Claims
- 1. A process for the manufacture of a coherently self-bonded, low density matting article which comprises:
- melt-spinning a plurality of synthetic fiber-forming polymer filaments from a first set of spinning orifices with a diameter of at least about 0.1 mm. vertically downwardly for deposit onto a moving support intersecting the filaments substantially horizontally at a distance of about 3 to 20 cm. below the spinning orifices, said moving support having an undulating peak and valley surface structure to receive and form the freshly melt-spun filaments from said first set of spinning orifices into a corresponding undulating peak and valley three-dimensional matting sheet structure with the filaments from adjacent spinning orifices overlapping and self-bonding with each other at random points of intersection;
- melt-spinning another plurality of synthetic fiber-forming polymer filaments from a second set of spinning orifices onto a second separate moving support having a substantially smooth and even surface structure to receive and form the freshly melt-spun filaments from said second set of spinning orifices into a substantially flat nonwoven web of overlapped filamentary loops self-bonding at random points of intersection, said nonwoven web being substantially thinner and exhibiting a substantially lower porosity than said matting structure;
- transferring said nonwoven web while still tacky from said second moving support directly onto the free surface of the matting sheet structure as the latter is carried while still tacky on said first moving support;
- lightly pressing said nonwoven web against the free surface of the matting sheet structure such that part of the tacky surface filaments in the contacting face portions of the web and the matting adhere to each other at mutual points of intersection; and
- cooling both the web and matting on said first moving support to firmly bond the adhered filaments to each other.
- 2. A process as claimed in claim 1 wherein the spun filaments of the matting and the nonwoven web have a diameter of more than about 0.2 mm.
- 3. A process as claimed in claim 2 wherein the spun filaments of the matting and the nonwoven web are nylon filaments.
- 4. A process as claimed in claim 3 wherein said nylon filaments are polycaprolactam filaments.
- 5. A process as claimed in claim 1 wherein the nonwoven web is formed on a smooth surfaced cylindrical roller as said second moving support which then presses the web lightly against the free surface of the matting carried on said first moving support.
- 6. A process as claimed in claim 1 wherein the matting sheet structure is formed with a thickness of about 5 to 70 mm. and the nonwoven web is formed with a thickness of about 1 to 4 mm.
- 7. A process as claimed in claim 1 wherein the matting sheet structure is formed with undulations in both transverse and longitudinal directions to provide a peak and valley waffle-like appearance, and the nonwoven web is bonded to the projecting peaks of the undulating matting structure.
- 8. Apparatus for the manufacture of a coherently bonded, low density matting article consisting essentially of self-bonded synthetic polymer filaments melt-spun from at least one spinneret, which apparatus comprises:
- a first set of spinning orifices for melt-spinning a first group of polymer filaments vertically downwardly;
- a first moving support means arranged to pass under said first set of spinning orifices at a predetermined distance therebelow to receive and form the filaments into a sheet matting layer, said first support means having an upper profiled surface of projections in a peak and valley pattern onto which said one group of spun filaments are deposited;
- a second set of spinning orifices arranged to one side of said first set of spinning orifices in the direction of movement of said first support means for melt-spinning a second group of polymer filaments;
- a second moving support means arranged between said second set of orifices and said first support means to receive and form the filaments spun from said second set of orifices into a substantially flat nonwoven web, said second support means having an essentially smooth and even surface onto which said second group of spun filaments are deposited and transported, and said second support means being positioned adjacent said first support means to deliver the formed nonwoven web for application onto the outer surface of the matting layer as it is carried on said first support means; and
- means to lightly press the nonwoven web against said outer surface of the matting layer.
- 9. Apparatus as claimed in claim 8 wherein said second moving support means is a smooth surfaced roller rotatably mounted below said second set of orifices and directly above said first moving support means to first receive filaments from said second set of orifices on its surface rotatably moved in a direction counter to the profiled surface of said first moving support means and to then feed the nonwoven web formed on the roller surface in the same direction as said first support means for said application onto the outer surface of the matting layer.
- 10. Apparatus as claimed in claim 9 wherein said smooth surfaced roller is positioned to act as said means to lightly press the nonwoven web against said outer surface of the matting layer and is thereby friction driven by said first moving support means.
- 11. Apparatus as claimed in claim 10 wherein said first moving support means is a cylindrical roll rotatably mounted directly below said first set of spinning orifices and having a diameter substantially larger than said smooth surfaced roller of the second moving support means.
Priority Claims (1)
Number |
Date |
Country |
Kind |
2720403 |
May 1977 |
DEX |
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Parent Case Info
This is a division of application Ser. No. 903,552 filed May 8, 1978.
US Referenced Citations (4)
Divisions (1)
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Number |
Date |
Country |
Parent |
903552 |
May 1978 |
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