller with a set of rings;

[0037] Figure 2 shows an example of a section of a set with different needles;

[0038] Figure 3 shows a fleece with variations of differently oriented needles;

[0039] Figure 4a shows a schematic representation of a slid-on or mounted set in a first embodiment;

[0040] Figure 4b shows a schematic representation of a slipped or mounted set in a second embodiment;

[0041] Figure 5a shows the positioning of trim rings on a roller;

[0042] Figure 5b shows the arrangement of garment rings on a roller with offset needles;

[0043] Figure 5c shows the design and arrangement of fitting rings with different joining points;

[0044] Figure 6a shows a roller for needle punching with a needle plate in a side view.

[0045] Figure 6b shows an enlarged representation of the cylinder with a needle plate in a front view;

[0046] Figure 6c shows an enlarged view of the stitch plate in a top view;

[0047] Figure 7 shows a section of a system with a roller for needle punching a nonwoven fabric;

[0048] Figure 8 shows another embodiment of a system with a roller for needle punching a

[0049] fleece;

[0050] Figure 9 shows another embodiment of a system with a roller for needle punching a nonwoven fabric;

[0051] Figure 10 shows a detailed view of a roller with a scraper element;

[0052] Figure 11 shows a further detailed view of a roller with a scraper element;

[0053] Figure 12 shows an embodiment of a system with two rollers for needling a nonwoven fabric; Internal file reference P230903W01

[0054] Figure 13 shows an embodiment with the arrangement of the needles on the roller.

[0055] Figure 1a shows a roller 1 with a set 2 as a set wire 2a in the form of an endless wire having a plurality of needles 3. Figure 1b shows a roller 1 having a plurality of sets 2 in the form of rings. Each set ring 2b can vary with respect to the number and shape of the needles 3. The set 2, both in the form of a set wire 2a and in the form of a set ring 2b, is wound or pushed onto the roller 1 in a rotationally fixed manner.

[0056] Figure 2 shows a section of a needle assembly, which can be configured as a needle wire 2a or a needle ring 2b. Various needle shapes 3, connected to a needle base 4, are shown as examples. The underside of the needle base 4 rests against the roller 1. The needles 3 extend from the top of the needle base 4 and can be connected to it in one or more parts. As in the classic needle-punching process, the needles 3 can have different geometric shapes, for example, cylindrical, pyramidal, or stepped cross-sections. The inclination of the needles 3 to the circumference of the roller 1 can also vary. Notches 3a can be arranged at regular or irregular intervals both along the height and circumference of the needles 3.For reed rings 2b, the needles 3 can be inserted, driven, or pressed into an opening in the ring, and this reed ring 2b can then be mounted onto the roller 1. Alternatively, a punching process is possible, so that the needles 3 are formed integrally with the reed ring 2b. For reed wire 2a, the classic method of punching from an endless wire is the preferred manufacturing method. The notches 3a can be incorporated into the needles 3 separately before, during, or after the manufacturing process. The use of obliquely arranged needles 3 (Figure 3) can improve stripping behavior for the process described here, and thus, in general, higher nonwoven strength can be achieved for the same basis weight.Because needle 3 penetrates the nonwoven fabric at an angle, it aligns and entangles the fibers more in the plane of the surface than would be the case with a needle 3 penetrating only perpendicular to the fiber material. This results in a potentially longer distance within the fiber material over which the fibers are entangled. The longer the entanglement, the higher the fiber-fiber friction forces and thus the strength. Needles 3 can be designed to be shorter than conventional needles because, in the described process, they have to penetrate fewer machine elements and smaller gaps. While a needle 3 in conventional needling must penetrate the needle board, the stripper, the gap between the stripper and the needle plate, and at least part of the needle plate, the path in roller needling is limited to partial penetration into the needle plate. Internal reference P230903W01.

[0057] Figure 4a shows a set 2, which can be designed as a set wire 2a or a set ring 2b, and whose tooth bases 4 interlock at intervals using a tongue-and-groove system. This creates a gap between the needles 3. Figure 4b shows the design of sets that can be wound or pushed side by side onto a roller as continuous wire or rings and separated from each other by spacers 5. When using a set wire 2a, the spacer 5 can also be wound as a continuous element parallel to the set wire 2a. When using a set ring 2b, the spacer 5 is pushed onto the roller alternately with the set rings 2b. The set rings 2b can be manufactured closed or open. In the latter case, a clamp or similar device can be used at a joining point 6 to connect and close two ends.The pin rings 2b can be designed at their base to be positively connected to one another or inserted into a tongue-and-groove system, overlapping and thus supporting each other. Alternatively, fixed or attachable spacers 5 can be arranged between the individual pin rings 2b. These spacers support the pin rings 2b and clamp them from above at the tooth base 4 on the roller. In addition to lateral support and the force generated during installation under tension, the spacers absorb tensile forces acting on the pin rings 2. For spunlace products, the typical waterjet marks are acceptable under certain circumstances. However, in general, it is important to achieve mechanically and visually uniform pinning during the needling process.For this purpose, needle patterns are designed that specify the positions of the needles 3 in the needle boards and have a distribution that is as stochastic as possible.

[0058] If the pin rings 2b are positioned randomly on the roller 1, this can lead to patterns that appear in the final product. If a predetermined pin pattern is desired during roller pinning, a positioning aid is required. Axial positioning can be achieved, for example, by the previously mentioned spacers 5 between the pin rings 2b or the pin wire 2a. For radial positioning, lugs, dovetails, grooves, etc., can be incorporated into both types of rings. A corresponding counterpart in the form of a recess on the roller 1 ensures precise radial positioning of the pin ring 2b, as shown in Figure 5a. In the left-hand embodiment, the pin ring 2b has a spring 2c or protrusion on its inner diameter that engages in a corresponding groove or recess in the roller 1, thus positioning the pin ring 2b at a twisted angle on the roller 1.In the right-hand embodiment, the set ring 2b has a groove 2d or recess in its inner diameter into which a corresponding spring or projection of the roller 1 engages. Figure 5b shows set rings 2b without the associated roller, with the inwardly directed springs 2c. The needles 3 arranged on the set ring 2b (Internal file reference P230903W01) are offset from the alignment point of the springs 2c, thus preventing a puncture pattern in the consolidated nonwoven fabric. To enable the set rings 2b with spring 2c or groove 2d to be mounted, the associated roller 1 has a corresponding counter element on its circumference, allowing the set rings 2b to be slid onto it. Alternatively or additionally, in an open design, the set rings 2b can have joining points 6 at which they can be closed as a ring, as shown in Figure 5c.The joining point 6 can, for example, be designed as an opening with a corresponding pin, as locking elements, or as a clamp. Advantageously, the arrangement of the joining points 6 is offset from one another so that no two potential weak points coincide. Since the fitting ring 2b has more material at the spring 2c, this point can also be used as a joining point 6. In this embodiment, where the joining points 6 are no longer offset from one another, the joining point 6 must be designed to be sufficiently robust so that, in the event of damage, not all fitting rings 2b spring open as a result of a chain reaction.

[0059] If the needle-punching assembly and spacers are not mounted continuously under tension, but rather as an assembly ring 2b, it is necessary to pre-tension them. This can be achieved either by shrinking or applying pressure to the inner body of the roller, or by using a suitable expanding mechanism, hydraulics, or pneumatics. It is also possible to axially compress the assembly rings 2b into a single unit to fix them to the roller 1.

[0060] Just as the needle boards can be replaced on classic lifting needle machines, the needle-punching rollers can also be replaced. After removing or releasing the set 2, a new set 2 or new set rings 2b can be fitted.

[0061] To avoid having to mount the set rings individually, they can be supplied on a transport carrier / roller. Like roller 1, the transport device uses a positioning aid, such as a groove or a lug, so that the set rings 2b are already pre-positioned for the customer. A slight amount of play between the set rings and the transport carrier allows the set rings to be slid from the carrier onto the actual roller 1 for needle insertion.

[0062] The customer can leave the rollers 1 in the machine. In this case, he must loosen a bearing and equip it with a device that holds the roller 1 and simultaneously provides space for part of the set of trim rings 2b, so that he can place it forward and then slide it onto the roller 1.

[0063] Traditional needlepoint requires new needle boards, as well as new stripper and needle plates, to create a new needle pattern. With the method described here (internal file number P230903W01), any needle pattern can be created within the width and spacing of the needle plate and stripper elements by using different set rings 2b. Even if the needle plates and stripper elements need to be replaced, the cost is lower than with traditional needlepoint.

[0064] To pierce the fiber pile, a counterforce must be applied to the material. In the case of velour needle-punching machines, this is a type of brush; in classic needle-punching, needle plates are used. These needle plates contain holes into which the needles dip after piercing the fiber material.

[0065] As shown in Figures 6a to 6c, the material rests on the needles 3 of the roller 1. Ideally, tension on the fiber material and a slight wrap are sufficient for the needles 3 to pierce the fiber material or the nonwoven fabric 10. If this force is insufficient, a needle plate 21 can also be used for the roller 1. Since the needles 3 rotate with the roller 1, the needle plate 21 has elongated holes 21a, which are designed to be as narrow as possible, depending on the dimensions of the needling element. This provides lateral support for the material and applies a counterforce that causes the needles 3 to pierce the nonwoven fabric 10. In Figure 6a, the roller 1 with the needles 3 rotates counterclockwise. The nonwoven fabric 10 is transported to the left at a speed corresponding to the peripheral speed of the roller 1. In Figure 6b the representation is rotated by 90° so that the viewing direction is in the longitudinal direction of the elongated holes 21a.In this sectional view of the roller 1 with the stitching rings 2b, the spacers 5 between the stitching rings 2b are visible. Figure 6c shows a top view of Figure 6b, in which the elongated holes 21a of the stitching plate 21 can be seen from above. Figure 6a shows that the force for needling is directed against the stitching plate 21, under which the nonwoven fabric 10 is guided, so that the penetrating needles 3 press the nonwoven fabric 10 against the stitching plate 21.

[0066] Figure 7 shows a section of a nonwovens machine in which an uncompressed nonwoven fabric 10 enters from the right side over a guide element 22 between the needle plate 21 and the roller 1 and is needled in the process. The nonwoven fabric 10 is compressed between the needle plate 21 and the roller 1 and consolidated by the needles 3 of the roller 1. The compressed nonwoven fabric 10 is guided with its underside over a stripper element 23, which in this embodiment is designed as an angle. The stripper element 23 is arranged downstream of the roller 1 in the production direction. Like the needle plate 21, the stripper element 23 has an arrangement of open elongated holes corresponding to the needles 3 of the roller 1, through which the needles 3 penetrate and are thereby drawn out of the nonwoven fabric 10. The arrangement of the elongated holes of the stripper element 23 can be similar to that of a comb. The stitch plates 21 can be adapted in their shape to suit their function.Curved needle plates 21 can be used, which partially "enclose" the roller 1, or they can be shaped in such a way that they form a funnel at the inlet, for example (Internal file number P230903W01), which compresses the incoming material. Depending on the embodiment, a driven compression variant is also necessary for the inlet, in which the material is compressed by means of driven rollers or belts before it runs into the space between roller 1 and needle plate 21 and is further compacted and needled.

[0067] In the punctured state, the nonwoven fabric 10 is advanced. After the nonwoven fabric 10 has been punctured, it must be separated from the needle 3 again in order to be punctured by another needling element.

[0068] For this purpose, the nonwoven fabric 10 is guided over a guide element 22, which can be driven, rolling, or static. Furthermore, the guide element 22 can be additionally coated to achieve properties desirable for the process, such as a low coefficient of friction, increased abrasion resistance, corrosion protection, or similar properties.

[0069] Figure 8 shows another embodiment of a section of a nonwovens machine in which a nonwoven fabric 10 enters from the right side over a guide element 22 between the needle plate 21 and the roller 1 and is needled in the process. A guide element 22, in the form of a stationary or rotating roller, is arranged on each side of the roller 1, over which the nonwoven fabric 10 is guided below the needle plate 21. Guiding the nonwoven fabric 10 causes it to be drawn off the needle 3. The guide element 22 can be positioned to match the needle 3. For example, it can be advantageous if the nonwoven fabric 10 is drawn off perpendicular to the needle 3. The guide element 22, arranged in the production direction in front of the roller 1 (the right-hand guide element 22 in Figure 8), is designed to guide the nonwoven fabric 10 between the roller 1 and the needle plate 21.The guide element 22, arranged downstream of the roller 1 in the production direction (the left guide element 22 in Figure 8), is designed to guide the nonwoven fabric 10 under the needle plate 21 and simultaneously serves as a stripper element 23 for the needles. This guide element 22 is arranged such that the needles 3 pass by it with only a small gap as the roller 1 rotates. This design requires a certain thickness or stiffness of the nonwoven fabric 10 to prevent jamming between the needle 3 and the guide element 22 due to folding of the nonwoven fabric 10.

[0070] For the unwinding behavior, it can also be advantageous if only one side of the needles 3 is provided with notches 3a, so that the nonwoven fabric 10 slides over the notchless side when unwinding from the needle 3. Depending on the material properties, it may not be possible to effectively unwind the nonwoven fabric 10 from the needle 3 using a simple guide element 22, but rather to strip it off as in conventional needling. In this case, the guide element 22 can be designed as a stripping element to strip the nonwoven fabric 10 from the needles 3. Here, too, the stripping element 23 can be positioned differently to optimize the stripping angle. The guide element 22 can be fixed or rotatable (Internal reference P230903W01) and its surface properties can also be optimized for the nonwoven fabric 10 by means of a coating.

[0071] Figure 9 shows a combination of Figure 7 and Figure 8, in which the guide element 22 is designed as a static or rotatable roller in the production direction in front of the roller 1, and the stripping element 23 is designed as an angle in the production direction after the roller 1, in which the needles 3 dip into open elongated holes 23a, as shown in Figure 10.

[0072] Figures 10 and 11 show two exemplary variants of a stripping element 23. The stripping element 23 has an open triangular shape with two legs, the open side being oriented towards the roller 1. Compared to a simple comb, this angle offers the advantage of higher bending stiffness and a rounder shape at the point where the nonwoven fabric is deflected. The stripping element in Figure 11 is depicted as a comb roller, whose elongated holes 23a for stripping the needles 3 from the nonwoven fabric 10 are designed around their circumference as a plurality of indentations or grooves, the depth and spacing of which correspond to the set 2 of the roller 1. The stripping element 23, designed as a comb roller, can rotate with the nonwoven fabric 10, thereby reducing frictional resistance. If necessary, such a comb roller can also be driven, so that even less force acts on the fiber material transported over it.

[0073] Figure 12 shows a system with several rollers 1.1, 1.2 for bonding a nonwoven fabric 10. Depending on the material properties, it is possible to place several stripping elements 23.1, 23.2 on one roller 1.1 and thus puncture the material multiple times with the same roller 1.1. The guide over the stripping elements 23.1, 23.2 creates a path difference between the needles 3 and the nonwoven fabric 10, so that the nonwoven fabric 10 is not punctured in the same place again. To achieve a high puncture density and puncture from both the top and bottom, the nonwoven fabric 10 is guided not only over one roller 1.1, but over several rollers 1.1, 1.2. In this way, the puncture density for both sides of the nonwoven fabric can be scaled by the number of rollers. When using multiple rollers, a slight offset between them is also possible.If the nonwoven fabric 10 is not yet firm enough after the first needling to be guided over a stripper element 23 to the next needling station of the same roller, only one needling contact occurs on each of the first rollers, from which the nonwoven fabric 10 is pulled off as straight as possible and transported further. As its strength increases, the nonwoven fabric 10 can be deflected more strongly and thus pass through several needling stations per roller. For this purpose, as shown above, the nonwoven fabric 10 is guided alternately under a needle plate 21 and then over a stripper element 23. In addition to the number of rollers, the diameter of the rollers is also a way to scale the needling capacity. More needle plates 21 and stripper elements 23 can be placed on a larger diameter roller. Furthermore, the last rollers 1 can also be equipped with brushes as needle plates to produce a velour-like surface. Internal file reference P230903W01.

[0074] In the embodiment shown in Figure 12, a nonwoven fabric 10 to be consolidated enters a consolidation unit comprising two rollers 1.1, 1.2, four needle plates 21.1, 21.2, 21.3, 21.4, and four stripping elements in the form of comb rollers 23.1, 23.2, 23.3, 23.4. The nonwoven fabric 10 can enter the unit from the top side, is guided by a guide element 22 between a first needle plate 21.1 and a first roller 1.1, and is needled there for the first time. The nonwoven fabric 10 is deflected above a first stripping element 23.1, whereby the needles 3 are pulled out of the nonwoven fabric 10 below the stripping element 23.1. The nonwoven fabric 10 is then guided further between the first roller 1.1 and a second needle plate 21.2 for further needle punching. In this embodiment, the second stitch plate 21.2 is arranged on the circumference of the first roller 1.1 at approximately 120° counterclockwise to the first stitch plate 21.1. A second wiper element 23.2, also designed as a comb roller, guides the nonwoven fabric 10 along its outer circumference to a second roller 1.2. In the second stripping element 23.2, the needles 3 of the first roller 1.1 are again pulled out of the nonwoven fabric 10. A second roller 1.2 can be arranged next to or below the first roller 1.1 and is also designed to consolidate the nonwoven fabric 10 at least twice around its circumference. This consolidation takes place from the other side of the nonwoven fabric. The first consolidation occurs between the second roller 1.2 and a third needle plate 21.3, to which a third stripping element 23.3, also designed as a comb roller, is assigned in the material flow direction. By means of this stripping element 23.3, the needles of the second roller 1.2 are pulled out of the nonwoven fabric 10. The fleece 10 is guided around the third stripping element 23.3 between the second roller 1.2 and a fourth stitch plate 21.4. Finally, a fourth stripping element 23 follows.4, around which the nonwoven fabric 10 is fed to further processing. The third and fourth stitch plates 21.3, 21.4 are also arranged at an angle of approximately 120° to each other on the circumference of the second roller 1.2.

[0075] In this embodiment, the nonwoven fabric is compacted twice on each roller 1.1, 1.2, twice from above and twice from below. Each roller 1.1, 1.2 is assigned two stitch plates 21.1, 21.2; 21.3, 21.4. Following the material flow direction, a stripping element 23.1, 23.2, 23.3, 23.4 is arranged after each stitch plate 21.1, 21.2, 21.3, 21.4. Depending on the size of the roller, multiple compaction steps can be performed on each roller. By arranging additional rollers with a meandering guide for the nonwoven fabric around the rollers, multiple compaction steps are possible in a very small space and at high production speeds. The decisive factor is not the dwell time of a needle 3 in the nonwoven fabric 10, but rather the frequency of the punctures with which the fibers are interwoven or entangled and thus consolidated. In contrast to a conventional needle-punching machine, the device and system according to the invention are significantly more flexible with regard to the variation of the needles.The system according to the invention can also be operated at a significantly higher production speed in a smaller usable space. Internal file number P230903W01.

[0076] The opening angle between the needles 3 is determined by the diameter of the rollers 1, provided that the needles are mounted at a constant distance and with the same orientation on the surface of the roller 1. As the diameter of the roller 1 increases, the opening angle decreases, which can be advantageous for minimizing compression of the nonwoven fabric 10 in the area between two needles 3 when the nonwoven fabric 10 is pressed onto the needles 3 towards the roller shell. Figure 13 illustrates this difference between a large roller and a small roller, where the opening angle α of the large roller 1.1 is smaller than the opening angle β of the small roller 1.2.

[0077] In another possible embodiment, tensioned wires can be used instead of the needle plates and wiper elements. These wires can be made of different materials, e.g., metal, plastic, or a combination in the form of sheathed metal wires. The wires are tensioned between the die rings and, in the case of the "needle plate" function, guide the material onto the needles, or, in the case of the "wiper" function, lift it from the needles.

[0078] The working width of the rollers 1 can be up to 9000 mm. The diameter of the rollers 1 can be arbitrarily chosen. To avoid increasing the number of needling stations, the roller diameter is preferably between 400 mm and 1500 mm, allowing for at least two needling stations and small angles a, β for each roller. A production speed of up to 400 m / min is possible. The basis weight of the nonwoven fabric to be processed can be between 20 g / m².2 up to 200g / m² 2 The best results for consolidation were achieved with a fiber length of the nonwoven fabric to be processed between 15mm and 150mm and a corresponding titer of 0.6dtex to 17dtex.

[0079] Internal file number P230903W01

[0080] Reference sign

[0081] 1 roller

[0082] 2 sets

[0083] 2a Set wire

[0084] 2b Set ring

[0085] 2c spring

[0086] 2d Nut

[0087] 3 needles

[0088] 3a Notch

[0089] 4 set foot

[0090] 5 spacers

[0091] 6 joint

[0092] 10 fleece

[0093] 11 fiber

[0094] 20 Annex

[0095] 21 stitch plate

[0096] 21a Slotted hole

[0097] 22 Guide element

[0098] 23 Wiper element

[0099] 23a Slotted hole a Angle between two needles across the circumference of a roller ß Angle between two needles across the circumference of a roller

Claims

Internal file number P230903W01 Patent claims 1. A system for consolidating a nonwoven fabric (10), comprising at least one rotatably designed roller (1) with a plurality of needles (3) arranged on the surface of the roller (1) over the circumference and over the working width, comprising at least one needle plate (21) arranged at a distance from the roller (1), which extends over the working width of the roller (1) and has elongated holes (21a) through which the needles (3) of the roller (1) can pass over an angle of rotation of the roller (1), wherein the system is designed to consolidate a nonwoven fabric (10) between the roller (1) and the needle plate (21).

2. System according to claim 1, characterized in that a guide element (22) is formed to introduce the nonwoven fabric (10) into the gap between the roller (1) and the stitch plate (21).

3. System according to claim 1, characterized in that a stripping element (23) is arranged behind the roller (1) in the material transport direction, which is designed to pull or strip the needles (3) of the roller (1) from the nonwoven fabric (10).

4. System according to claim 1, characterized in that the roller (1) is further associated with a stitch plate (21) and a further stripping element (23) for consolidating the nonwoven fabric (10).

5. System according to one of the preceding claims 1 to 4, characterized in that the nonwoven fabric (10) is consolidated by means of a second roller (1.2) and a further stitching plate (21).

6. System according to claim 3, characterized in that the wiping element (23) has elongated holes (23a) open to an outside which correspond to the needles (3) of the roller (1) or that the wiping element (23) is designed as a comb roller, brush or brush roller.

7. System according to claim 5, characterized in that the rollers (1.1, 1.2) are arranged offset from one another and / or next to each other.

8. System according to one of the preceding claims, characterized in that the wiping element (23) has at least one surface designed to guide the nonwoven fabric (10).

9. System according to claim 6, characterized in that the scraper element (23), which is designed as a comb roller or brush roller, is rotatable. Internal file number P230903W01 10. Method for consolidating a nonwoven fabric (10), comprising at least one rotatably designed roller (1) with a plurality of needles (3) arranged on the surface of the roller (1) over the circumference and over the working width, comprising at least one needle plate (21) arranged at a distance from the roller (1), wherein a nonwoven fabric (10) is inserted between the needle plate (21) and the roller (1), into which the needles (3) of the roller (1) enter and exit via a rotation angle of the roller (1), wherein the circumferential speed of the roller (1) during consolidation corresponds to the transport speed of the nonwoven fabric (10).

11. Method according to claim 10, characterized in that the nonwoven fabric (10) is introduced into the gap between the roller (1) and the stitch plate (21) by means of a guide element (22), wherein the nonwoven fabric (10) is compressed between the stitch plate (21) and the guide element (22).

12. Method according to claim 10, characterized in that the nonwoven fabric is guided over a stripping element (23) so that the needles (1) of the roller (1) are pulled out of the nonwoven fabric (10) with the further rotational movement of the roller (1).

13. Method according to claim 12, characterized in that the nonwoven fabric is compacted on the roller (1) by means of a further stitching plate (21).

14. Method according to one of claims 10 to 13, characterized in that the nonwoven fabric (10) is consolidated between a second roller (1.2) and a further stitch plate (21).

15. Method according to one of claims 10 to 14, characterized in that the rollers (1.1, 1.2) are operated at different speeds, so that the nonwoven fabric is stretched or compressed.

16. Roller for consolidating a nonwoven fabric, comprising a set (2) with a plurality of needles (3) arranged and fixed on the circumference of the roller (1), wherein the set is wound around the roller (1) as a set wire (2a), or is pushed on and fixed as set rings (2b), or is attached to the roller (1) as a needle assembly.

17. Roller according to claim 16, characterized in that the needles (3) have cylindrical, pyramidal or stepped cross-sections which have notches (3a) at regular or irregular intervals along the height as well as on the circumference. Internal file number P230903W01 18. Roller according to claim 16, characterized in that the needles (3) of the assembly (2) are arranged at a distance from one another over the working width of the roller (1), the distance being achieved by a widened assembly base (4) or by spacers (5).

19. Roller according to claim 16, characterized in that the assembly rings (2b) have a groove (2d) or a tongue (2c) on their inner diameter which engages positively with the surface of the roller (1).

20. Roller according to claim 16, characterized in that the assembly rings (2b) have a joining point (6) with which the assembly rings (2b) are to be joined to form a closed circumference.

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