DE3117737C2 - - Google Patents

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Publication number
DE3117737C2
DE3117737C2 DE3117737A DE3117737A DE3117737C2 DE 3117737 C2 DE3117737 C2 DE 3117737C2 DE 3117737 A DE3117737 A DE 3117737A DE 3117737 A DE3117737 A DE 3117737A DE 3117737 C2 DE3117737 C2 DE 3117737C2
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Prior art keywords
nozzle
filaments
cooling
cooling fluid
cooling chamber
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Expired - Lifetime
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DE3117737A
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English (en)
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DE3117737A1 (de
Inventor
David W. Wittenberg Wis. Us Appel
Michael T. Appleton Wis. Us Morman
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Kimberly Clark Corp
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Kimberly Clark Corp
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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/15Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/02Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
    • D04H3/03Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments at random
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/05Filamentary, e.g. strands
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25Component parts, details or accessories; Auxiliary operations
    • B29C48/78Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling
    • B29C48/86Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling at the nozzle zone
    • B29C48/87Cooling
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/16Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001Combinations of extrusion moulding with other shaping operations
    • B29C48/0018Combinations of extrusion moulding with other shaping operations combined with shaping by orienting, stretching or shrinking, e.g. film blowing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/07Flat, e.g. panels
    • B29C48/08Flat, e.g. panels flexible, e.g. films
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25Component parts, details or accessories; Auxiliary operations
    • B29C48/30Extrusion nozzles or dies
    • B29C48/345Extrusion nozzles comprising two or more adjacently arranged ports, for simultaneously extruding multiple strands, e.g. for pelletising
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25Component parts, details or accessories; Auxiliary operations
    • B29C48/78Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling
    • B29C48/86Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling at the nozzle zone
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29LINDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00Other particular articles
    • B29L2031/731Filamentary material, i.e. comprised of a single element, e.g. filaments, strands, threads, fibres
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2555/00Personal care
    • B32B2555/02Diapers or napkins

Description

Die Erfindung bezieht sich auf eine Vorrichtung zum Bilden einer nicht gewebten Bahn aus einem fließfähigen Material der im Oberbegriff von Anspruch 1 erläuterten Art.
Eine derartige Vorrichtung ist aus der GB-PS 12 85 381 bekannt. Die bekannte Vorrichtung enthält eine sich über die gesamte Maschinenbreite erstreckende Verstreckkammer, in der die extrudierten Filamente abgekühlt werden. Am unteren Ende der Verstreckkammer sind einzelne, rohrförmige Verstreckdüsen angeordnet, wobei jede Verstreckdüse nur ein Einzelfilament bzw. ein Filamentbündel aufnehmen kann. Unmittelbar oberhalb der Verstreckdüsen mündet eine Leitung für Kühl- und Verstreckluft unter einem Druck von mindestens 1×10⁵ Pa, bevorzugt 3×10⁵ Pa, ein.
Bei der Vorrichtung nach der DE-AS 17 60 713 ist im Abstand unterhalb des Spinnkopfes ein Paar nach unten konvergierender Wände angeordnet, zwischen denen die Filamente in Richtung auf die Ablageeinrichtung durchlaufen. Die Düse zum Erzeugen des die Filamente ausziehenden Fluidstromes ist in der einen, vertikal und parallel zur Filamentlaufrichtung ausgerichteten Wand in Gestalt einer Lavaldüse angeordnet. Das unter hohem Druck (3,5×10⁵ Pa) stehende Fluid strömt aus der Düse mit Überschallgeschwindigkeit aus und wird durch den Coanda-Effekt in Anlage an der vertikalen Wand gehalten. Dadurch werden die auf dem Weg vom Spinnkopf bis zur Düse verfestigten Filamente mit hoher Geschwindigkeit ausgezogen. Die der Wand gegenüberliegende Wand dient nur dazu, an den Randzonen des Fluidstrahles künstlich Sekundärluft einzusaugen, um die Fäden der Randzonen einzuziehen.
Weitere Vorrichtungen, bei denen die Filamente mit Hilfe von unter hohem Druck stehender Luft ausgezogen werden, sind in der US-PS 36 92 618, der US-PS 38 02 817 und der US-PS 40 64 605 beschrieben.
Die bekannten Vorrichtungen sind wegen der Notwendigkeit, ein Hochdruckfluid zur Verfügung zu stellen, aufwendig. Für den Fall, daß eine ausreichende Verfestigung auf dem Weg der Filamente zwischen dem Spinnkopf und der Düse durch normales Durchlaufen der Umgebungsluft nicht erreicht werden kann, ist in diesem Bereich außerdem eine gesonderte Kühlluftzufuhr erforderlich. Darüber hinaus erzeugt unter hoher Geschwindigkeit austretende Luft einen hohen Lärmpegel und erfordert einen sehr großen Luftdurchsatz, was wiederum einen leistungsfähigen und daher energieaufwendigen Kompressor voraussetzt. Die wegen der Turbulenzen im Hochgeschwindigkeitsstrom erforderlichen Einzeldüsen verstopfen jedoch leicht, wenn ein Filament bricht. Zur Reinigung der Düsen muß dann das gesamte System längerfristig abgeschaltet werden, was wiederum die Betriebskosten erhöht.
Der Erfindung liegt die Aufgabe zugrunde, eine Vorrichtung der eingangs geschilderten Gattung zu schaffen, die einfach aufgebaut ist und niedrige Betriebskosten erfordert.
Die Aufgabe wird durch die kennzeichnenden Merkmale des Anspruches 1 gelöst.
Bei der erfindungsgemäßen Vorrichtung wird ein Niederdruckfluid sowohl zum Verfestigen der Filamente als auch zum anschließenden Ausziehen derselben benützt. Das Fluid strömt auf einer Seite der Filamente in die Kühlkammer ein und umspült diese mit einer Strömungsgeschwindigkeit, die wegen der Größe der Kühlkammer gering gehalten werden kann. Dadurch tritt eine rasche Verfestigung der Filamente ein, ohne daß sich diese zu stark bewegen. Damit ist die Gefahr eines gegenseitigen Verklebens und eines Anhaftens an den Wänden der Kühlkammer gebannt. Da die Düse die Hauptaustrittsöffnung für das Fluid aus der Kühlkammer bildet, beschleunigt sich das Kühlmittel in der Düse, wodurch die die Düse verlassenden Filamente mitgenommen und ausgezogen werden. Auf diese Weise wird erfindungsgemäß eine rasche Verfestigung der Filamente unter gut kontrollierbaren Bedingungen erreicht. Für das Ausziehen der Filamente ist kein gesondert bereitzustellendes und unter Hochdruck zu setzendes Fluid erforderlich. Die erfindungsgemäße Vorrichtung ist daher einfach aufgebaut und arbeitet sehr wirtschaftlich.
Vorteilhafte Weiterbildungen der Erfindung sind den Unteransprüchen zu entnehmen.
Mit der erfindungsgemäßen Vorrichtung können insbesondere nicht gewebte Bahnen mit Flächengewichten zwischen 3,39 bis 339 g/m² hergestellt werden. Diese Bahnmaterialien werden beispielsweise in großem Umfange für die Herstellung von Wegwerfprodukten, wie Windeleinlagen, Umhüllungen für Damenbinden, Tücher für chirurgische Zwecke oder Wischtücher, jedoch auch für dauerhaftere Produkte, wie beispielsweise Teppich-Trägerschichten, Zelttuch und dergleichen, verwendet.
Durch die Wahl einer geeigneten Düsenlänge kann die erforderliche Auszieh- bzw. Verstreckspannung mit einer Luftgeschwindigkeit in der Düse erreicht werden, die lediglich das 1,5- bis 4fache der Filamentgeschwindigkeit beträgt. So wurde beispielsweise bei einer Düsenöffnung von 9,525 mm (Beispiel 6 in der beiliegenden Tabelle) eine Luftgeschwindigkeit von 83,82 m/s) verwendet, um eine Filamentgeschwindigkeit von 47,85 m/s zu erzeugen, wobei ein Vorratsdruck von nur 4,48×10³ Pa erforderlich ist. In diesem Falle beträgt die erforderliche Luftmenge nur etwa 0,48 m³/min pro cm Maschinenbreite. Das Abkühlen der Filamente wird durch Regulieren der Temperatur der Kühlluft (z. B. zwischen 4,4 bis 54,4 Grad Celsius) und des Strömungsdurchsatzes der Luft durch die Auspufföffnung (z. B. zwischen 0 bis 0,1 m³/min pro cm Maschinenbreite) kontrolliert. Der Strömungsdurchsatz durch die Auspufföffnung kann in engen Grenzen überwacht und gesteuert werden, so daß die Betriebsbedingungen auf einfache Weise zu verändern und den Erfordernissen anzupassen sind. Der Strömungsdurchsatz des Kühlströmungsmittels durch die Düse sollte innerhalb des Bereiches von 0,223 bis etwa 0,892 m³/min pro cm Maschinenbreite und die Düsenöffnung zwischen 3,175 bis 25,4 mm gehalten werden. Die Länge der Kühlkammer, die Länge der Düse und der Abstand zwischen Düse und Ablagevorrichtung hängen selbstverständlich von den Eigenschaften des zu verspinnenden Materials sowie von den gewünschten Eigenschaften des Bahnmaterials ab. Dementsprechend können diese Parameter innerhalb weiter Grenzen variiert werden. Durch diese Veränderungsmöglichkeiten ist die Vorrichtung der vorliegenden Erfindung außerordentlich flexibel und kann auf einfache Weise an unterschiedliche Eigenschaften der zu verspinnenden Materialien, unterschiedliche Betriebsbedingungen und unterschiedliche Eigenschaften des hergestellten Bahnmaterials angepaßt werden.
Ein Ausführungsbeispiel der Erfindung wird nachfolgend anhand der schematischen Zeichnung näher erläutert. Es zeigt:
Fig. 1 ein verallgemeinertes Strömungsdiagramm einer Anlage mit der vorliegenden Erfindung,
Fig. 2 eine schematische, teilgeschnittene Perspektivansicht der erfindungsgemäßen Vorrichtung, und
Fig. 3 eine Schnittansicht der Vorrichtung nach Fig. 2.
Anhand Fig. 1 wird zunächst das Vorgehen beim Betrieb der erfindungsgemäßen Vorrichtung näher beschrieben. Der erste Schritt besteht in der Bereitstellung eines thermoplastischen Polymers in flüssigem Zustand zum Spinnen. Die Einrichtung der vorliegenden Erfindung erlaubt eine weite Vielfalt von zu verarbeitenden Polymeren, wie z. B. Polyamide, Polyester, Polyolefine, Polyvinylacetat, Polyvinylchlorid, Polyvinylalkohol, Celluloseacetat, Viskose und dgl. Es können jedoch auch andere spinnfähige Materialien, die üblicherweise nicht als Polymere bezeichnet werden, wie beispielsweise geschmolzenes Glas, verwendet werden.
Das Polymer wird von einem Vorrat 10 zu einem Trichter 12, dann durch einen Extruder 14, ein Filter 16 und eine Dosierpumpe 17 einem Spinnkasten 18 zugeführt. Filamente 20 werden durch einen Spinnkopf 22 ausgesponnen, der Öffnungen aufweist, die in einer oder mehr Reihen angeordnet sind und einen Filamentvorhang bilden, der in die Kühlkammer 24 gerichtet ist. In der Kühlkammer 24 werden die Filamente 20 in Berührung mit Luft oder einem anderen Kühlströmungsmittel gebracht, das durch den Lufteinlaß 26 und Siebe 25 eingeleitet wird, wobei die Siebe 25 als Strömungsgleichrichter zur Erzielung laminarer Strömung dienen. Das Kühlströmungsmittel wird unter niedrigem Druck bzw. Überdruck von weniger als 8,274×10⁴ Pa beispielsweise von weniger als 1,379×10⁴ Pa zugeführt. Ein Teil des Kühlströmungsmittels wird durch den Filamentvorhang hindurchgeleitet und als Abluft durch die Auspufföffnung 28 entfernt. Der als Abluft abgeleitete Teil der zugeführten Kühlluft hängt vom verwendeten Polymer sowie von der Abkühlgeschwindigkeit ab, die erforderlich ist, um die gewünschten Filamenteigenschaften zu liefern, wie etwa den Titer, die Zähigkeit bzw. Reißfestigkeit und dgl. Im allgemeinen gilt: je größer die Menge der Abluft ist, desto größer ist der sich ergebende Titer des Filamentes; und umgekehrt, je niedriger das Abluftverhältnis ist, desto niedriger ist der Titer.
Wenn der Abkühlungsvorgang beendet ist, wird der Filamentvorhang durch ein sich sanft verengendes unteres Ende der Kühlkammer in eine Düse 32 geleitet, wo die Luft eine Geschwindigkeit von etwa 45,72 bis 243,84 m/s erreichen kann. Die Düse weist die volle Maschinenbreite auf und ist beispielsweise von einer ortsfesten Wand 34 und einer beweglichen Wand 36 gebildet. Wie in Fig. 3 ersichtlich, kann die bewegliche Wand zurückgefahren oder zur ortsfesten Wand hin bewegt werden. Während der Inbetriebnahme wird die Wand voll zurückgefahren, so daß die Filamente infolge der Schwerkraft durch die weit offene Düse hindurchfallen. Die niedrige Geschwindigkeit der ankommenden Kühlluft wird durch die weit offene Düse beibehalten, so daß tatsächlich nur ein geringes aerodynamisches Verstrecken stattfindet. Wenn die Polymerströmung voll hergestellt ist, dann wird die bewegliche Wand nach vorne bewegt, um die Düsenöffnung zu verkleinern, die Luftgeschwindigkeit zu erhöhen und die Filamente auszuziehen bzw. zu verstrecken. Wenn eine größere Verfahrensstörung auftritt und die Düse teilweise während des Betriebes mit Polymer verstopft ist, wird die bewegliche Wand kurzzeitig zurückgezogen, bis der Pfropfen durch die vergrößerte Düse hindurchfällt. Die Wand wird dann wieder nach vorne in ihre normale Betriebsstellung gefahren.
Die Position dieser beweglichen Wand bestimmt die Düsenöffnung und somit die Geschwindigkeit der Luft, welche durch die Düse tritt, und zwar abhängig von dem vorgegebenen Gesamtkühlluftdurchsatz und der vorgegebenen Ablufteinstellung. Die Kraft zum Verstrecken der Filamente nimmt zu, wenn die Luftgeschwindigkeit zunimmt, so daß der Filament-Titer ganz einfach durch Veränderung der Größe der Düsenöffnung verändert werden kann. Der Titer des Filamentes kann also bei der Erfindung ganz einfach erhöht werden durch die folgenden Schritte:
  • 1) Vergrößern der Düsenöffnung,
  • 2) Verringern des Luftströmungsdurchsatzes durch die Düse,
  • 3) Erhöhen des Abluftdurchsatzes.
Die Schritte 1) und 2) verringern die Verstreckungskraft der Luft, Schritt 3) erhöht die Abkühlungsrate des Polymers.
In allen Fällen überspannt die Düse die gesamte Breite der Maschine. Deshalb wird die Verteilung der Filamente, welche im wesentlichen der Verteilung der Düsenöffnungen in der Spinnplatte entspricht, über die Maschinenbreite hinweg den gesamten Weg bis zum Auslaß der Düse aufrechterhalten.
Nach dem Verlassen der Düse können die Filamente auf einer bewegten, mit Öffnungen versehenen Ablagefläche 38, wie etwa einer endlosen Bahn oder einem Endlosriemen, zur Bildung eines nichtgewebten Bahnmateriales gesammelt werden. Durch Auswahl der Düsenöffnung und des Abstandes zwischen Düse und Ablagefläche können die Abmessungseigenschaft der Schlaufenbildung der einzelnen Filamente kontrolliert werden, um die Überlagerung der Einzelfilamente herzustellen. Dies führt zu einem gewissen Maß gegenseitiger Verschlingung und hinlänglicher Gleichförmigkeit beim resultierenden Bahnmaterial, um die weitere Bearbeitung zu erleichtern, wie etwa das Verdichten des Bahnmateriales am Walzenspalt 40, das Bondieren am Walzenspalt 42 und sein Aufwickeln.
In den Fig. 2 und 3 werden die Kühlkammer 24 und die Düse 32 näher dargestellt. Der Spinnkopf 22 kann eine herkömmliche Konstruktion aufweisen und derart angeordnet sein, daß er Filamente 20 mit einem Abstand von etwa 3,81 mm bis 14,22 mm aus in einer oder mehreren Reihen mit gleichmäßigem Abstand über die volle Breite der Maschine angeordneten Öffnungen 46 extrudiert und in die Kühlkammer leitet. Bei einem Ausführungsbeispiel ist der Spinnkopf 22 aus der Düsenmittellinie in Maschinenrichtung zur Kühlluftzufuhr 26 hin versetzt angeordnet, um die durch das durchströmende Kühlströmungsmittel bewirkte Ablenkung der Filamente aufzunehmen. Das Kühlströmungsmittel wird unter einem Winkel eingeleitet, der die Hauptgeschwindigkeitskomponente in Richtung zum Düseneingang aufweist. Das Kühlströmungsmittel kann irgendein geeignetes Gas sein, aber aus Gründen der Wirtschaftlichkeit ist Luft bevorzugt.
Der Grad der o. g. Versetzung des Spinnkopfes sollte so gewählt werden, daß die Filamente in die Düse möglichst ohne Berührung der gekrümmten Eintrittsfläche einlaufen können. Die Abkühlung der Filamente soll bis auf eine klebfreie Temperatur vor dem Eintritt in die Düse stattgefunden haben. Dazu hat sich eine Mindestlänge der Kühlkammer von 61 cm als ausreichend erwiesen, weil diese eine geeignete Zeit zum Abkühlen einer großen Anzahl von Filamenten bei hohen Produktionsraten gestattet, ohne daß Luft mit bes. niedriger Temperatur oder eine hohe Abluftströmung erforderlich sind. Die verstellbare Düsenwand 36 ist zum Kühllufteinlaß 26 hin um etwa 135° abgewinkelt. Die dadurch entstehende Kante 56 am Eintritt in die Düse ist geglättet, um den Bruch von Filamenten zu verringern. Zur Verstellung der Relativlagen der Wände 34 und 36 ist beispielsweise ein Kolben 35 vorgesehen, der gelenkig an der Stelle 37 an der Wand 36 befestigt ist. Um zu verhindern, daß sich eine Zone mit Turbulenzen in der Kühlluft bildet, sind in der Kühlkammer 24 beispielsweise Rippen 54 angeordnet, die die gesamte Ecke ausfüllen, die durch die abgelenkten Filamente gebildet ist. Die Abmessungen, ihr Abstand und Anzahl hängen von verschiedenen Faktoren wie der Kühlkammerbreite der Filamentablenkung usw. ab. Beispielsweise kann ihre Dicke 3,18 mm und ihr Abstand max. 19,05 mm betragen.
Die spezielle Düsenöffnung zwischen den Wänden 34 und 36 ist abhängig von den gewünschten Filamenteigenschaften und Verfahrensparametern und kann für gewöhnlich im Bereich von etwa 3,18 mm bis 25,4 mm liegen.
Im Austritt der Düse nimmt die mittlere Luftgeschwindigkeit ab und innerhalb eines Abstandes von etwa dem 20fachen der kleinen Abmessung der Düsenöffnung erreicht die Verstreckkraft Null und die Spannung in den Filamenten wird aufgehoben, was diese durch örtliche turbulente Wirbel aus der Bahn bringen kann. Dies führt zur Bildung unregelmäßiger Schlaufen im zu bildenden Bahnmaterial und liefert hierbei ein Maß körperlicher Überlagerung, das zur Erzeugung einer integrierten bzw. einteiligen Bahn erforderlich ist. Diese Schlaufenbildung weist eine charakteristische Größe auf, welche durch die Düsenöffnung und den Abstand zu den Öffnungen der Ablagefläche bestimmt ist. Bei einem Ausführungsbeispiel der vorliegenden Erfindung sind die Düsenwände 36 und 34 unterschiedlich lang. Der Längenunterschied kann bis etwa 76,2 mm betragen und bevorzugt zwischen 19,05 und 31,75 mm liegen. Diese Anordnung fördert die regelmäßige und vorhersagbare Filament-Wellenbewegung in Querrichtung zur Maschine, was die Verschlingung der Bahn fördert und kurzzeitige Unterbrechungen von Filamenten überdeckt, welche die Düse verlassen. Dadurch ist die Schlaufenbildung vollständig frei von großformatigen Komponenten, insbesondere beim Betrieb mit hohen Erzeugungsraten, beispielsweise 0,893 kg pro cm Maschinenbreite und Stunde oder mehr. Filamente, die aus einer kleinen Düsenöffnung z. B. von 3,18 mm kommen, und im Abstand von 381 mm von der Düse abgelegt werden, weisen Schlaufengrößen hauptsächlich im Bereich von etwa 3,18 bis 6,35 mm auf, wobei die größten Schlaufen der Filamente nur etwa 25,4 mm betragen. Andererseits liefert eine Düse von 12,7 mm Öffnungsweite größere Schlaufen hauptsächlich in der Größe von 6,35 bis 12,7 mm.
Die Bildung kleiner Filamentschlaufen mit großer Zuverlässigkeit bezüglich der Gleichmäßigkeit der Schlaufenabmessung ist ein bes. Vorzug der Erfindung, denn damit ist eine bes. Gleichmäßigkeit in der Flächengewichtsverteilung erzielbar, wobei der Abstand zwischen Düsenausgang und Ablage keine bes. Auswirkung auf die Flächengewichtsverteilung in der Bahnbreite aufweist, so daß diese nur von der Verteilung der Löcher in der Spinnplatte abhängt.
Da die erfindungsgemäße Vorrichtung auch sehr unempfindlich gegenüber Filamentbruch ist, können Filamente versponnen werden, welche mit Pigmenten und dgl. hochbeladen sind, was gefärbte und durch Additive modifizierte Bahnen liefert.
Die nachfolgenden, speziellen Beispiele wurden auf einer erfindungsgemäßen Einrichtung mit den Parametern der Tabelle, einer Länge des Kühlbereiches von 1,4224 m, einer Düsenlänge von 1,016 m, und dem angegebenen Kapillardurchsatz erzielt.
In der Tabelle bedeuten die senkrechten Spalten
  • a) laufende Nummer des Beispieles
  • b) ankommender Schmelzestrom (Polypropylen) (g/10 min)
  • c) verarbeiteter Schmelzestrom (Polypropylen) (g/10 min)
  • d) Schmelzetemperatur (°C)
  • e) Düsenspalt (mm)
  • f) Kühlluft (m³/min pro cm)
  • g) Auspuffluft (m³/min pro cm)
  • h) Kühllufttemperatur (°C)
  • i) Durchsatz (g/Loch/min)
  • j) Druck in der Kühlluftzuleitung (×133,3 Pa)
  • k) Titer (×1,1 dtex)
  • l) Zähigkeit (×0,9 g/dtex)
  • m) Längung (%)
In Beispiel 4 wurde ein TiO₂-Pigment bis zu einem Maß von 7,28 Gew.-% zugesetzt.
Im Beispiel 5 wurde Triton X-102 bis zu einem Maß von 0,8 Gew.-% zugesetzt.
Im Beispiel 27 war das verwendete Polymer Nylon 6.
Tabelle
Schallpegelmessungen wurden mit einem Düsenspalt von 6,35 mm und einem voll offenen Düsenspalt, bei einem Hintergrundgeräusch von 80 bis 90 dB vorgenommen. In Ohrenhöhe der Bedienungsperson (30,48 cm unterhalb der Düsenöffnung) überschritt lediglich eine Messung mit einem Wert von 100,5 das Maß von 100 dB. Die übrigen Meßergebnisse lagen unter 90 dB.
Bevorzugte Anwendungsfälle sind die Herstellung von Bahnen mit niedrigem Grundgewicht aus feinen Polypropylenfilamenten von weniger als 5,5 dtex (5 Denier) und Punktbindung.

Claims (10)

1. Vorrichtung zum Bilden einer nicht gewebten Bahn aus einem fließfähigen Material, mit einem Spinnkopf (22) mit einer Kapillaranordnung, welcher eine oder mehrere Reihen von mit engem Abstand angeordneten Filamenten (20) aus dem fließfähigen Material bildet, einer Kühlkammer (24) zur Verfestigung der Filamente innerhalb der Kühlkammer, die sich über die Maschinenbreite erstreckt, einer Quelle für ein Kühlströmungsmittel, einem Einlaß (26) in der Kühlkammer (24) zum Einleiten des Kühlströmungsmittels, einer Düse (32) zum Verstrecken bzw. Ausziehen der Filamente und mit einer Ablageeinrichtung (38) zum Aufnehmen der Filamente in Form einer nicht gewebten Bahn, dadurch gekennzeichnet, daß das Kühlströmungsmittel unter einem Überdruck von weniger als 8,3×10⁴ Pa zuführbar ist, daß in der Kühlkammer (24) der Einlaß (26) für das Kühlströmungsmittel an der einen Seite der Filamente (20) vorgesehen ist, und daß sich die Düse (32) als Schlitzdüse über die Maschinenbreite erstreckt.
2. Vorrichtung nach Anspruch 1, dadurch gekennzeichnet, daß die Kühlkammer (24) auf der dem Einlaß (26) bezüglich der Filamente (20) gegenüberliegenden Seite eine Auspufföffnung (28) zum Ableiten eines Teiles des Kühlströmungsmittels aufweist.
3. Vorrichtung nach einem der Ansprüche 1 oder 2, dadurch gekennzeichnet, daß die Düse (32) an ihrem Einlaß an einer Seite durch eine Wand (36) begrenzt ist, die einen Winkel (A) von mindestens 135° unter Bildung einer glatten Kante (56) einschließt.
4. Vorrichtung nach einem der Ansprüche 1 bis 3, dadurch gekennzeichnet, daß eine der die Düse (32) begrenzenden Wände (34, 36) zum Verändern der Abmessungen der Düsenöffnung verstellbar ist.
5. Vorrichtung nach einem der Ansprüche 1 bis 4, dadurch gekennzeichnet, daß in der Kühlkammer (24) eine Einrichtung zum Verringern der Turbulenz des Kühlströmungsmittels vorgesehen ist.
6. Vorrichtung nach einem der Ansprüche 1 bis 5, dadurch gekennzeichnet, daß die eine der die Düse (24) begrenzenden Wände (34, 36) austrittsseitig um bis zu 76,2 mm, bevorzugt zwischen 19,05 mm und 31,75 mm, länger ist als die andere.
7. Vorrichtung nach einem der Ansprüche 1 bis 6, dadurch gekennzeichnet, daß die Ablageeinrichtung (38) einen Mindestabstand von der Düse (32) hat, der das 20fache der kleineren Abmessung der Düsenöffnung beträgt.
8. Vorrichtung nach einem der Ansprüche 1 bis 7, dadurch gekennzeichnet, daß die durch die Auspufföffnung (28) austretende Menge des Kühlströmungsmittels veränderbar ist.
9. Vorrichtung nach einem der Ansprüche 1 bis 8, dadurch gekennzeichnet, daß der Spinnkopf (22) aus der Düsenmittellinie in Maschinenrichtung zur Kühlluftzufuhr (26) hin versetzt angeordnet ist.
10. Vorrichtung nach einem der Ansprüche 5 bis 9, dadurch gekennzeichnet, daß zum Verringern der Turbulenz des Kühlströmungsmittels Rippen (54) in der Kühlkammer (24) vorgesehen sind.
DE19813117737 1980-05-05 1981-05-05 Vorrichtung und verfahren zum bilden einer nichtgewebten bahn aus filamenten Granted DE3117737A1 (de)

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GB2077181A (en) 1981-12-16
MX152986A (es) 1986-07-14
GB2077181B (en) 1983-09-28
IT8148387A0 (it) 1981-05-04
KR830006510A (ko) 1983-09-28
IT1170940B (it) 1987-06-03
JPS5735053A (en) 1982-02-25
NL191892B (nl) 1996-06-03
FR2481719B1 (de) 1983-05-06
BR8102691A (pt) 1982-01-26
NL8102208A (nl) 1981-12-01
AU536472B2 (en) 1984-05-10
CA1160412A (en) 1984-01-17
AU7014081A (en) 1981-11-12
FR2481719A1 (fr) 1981-11-06
KR840000196B1 (ko) 1984-02-28
JPS646305B2 (de) 1989-02-02
DE3117737A1 (de) 1982-02-11
US4340563A (en) 1982-07-20

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