U.S. patent application number 11/399039 was filed with the patent office on 2006-10-12 for method and apparatus for melt-spinning and cooling a plurality of filaments.
This patent application is currently assigned to Saurer GmbH & Co. KG. Invention is credited to Horst Kropat, Anton Mooshammer, Mathias Stundl.
Application Number | 20060226573 11/399039 |
Document ID | / |
Family ID | 36581734 |
Filed Date | 2006-10-12 |
United States Patent
Application |
20060226573 |
Kind Code |
A1 |
Stundl; Mathias ; et
al. |
October 12, 2006 |
Method and apparatus for melt-spinning and cooling a plurality of
filaments
Abstract
A method and an apparatus for melt-spinning and cooling a
plurality of filaments which are processed to form a non-woven
fabric or web. The filaments are guided after extrusion in the form
of a filament curtain through a cooling zone and are cooled by a
cooling air stream blown transversely to the filament curtain. In
order to prevent the flow effects created by air swirls in the side
edge zones of the filament curtain, an additional quenching air
stream acts inside the cooling zone on each side edge of the
filament curtain. For this purpose, the inventive apparatus
comprises a quenching member positioned below each longitudinal end
of the spinneret.
Inventors: |
Stundl; Mathias; (Wedel,
DE) ; Kropat; Horst; (Neumunster, DE) ;
Mooshammer; Anton; (Wankendorf, DE) |
Correspondence
Address: |
ALSTON & BIRD LLP
BANK OF AMERICA PLAZA
101 SOUTH TRYON STREET, SUITE 4000
CHARLOTTE
NC
28280-4000
US
|
Assignee: |
Saurer GmbH & Co. KG
|
Family ID: |
36581734 |
Appl. No.: |
11/399039 |
Filed: |
April 6, 2006 |
Current U.S.
Class: |
264/211.14 ;
425/72.2 |
Current CPC
Class: |
D01D 5/088 20130101 |
Class at
Publication: |
264/211.14 ;
425/072.2 |
International
Class: |
D01D 5/088 20060101
D01D005/088 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 7, 2005 |
DE |
102005015974.5 |
Claims
1. A method for melt spinning and cooling a plurality of filaments
comprising the steps of melt spinning a plurality of downwardly
advancing filaments in the form of an elongate curtain which
defines opposite side edges and a longitudinal direction extending
between the side edges, guiding the downwardly advancing filaments
through a cooling zone, and cooling the downwardly advancing
filaments inside the cooling zone by directing a cooling air stream
transversely toward the filaments along the longitudinal length of
the curtain, and directing a quenching air stream transversely
toward the filaments at at least one of the side edges of the
curtain.
2. The method of claim 1, wherein the quenching air stream
comprises a separate quenching air stream acting on each side edge
of the filament curtain and which are oriented to be transverse to
the cooling air stream.
3. The method of claim 2, wherein the separate quenching air
streams at the side edges of the filament curtain are each oriented
to have a directional component which extends in the advancing
direction of the filaments and to form a quench angle of between
about 0.degree. and 45.degree. between the advancing filaments and
the associated separate quenching air stream.
4. The method of claim 3, wherein each separate quenching air
stream forms a quench angle of less than about 20.degree. at the
associated side edge of the filament curtain.
5. The method of claim 1 wherein the cooling air stream and the
quenching air stream both operate at an inlet region of the cooling
zone.
6. The method of claim 1 wherein the quenching air stream has an
air speed greater than the air speed of the cooling air stream.
7. The method of claim 1, wherein the cooling air stream and the
quenching air stream are each temperature controlled so as to have
substantially the same temperature.
8. The method of claim 1, wherein the cooling air stream has a
component acting on each of the longitudinal sides of the curtain
inside the cooling zone, and so that the components are directed
toward each other.
9. The method of claim 1, comprising the further step of
positioning a pair of laterally adjustable cover plates adjacent
said at least one side edge of the curtain to control the air flow
along the at least one side edge of the curtain.
10. A method for melt spinning and cooling a plurality of filaments
comprising the steps of melt spinning a plurality of downwardly
advancing filaments in the form of an elongate curtain which
defines opposite side edges and a longitudinal direction extending
between the side edges, guiding the downwardly advancing filaments
through a cooling zone, and cooling the downwardly advancing
filaments inside the cooling zone by directing a cooling air stream
transversely toward the filaments along the longitudinal length on
each side of the curtain, and directing a quenching air stream
transversely toward the filaments at each side edge of the curtain,
and wherein the cooling air streams are directed toward each other
and the quenching air streams are directed toward each other and
transverse to the cooling air streams.
11. An apparatus for melt spinning and cooling a plurality of
filaments comprising an elongate spinneret for extruding a
plurality of downwardly advancing filaments in the form of an
elongate curtain which defines opposite side edges and a
longitudinal direction extending between the side edges, said
spinneret comprising opposite longitudinally extending sides and
opposite ends, a cooling unit arranged below the spinneret and
including (a) a cooling wall oriented to extend parallel to one of
the longitudinally extending sides of the spinneret, with a cooling
chamber connected to the cooling wall so that a cooling air stream
can be directed transversely toward the downwardly advancing
filaments along the longitudinal length of the curtain, and (b) at
least one quenching member positioned adjacent at least one of the
ends of the spinneret for directing a quenching air stream
transversely toward the advancing filaments at at least one of the
side edges of the curtain.
12. The apparatus of claim 11, wherein the at least one quenching
member is oriented to generate a quenching air stream which is
transverse to the direction of the cooling air stream.
13. The apparatus of claim 12, wherein the at least one quenching
member comprises a quench opening oriented towards the side edge of
the filament curtain and a pressure chamber connected to the quench
opening, and wherein the quench opening has an inclination for
forming a quenching angle (.alpha.) in a range between about
0.degree. and 45.degree. between the filaments and the quenching
air stream.
14. The apparatus of claim 11, wherein a cooling wall and an
associated cooling chamber are positioned on each side of the
filament curtain, and a quenching member is positioned adjacent
each of the ends of the spinneret.
15. The apparatus of claim 14, wherein the quenching member on each
end of the spinneret comprises a quench opening which has an
inclination for forming a quenching angle (.alpha.) in a range less
than about 20.degree. between the filaments and the associated
quenching air stream.
16. The apparatus of claim 15, wherein each quench opening has a
rectangular outlet in cross-section, which extends essentially
parallel to the adjacent end of the spinneret and over the depth of
the filament curtain.
17. The apparatus of claim 16, wherein a flow straightener is
arranged inside each quench opening.
18. The apparatus of claim 11, wherein the at least one quenching
member is arranged in an inlet region of the cooling unit.
19. The apparatus of claim 11, wherein the cooling chamber and the
at least one quenching member are connected to a common cooling air
source.
20. The apparatus of claim 11, wherein the cooling unit comprises a
second cooling wall having a second cooling chamber on the opposite
longitudinal side of the spinneret, wherein said second cooling
chamber directs a second cooling air stream transversely to the
filament curtain opposite to the first mentioned cooling air
stream.
21. The apparatus of claim 11, wherein a pair of cover plates are
positioned adjacent the at least one quenching member, wherein said
cover plates extend at a distance from and parallel to one of the
side edges of the filament curtain and are constructed to be
displaceable.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a method for melt spinning
and cooling a plurality of filaments used in the production of a
non-woven fabric or web, and also an apparatus for carrying out the
method.
[0002] It is known when manufacturing spun-bonded fabric that a
plurality of filaments are extruded in a spinning apparatus, cooled
collectively as a filament curtain and are deposited to form a
non-woven fabric. For this purpose, draw-off nozzles are used,
which draw off the filament curtain from the spinning apparatus and
guide it to a delivery belt arranged below the draw-off nozzle. For
cooling the freshly extruded filaments, the filaments are quenched
with a cooling air stream which moves transversely to the filament
curtain, so that the filaments are strengthened before entering
into the draw-off nozzle. Such a method and/or apparatus are known,
e.g., from U.S. Pat. No. 6,183,684.
[0003] In order to be able to meet the requirements of uniformity
of characteristics of the individual filaments and also the
requirements of greater production speeds, the filaments have to be
cooled after extrusion uniformly and evenly to the maximum extent
possible. In the known apparatus, a cross-flow quench system is
used for this purpose, which is positioned on both of the
longitudinal sides of the spinneret and which instantaneously blows
a cooling air stream transversely to the filament curtain on the
filaments. The immediate concurrence of the cooling air streams
outside the filament curtain leads to air swirls, which act
especially on those filaments, which are guided directly in the
side edge zones of the filament curtain.
[0004] In order to eliminate such negative effects, DE 33 18 096
discloses a apparatus, in which guide plates are arranged which can
be displaced parallel to the front sides of the filament curtain.
However, this helps achieve only certain flow guidances of the
cooling air in relation to the atmosphere. The cooling of the
filaments in the side edge zones and also the side edge flow
effects can be little influenced by this.
[0005] It is therefore the object of the invention to create a
method and a apparatus of the above-mentioned type, in which all
the filaments of a filament curtain, especially those in the side
edge zones of the filament curtain, can be cooled intensively and
uniformly.
SUMMARY OF THE INVENTION
[0006] The above and other objects and advantages of the invention
are achieved by a method and apparatus of the above described type
and wherein the filaments guided in the side edge zones of the
filament curtain are guided in a predetermined atmosphere using
defined flow ratios. For this purpose an additional quenching air
stream created at least at the front end of the spinneret by a
quenching member acts directly on the filaments at the side edge of
the filament curtain. Air swirls caused by a transversely directed
cooling air stream on the side edge of the filament curtain can
thus be prevented advantageously. A balancing of the quenching
ratios, in particular, can be achieved using the quenching air
stream.
[0007] In order to obtain equal effects on each side edge of the
filament curtain, a separate quenching air stream, preferably on
each side edge of the filament curtain, acts on the filaments,
wherein said quenching air stream is oriented transversely to the
cooling air stream. For this purpose, separate quenching members
are provided at each end of the spinneret.
[0008] In order to bring about the cooling of the filaments of the
filament curtain essentially using the transversely oriented
cooling air stream, the improved configuration of the inventive
method is particularly advantageous in which the quenching air
stream is generated next to the side edge of the filament curtain
in a quenching direction that has a component oriented in the
running direction of the filaments, and wherein a quenching angle
in the range of 0.degree. to 45.degree. is provided between the
filaments and the quenching stream. Thus in the extreme case, a
parallel flow relative to the filament curtain can be provided,
wherein said parallel flow essentially influences only the side
edge air layers of the filament curtain. In order to be able to use
additional cooling effects of the quenching air stream, the
quenching angle is advantageously increased, wherein quenching
angles in the range of up to 45.degree. have turned out to be
suitable for the purpose of preventing any unreliable differences
between the cooling conditions in the center of the filament
curtain and those at the side edges of the filament curtain.
[0009] The quenching air streams at both of the side edges of the
filament curtain preferably impinge on the filaments at a quenching
angle in the range of 0.degree. to 20.degree.. For this purpose,
the inventive apparatus comprises a quench opening and a pressure
chamber connected to the quench opening, wherein the quench opening
has an inclination for forming a quenching angle in the range of
0.degree. to 45.degree. between the filaments and the quenching
stream.
[0010] The use of the variant of the method in which the quenching
air stream and the filaments operate in an entry region of the
cooling zone enables all the filaments to be spun out uniformly.
The filaments are confronted with the quenching air stream only
after they pass through a short spinning zone.
[0011] In order to achieve the most effectual impact over the
entire cooling length in the side edges of the filament curtain,
the quenching air stream is created according to an advantageous
variant of the method at a quenching speed, which is greater than
that of the cooling air stream. It is thus possible to create a
turbulence free flow in the border region of the filament curtain
up to the outlet of the cooling unit.
[0012] The quenching air stream and the cooling air stream are
thereby preferably formed by conditioned air, which essentially has
the same temperature. Basically, however it is also possible to
supply the filament curtain with a quenching air stream and a
cooling air stream having different temperatures. Thus the
quenching air stream can also be formed advantageously using
ambient air.
[0013] In order to achieve a sufficient cooling even in case of a
high filament density inside the filament curtain, preferably a
second cooling air stream acts on the filaments inside the cooling
zone, said second cooling air stream being blown transversely to
the filament curtain opposite to the first cooling air stream. The
filament curtain can thus be cooled intensively and uniformly on
both of its longitudinal sides. In the inventive apparatus, the
quenching member is preferably formed by a quench opening oriented
towards the side edge of the filament curtain and a pressure
chamber connected to said quench opening. The quench opening
preferably has a rectangular outlet cross-section, which extends
essentially parallel to the front end of the spinneret over the
entire thickness of the filament curtain.
[0014] In order to achieve a turbulence free flow inside the
quenching air stream to the maximum extent possible, a flow
straightener is arranged inside the quench opening.
[0015] The inventive apparatus is operated according to a preferred
improved configuration using a cooling unit, which contains a
cooling wall with a cooling chamber, on both longitudinal sides of
the spinneret. Two separate cooling air streams can thus be
created, each of which is oriented towards the filaments
transversely to the filament curtain. Such cooling units enable an
intensive cooling, as a result of which high process speeds are
possible even in case of high filament densities inside the
filament curtain.
[0016] For influencing the flow configured parallel to the side
edges of the curtain, it is further suggested that one or more
cover plates be assigned to each of the quenching members, wherein
said cover plates extend at a distance from and parallel to the
side edges of the curtain and are configured to be displaceable.
Additional flow effects for ensuring an even side edge flow can
thus be created. In this manner it is also possible to utilize the
entrained ambient air in case of a partial cover.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Several embodiments of the inventive method and apparatus
are described below in more detail, with reference to the enclosed
drawings, of which:
[0018] FIG. 1 schematically illustrates a first embodiment of the
inventive apparatus for carrying out the inventive method;
[0019] FIG. 2 schematically illustrates a cross-section of the
embodiment shown in FIG. 1;
[0020] FIG. 3 schematically illustrates a top view of another
embodiment of the inventive apparatus; and
[0021] FIG. 4 illustrates a cross-section of another embodiment of
the inventive apparatus.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] FIG. 1 and FIG. 2 illustrate a first embodiment of the
inventive apparatus for carrying out the inventive method for
melt-spinning and cooling a plurality of filaments. FIG. 1
schematically illustrates a perspective view of the embodiment and
FIG. 2 schematically illustrates a cross-section thereof. The
following description applies to both figures unless explicit
reference is made to either of the figures.
[0023] The embodiment comprises a spinneret 1, which has on its
bottom side a plurality of nozzle bores arranged preferably in one
or more longitudinally extending rows. The spinneret 1 is connected
to a melt source (not illustrated here) using a melt inlet 2.
[0024] A cooling unit 3 is arranged below the spinneret 1. Between
the spinneret 1 and the cooling unit 3 a short spinning zone is
provided, in which the filaments are guided without an active
cooling. The cooling unit 3 comprises a cooling wall 4.1 extending
parallel to a longitudinal side of the spinneret 1, said cooling
wall being connected to a cooling chamber 5.1. The cooling chamber
5.1 is connected to a cooling air source (not illustrated here)
using an air inlet 17. A fan or an air-conditioner can be provided
as the cooling air source.
[0025] The cooling unit 3 further comprises separate quenching
members 8.1 and 8.2, below the ends of the spinneret 1. FIG. 2
illustrates the cross-section of each of the quenching members 8.1
and 8.2, wherein the quenching member 8.1 is assigned to the left
end of the spinneret 1 and the quenching member 8.2 is assigned to
the right end of the spinneret 1. The quenching member 8.1 is
formed by a quench opening 9.1 and a pressure chamber 10.1
connected to the quench opening 9.1. The pressure chamber 10.1 is
connected to a pressure source (not illustrated here). Likewise,
the quenching member 8.2 arranged at the opposite end is formed by
a quench opening 9.2 and a pressure chamber 10.2 connected to the
quench opening 9.2. The pressure chamber 10.2 is also connected to
a pressure source.
[0026] The quench openings 9.1 and 9.2 each have an essentially
rectangular outlet cross-section, in which a flow straightener 11
is arranged. The quench opening 9.1 on the left end of the
spinneret has an inclination relative to a plumb line, so that the
quenching stream discharged from the outlet cross-section of the
quench opening 9.1 impinges on the filaments 6 extruded from the
spinneret 1 at a quenching angle. In FIG. 2, the quenching angle is
indicated by the reference symbol .alpha..
[0027] The quench opening 9.2 on the opposite end of the spinneret
1 is embodied essentially laterally reversed to the quench opening
9.1. The quench opening 9.2 has an opposite inclination so that the
quenching air stream discharged from the outlet cross-section of
the quench opening 9.2 impinges on the filaments 6 extruded from
the spinneret 1 at a quenching angle. The quenching angle here also
is indicated by the reference symbol .alpha.. The quenching angles
and thus the arrangement of the quench openings 9.1 and 9.2 are
configured preferably identically in mirror image relationship at
both ends of the spinneret 1.
[0028] As illustrated in FIG. 1, a draw-off nozzle 12 is arranged
below the cooling unit 3 in order to draw off the filaments 6 from
the spinneret 1 and to deposit them in the form of a spun-bonded
non-woven fabric 18 on a delivery belt 13 arranged below the
draw-off nozzle 12. The delivery belt 13 is constructed to be
air-permeable and is driven transversely to the draw-off nozzle 12
in the direction of the arrow, using a drive system which is not
illustrated here in more detail.
[0029] In the inventive apparatus illustrated in FIGS. 1 and 2, a
polymer melt is supplied to the spinneret 1 and is extruded under
pressure from nozzle bores arranged on the bottom side of the
spinneret 1. The filaments 6 discharged from the nozzle bores of
the spinneret 1 are guided in a row-shaped arrangement as a
so-called filament curtain 7. The filament curtain 7 is thereby
drawn off by the draw-off nozzle 12 from the spinneret 1. For this
purpose, the filament curtain 7 is guided through a guide channel
14 of the draw-off nozzle 12, wherein a conveying fluid is fed to
the guide channel 14.
[0030] Before the filaments 6 of the filament curtain 7 enter into
the guide channel 14 of the draw nozzle 12, they are cooled by a
cooling air stream oriented transversely to the filament curtain 7
in the cooling zone formed by the cooling unit 3. For this purpose,
the cooling air stream is generated by the cooling chamber 5.1 and
the cooling wall 4.1 and is blown uniformly over the entire width
and length of the cooling wall 4.1 onto the filaments 6 of the
filament curtain 7. In order to prevent air turbulences on the side
edges of the filament curtain 7, the side edges being formed at the
longitudinal ends of the spinneret 1, the quenching members 8.1 and
8.2 create additional quenching air streams, which impinge on the
filaments 6 guided in the side edges of the filament curtain at a
quenching angle .alpha. of approx. 20.degree.. The quenching air
streams created by the quenching members 8.1 and 8.2 are blown in
the running direction of the filaments 6 so as to prevent the
occurrence of any substantial air friction on the filaments.
[0031] The transversely oriented cooling air stream and also the
quenching air streams configured on the side edges of the filament
curtain 7 are coordinated to one another in such a way that the
filaments inside the filament curtain 7 are cooled essentially
uniformly independent of the location at which the filaments 6 are
guided. The quenching air streams are configured to have a slightly
higher quenching speed as compared to the transversely oriented
cooling air stream so as to prevent the occurrence of air swirls
over the entire cooling length and so as to ensure a uniform
guidance of the filaments up to the draw-off nozzle 12. The
filament curtain 7 is received by the draw-off nozzle 12 and
deposited in the form of a spun-bonded fabric 18 on the delivery
belt 13.
[0032] For the purpose of not influencing the spin out of the
filaments in the spinning zone, the quenching air streams engage
the filaments in the inlet region of the cooling zone. The cooling
air stream is thus superimposed over the entire length of the
cooling zone with the quenching air streams.
[0033] In the embodiment illustrated in FIGS. 1 and 2, the quench
openings 9.1 and 9.2 are aligned in such a manner that each
quenching air stream impinges on the filaments 6 of the filament
curtain 7 at a quenching angle of approx. 20.degree.. Basically,
quenching angles lying in the range of 0.degree. to 45.degree.
could be configured in order to achieve an advantageous guidance
and cooling of the filaments at the side edges of the filament
curtain 7. However, the quenching angle on both of the side edges
is configured identically in a range of 0.degree. to 20.degree..
The quench openings 9.1 and 9.2 could each be embodied on movable
quench lugs whereby a variation of the quenching angle is possible.
Furthermore, it is also possible to create the quenching air
streams without the help of flow straighteners in the quench
openings 9.1 and 9.2.
[0034] Another embodiment of the inventive apparatus for carrying
out the inventive method is illustrated in FIG. 3. The embodiment
shown in FIG. 3 being essentially identical to the previous
embodiment, a top view thereof is schematically illustrated here.
Essentially only the differences between the two embodiments are
explained below.
[0035] In the embodiment illustrated in FIG. 3, the cooling unit 3
comprises on both of the longitudinal sides of the spinneret 1 a
cooling wall 4.1 and 4.2, each of which is connected to a cooling
chamber 5.1 and 5.2. The cooling walls 4.1 and 4.2 are arranged
essentially parallel to the spinneret 1 on the side of the cooling
unit 3 adjacent the curtain 7. The cooling chambers 5.1 and 5.2 are
connected to a cooling air source (not illustrated), so that the
cooling chambers 5.1 and 5.2 are filled with a cooling medium,
preferably cooling air, which is guided under the pressure effect
by the cooling walls 4.1 and 4.2 transversely to the filament
curtain 7.
[0036] The quenching members 8.1 and 8.2 are arranged on both of
the side edges of the filament curtain. Each of the quenching
members 8.1 and 8.2 comprises a quench opening 9.1 and 9.2, through
which a quenching air stream is generated and blown on the
filaments 6 of the filament curtain at a quench angle, as described
above. Each quench opening 9.1 and 9.2 can contain a flow
straightener, whereby an essentially rectified air flow is
generated so as to give rise to a quenching stream that is uniform
over the entire thickness of the filament curtain 7. Each of the
quench openings 9.1 and 9.2 is connected to a pressure chamber 10.1
and 10.2.
[0037] Especially high filament densities inside the filament
curtain 7 can be cooled intensively and uniformly in the embodiment
illustrated in FIG. 3. Due to the intensive cooling effect, high
draw-off speeds can thereby be advantageously configured using a
draw-off nozzle arranged downstream.
[0038] FIG. 4 schematically illustrates a transverse section of
another embodiment of the inventive apparatus for carrying out the
inventive method. The embodiment being essentially identical to
that shown in FIG. 3, only the differences are explained below.
[0039] The cooling unit 3 arranged below the spinneret 1 is formed
by the cooling walls 4.1 and 4.2 extending along the longitudinal
sides, together with the cooling chambers 5.1 and 5.2. Quenching
members 8.1 and 8.2 are provided on each of the side edges, wherein
only quenching member 8.2 is illustrated in FIG. 4. Several cover
plates are provided at the side edges of the filament curtain 7 in
order to be able to shield the filaments 6 from the environment.
The cover plates 19.1 and 19.2 assigned to the quenching member 8.2
are illustrated in FIG. 4. The cover plates 19.1 and 19.2 are
displaceably held in a top guide 20 and a bottom guide 21. The
cover plates 19.1 and 19.2 can thereby be selectively adjusted
between a closed position and an open position. A lateral air
outlet 22 is formed in the open position. Due to this, additional
flow effects can be created on the side edge zones of the filament
curtain 7 inside the cooling zone.
[0040] The filament curtain 7 is drawn-off by the draw-off nozzle
12 from the spinneret 1. The filament curtain 7 guided in the guide
channel 14 is conveyed by a conveying fluid, which is supplied by
the fluid chambers 16.1 and 16.2 and the fluid inlets 15.1 and 15.2
to the guide channel 14.
[0041] The embodiments illustrated in FIGS. 1 to 4 of the inventive
apparatus for carrying out the inventive method serve as examples
for the design and arrangement of the quenching means. What is
important here is that an additional quenching air stream for
guiding the filaments on the side edge zones of the filament
curtain can be created. It is especially possible to thereby
effectively prevent the air swirls on the side edge zones of the
filament curtain, such air swirls being created by cross-flow
quenching.
[0042] Many modifications and other embodiments of the invention
set forth herein will come to mind to one skilled in the art to
which the invention pertains having the benefit of the teachings
presented in the foregoing description and the associated drawings.
Therefore, it is to be understood that the invention is not to be
limited to the specific embodiments disclosed and that
modifications and other embodiments are intended to be included
within the scope of the appended claims. Although specific terms
are employed herein, they are used in a generic and descriptive
sense only and not for purposes of limitation.
* * * * *