U.S. patent application number 13/759293 was filed with the patent office on 2013-11-28 for nonwoven fabric and method and apparatus for manufacturing the same.
This patent application is currently assigned to TAIWAN TEXTILE RESEARCH INSTITUTE. The applicant listed for this patent is Victor J. Lin, TAIWAN TEXTILE RESEARCH INSTITUTE. Invention is credited to Cheng-Kun Chu, Ming-Chih Kuo, Victor J. Lin, Chao-Chun Peng, Chia-Kun Wen.
Application Number | 20130316608 13/759293 |
Document ID | / |
Family ID | 49621960 |
Filed Date | 2013-11-28 |
United States Patent
Application |
20130316608 |
Kind Code |
A1 |
Lin; Victor J. ; et
al. |
November 28, 2013 |
Nonwoven Fabric and Method and Apparatus for Manufacturing the
Same
Abstract
A nonwoven fabric includes a plurality of discontinuous fibers,
a plurality of natural keratin fibers, and a plurality of meltblown
fibers. The discontinuous fibers, the natural keratin fibers, and
the meltblown fibers form a continuous bonding web structure.
Inventors: |
Lin; Victor J.; (Washington,
NJ) ; Chu; Cheng-Kun; (New Taipei City, TW) ;
Kuo; Ming-Chih; (New Taipei City, TW) ; Peng;
Chao-Chun; (New Taipei City, TW) ; Wen; Chia-Kun;
(New Taipei City, TW) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Lin; Victor J.
TAIWAN TEXTILE RESEARCH INSTITUTE |
New Taipei City |
|
US
TW |
|
|
Assignee: |
TAIWAN TEXTILE RESEARCH
INSTITUTE
New Taipei City
NJ
Lin; Victor J.
Washington
|
Family ID: |
49621960 |
Appl. No.: |
13/759293 |
Filed: |
February 5, 2013 |
Current U.S.
Class: |
442/416 ;
19/98 |
Current CPC
Class: |
D04H 1/54 20130101; Y10T
442/698 20150401; D01G 15/12 20130101; D04H 1/56 20130101 |
Class at
Publication: |
442/416 ;
19/98 |
International
Class: |
D04H 1/54 20060101
D04H001/54; D01G 15/12 20060101 D01G015/12 |
Foreign Application Data
Date |
Code |
Application Number |
May 25, 2012 |
TW |
101118712 |
Claims
1. A nonwoven fabric comprising: a plurality of discontinuous
fibers; a plurality of natural keratin fibers; and a plurality of
meltblown fibers, wherein the discontinuous fibers, the natural
keratin fibers, and the meltblown fibers form a continuous bonding
web structure.
2. The nonwoven fabric of claim 1, wherein the meltblown fibers
bond the discontinuous fibers and the natural keratin fibers.
3. The nonwoven fabric of claim 1, wherein each of the meltblown
fibers has a diameter ranging from about 0.5 to about 100
.mu.m.
4. The nonwoven fabric of claim 1, wherein the nonwoven fabric has
from about 2.5 wt % to about 95 wt % of the discontinuous fibers,
from about 2.5 wt % to about 95 wt % of the natural keratin fibers,
and from about 2.5 wt % to about 95 wt % of the meltblown
fibers.
5. The nonwoven fabric of claim 1, wherein the meltblown fibers are
made of any thermoplastic resin which is capable of being
meltblown.
6. The nonwoven fabric of claim 1, wherein the meltblown fibers are
made of polypropylene (PP), polyethylene (PE), thermoplastic
polyurethane (TPU), styrene-butadiene-styrene (SBS), thermoplastic
elastomers (TPE), thermoplastic rubber (TPR), polyethylene
terephthalate (PET), poly trimethylene terephthalate (PTT),
polybutylene terephthalate (PBT), polylactate (PLA), cellulose,
polystyrene (PS), polyamide (PA), polytetrafluoroethylene (PTFE),
thermomelt plastic, ethylene-methyl acrylate copolymer (EMA),
ethylene vinyl acetate copolymer (EVA), or any combination
thereof.
7. The nonwoven fabric of claim 1, wherein the discontinuous fibers
are made of polypropylene (PP), polyethylene (PE), polyethylene
terephthalate (PET), polybutylene terephthalate (PBT), nylon,
acrylic, elastic fibers, rubber, elastane, or any combination
thereof.
8. An apparatus for manufacturing a nonwoven fabric, the apparatus
comprising: a carding machine for processing a plurality of
discontinuous fibers; an air source for providing airflow; a
feeding channel for directing the airflow to the carding machine to
card the discontinuous fibers and to blow a plurality of natural
keratin fibers into spaces between the discontinuous fibers; a
meltblowing machine for providing a curtain of semi-molten
meltblown fibers; and an import channel for directing the airflow
with the discontinuous fibers and the natural keratin fibers to the
curtain of semi-molten meltblown fibers, such that the semi-molten
meltblown fibers bond the discontinuous fibers and the natural
keratin fibers to form a continuous bonding web structure.
9. The apparatus of claim 8, further comprising: a collecting
device for collecting the continuous bonding web structure to form
a fabric roll.
10. A method for manufacturing a nonwoven fabric, the method
comprising: processing a plurality of discontinuous fibers by a
carding machine; directing airflow to blow a plurality of natural
keratin fibers into spaces between the discontinuous fibers; and
directing the airflow with the discontinuous fibers and the natural
keratin fibers to a curtain of semi-molten meltblown fibers, such
that the semi-molten meltblown fibers bond the discontinuous fibers
and the natural keratin fibers to form a continuous bonding web
structure.
11. The method of claim 10, further comprising: collecting the
continuous bonding web structure to form a fabric roll.
12. The method of claim 10, further comprising: carding the
discontinuous fibers and the natural keratin fibers by an air
carding machine before directing the airflow with the discontinuous
fibers and the natural keratin fibers to the curtain of semi-molten
meltblown fibers; and wherein directing the airflow with the
discontinuous fibers and the natural keratin fibers to the curtain
of semi-molten meltblown fibers comprises: directing the airflow
with the carded discontinuous fibers and the carded natural keratin
fibers to the curtain of semi-molten meltblown fibers.
Description
RELATED APPLICATIONS
[0001] This application claims priority to Taiwan Application
Serial Number 101118712, filed May 25, 2012, which is herein
incorporated by reference.
BACKGROUND
[0002] 1. Technical Field
[0003] The present disclosure relates to fabrics. More
particularly, the present disclosure relates to nonwoven
fabrics.
[0004] 2. Description of Related Art
[0005] The down of birds is a layer of fine feathers found under
the tougher exterior feathers. Down is one of the best natural
thermal insulators. Down is made of fine rachis, on which are barbs
and babules interconnected to form a fiborous loose structure. The
loose structure encapsulates numerous tiny air pockets that entrap
air, which helps to stop convection of air and thus insulate
against cold air. Generally, the down is used in warm gears such as
jackets, bedding, pillows and sleeping bags by forming a padding
like layer.
[0006] However, down jackets often give an impression of styleless,
bloated and bulky. In addition, in manufacturing a down jacket, a
down chamber is formed first, then a pre-weighted down is blown
into the down chamber, and finally the down chamber is seam sealed
by needle stitching to restrain the down in the down chamber. Thus,
the down jacket may lose its down through the needle holes of the
seams. Since along the seams there are only two layers of fabrics
stiched together, the space near the seams may only have the lining
and the shell without the down, and the down fibers are not bonded
together and thus shift around in the down chamber, thereby
producing a nonuniform insulation effect. Moreover, in
manufacturing the down jacket, sewing and down filling processes
require a lot of labor and consuming a lot of time and thus adding
up the cost of the jacket. These are the problems that the garment
industry must face and the consumers have to pay for when enjoying
down.
SUMMARY
[0007] According to one embodiment of the present invention, a
nonwoven fabric includes a plurality of discontinuous fibers, a
plurality of natural keratin fibers, and a plurality of meltblown
fibers. The discontinuous fibers, the natural keratin fibers, and
the meltblown fibers form a continuous bonding web structure.
[0008] Optionally, the meltblown fibers may bond the discontinuous
fibers and the natural keratin fibers.
[0009] Optionally, each of the meltblown fibers may have a diameter
ranging from about 0.5 .mu.m to about 100 .mu.m.
[0010] Optionally, the nonwoven fabric may have from about 2.5 wt %
to about 95 wt % of the discontinuous fibers, from about 2.5 wt %
to about 95 wt % of the natural keratin fibers, and from about 2.5
wt % to about 95 wt % of the meltblown fibers.
[0011] Optionally, the meltblown fibers may be made of any
thermoplastic resin which is capable of being meltblown.
[0012] Optionally, the meltblown fibers may be made of
polypropylene (PP), polyethylene (PE), thermoplastic polyurethane
(TPU), styrene-butadiene-styrene (SBS), thermoplastic elastomers
(TPE), thermoplastic rubber (TPR), polyethylene terephthalate
(PET), poly trimethylene terephthalate (PTT), polybutylene
terephthalate (PBT), polylactate (PLA), cellulose, polystyrene
(PS), polyamide (PA), polytetrafluoroethylene (PTFE), thermomelt
plastic, ethylene-methyl acrylate copolymer (EMA), ethylene vinyl
acetate copolymer (EVA), or any combination thereof.
[0013] Optionally, the discontinuous fibers may be made of
polypropylene (PP), polyethylene (PE), polyethylene terephthalate
(PET), polybutylene terephthalate (PBT), nylon, acrylic, elastic
fibers, rubber, elastane, or any combination thereof.
[0014] According to another embodiment of the present invention, an
apparatus for manufacturing a nonwoven fabric includes a carding
machine, an air source, a feeding channel, a meltblowing machine,
and an import channel. The carding machine is for processing a
plurality of discontinuous fibers. The air source is for providing
airflow. The feeding channel is for directing the airflow to the
carding machine to card the discontinuous fibers and to blow a
plurality of natural keratin fibers into the spaces between the
discontinuous fibers. The meltblowing machine is for providing a
curtain of semi-molten meltblown fibers. The import channel is for
directing the airflow with the discontinuous fibers and the natural
keratin fibers to the curtain of semi-molten meltblown fibers, such
that the semi-molten meltblown fibers bond the discontinuous fibers
and the natural keratin fibers to form a continuous bonding web
structure.
[0015] Optionally, the apparatus may include a collecting device.
The collecting device is for collecting the continuous bonding web
structure to form a fabric roll.
[0016] According to yet another embodiment of the present
invention, a method for manufacturing a nonwoven fabric includes
the following steps: (The steps are not recited in the sequence in
which the steps are performed. That is, unless the sequence of the
steps is expressly indicated, the sequence of the steps is
interchangeable, and all or part of the steps may be
simultaneously, partially simultaneously, or sequentially
performed.)
[0017] (1) processing a plurality of discontinuous fibers by a
carding machine;
[0018] (2) directing airflow to blow a plurality of natural keratin
fibers into the spaces between the discontinuous fibers; and
[0019] (3) directing the airflow with the discontinuous fibers and
the natural keratin fibers to a curtain of semi-molten meltblown
fibers, such that the semi-molten meltblown fibers bond the
discontinuous fibers and the natural keratin fibers to form a
continuous bonding web structure.
[0020] Optionally, the method may further include collecting the
continuous bonding web structure to form a fabric roll.
[0021] Optionally, the method may further include carding the
discontinuous fibers and the natural keratin fibers by an air
carding machine before directing the airflow with the discontinuous
fibers and the natural keratin fibers to the curtain of semi-molten
meltblown fibers.
[0022] Optionally, the step of directing the airflow with the
discontinuous fibers and the natural keratin fibers to the curtain
of semi-molten meltblown fibers may include directing the airflow
with the carded discontinuous fibers and the carded natural keratin
fibers to the curtain of semi-molten meltblown fibers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a drawing of a nonwoven fabric according to one
embodiment of the present invention.
[0024] FIG. 2 is a drawing of an apparatus for manufacturing a
nonwoven fabric according to one embodiment of the present
invention.
DETAILED DESCRIPTION
[0025] In the following detailed description, for purposes of
explanation, numerous specific details are set forth in order to
provide a thorough understanding of the disclosed embodiments. It
will be apparent, however, that one or more embodiments may be
practiced without these specific details. In other instances,
well-known structures and devices are schematically depicted in
order to simplify the drawings.
[0026] FIG. 1 is a drawing of a nonwoven fabric 100 according to
one embodiment of the present invention. As shown in FIG. 1, the
nonwoven fabric 100 includes a plurality of discontinuous fibers
110, a plurality of natural keratin fibers 120, and a plurality of
meltblown fibers 130. The discontinuous fibers 110, the natural
keratin fibers 120, and the meltblown fibers 130 form a continuous
bonding web structure.
[0027] In FIG. 1, the discontinuous fibers 110 can be the framework
of the nonwoven fabric 100 to provide the nonwoven fabric 100 with
suitable fluffiness, softness-stiffness, and resilience. The
natural keratin fibers 120 have small air pockets to provide the
nonwoven fabric 100 with insulation and warmth. Furthermore, the
natural keratin fibers 120 can increase the compressional
resilience of the nonwoven fabric 100 as well. The meltblown fibers
130 can bond the discontinuous fibers 110 and the natural keratin
fibers 120 to form a continuous bonding web structure. Furthermore,
since the meltblown fibers 130 and spaces between the meltblown
fibers 130 are small enough, the meltblown fibers can enhance the
insulation and warmth of the nonwoven fabric 100 as well.
[0028] Relative to long fibers or continuous fibers, the
discontinuous fibers 110, also known as short fibers, have a
general aspect ratio (defined as the ratio of fiber length to
diameter) ranging from about 20 to about 60. The length of the
discontinuous fibers 110 may range from about 17 mm to about 61 mm.
The discontinuous fibers 110 may be made of polypropylene (PP),
polyethylene (PE), polyethylene terephthalate (PET), recycled PET,
insulation PET, polybutylene terephthalate (PBT), nylon, acrylic,
elastic fibers, rubber, elastane, or any combination thereof which
has fiber formability, suitable softness-stiffness, and
resilience.
[0029] The natural keratin fibers 120 are made of natural keratin.
Specifically, the natural keratin fibers 120 can be, for example,
down and/or feathers of birds, animal fur, or any combination
thereof.
[0030] The meltblown fibers 130 are fibers manufactured by melt
blowing. The diameter of the meltblown fibers 130 may range from
about 0.5 .mu.m to about 100 .mu.m. In the present embodiment, the
meltblown fibers 130 can bond the discontinuous fibers 110 and the
natural keratin fibers 120 to form a continuous bonding web
structure.
[0031] The meltblown fibers 130 are made of any thermoplastic resin
which is capable of being meltblown, for example polypropylene
(PP), polyethylene (PE), thermoplastic polyurethane (TPU),
styrene-butadiene-styrene (SBS), thermoplastic elastomers (TPE),
thermoplastic rubber (TPR), polyethylene terephthalate (PET), poly
trimethylene terephthalate (PTT), polybutylene terephthalate (PBT),
polylactate (PLA), cellulose, polystyrene (PS), polyamide (PA),
polytetrafluoroethylene (PTFE), thermomelt plastic, ethylene-methyl
acrylate copolymer (EMA), ethylene vinyl acetate copolymer (EVA),
or any combination thereof.
[0032] The weight ratio of the discontinuous fibers 110, the
natural keratin fibers 120, and the meltblown fibers 130 in the
nonwoven fabric 100 of FIG. 1 depends on actual requirements. In
the present embodiment, the nonwoven fabric 100 has from about 2.5
wt % to about 95 wt % of the discontinuous fibers 110, from about
2.5 wt % to about 95 wt % of the natural keratin fibers 120, and
from about 2.5 wt % to about 95 wt % of the meltblown fibers
130.
[0033] The nonwoven fabric 100 of FIG. 1 has a base weight ranging
from about 50 g/m.sup.2 to about 500 g/m.sup.2 and a thickness
ranging from about 0.3 mm to about 50 mm. It should be appreciated
that the aforementioned specifications of the nonwoven fabric 100
are illustrative only and should not limit the claimed scope of the
present disclosure. Any one of ordinary skill in the art should be
able to determine the specifications of the nonwoven fabric
according to actual requirements.
[0034] FIG. 2 is a drawing of an apparatus 200 for manufacturing a
nonwoven fabric 100 according to one embodiment of the present
invention. As shown in FIG. 2, the apparatus 200 for manufacturing
the nonwoven fabric 100 includes a carding machine 210, an air
source 220, a feeding channel 230, a meltblowing machine 240, and
an import channel 250. The carding machine 210 is for processing a
plurality of discontinuous fibers 110. The air source 220 is for
providing airflow 225. The feeding channel 230 is for directing the
airflow 225 to the carding machine 210 to card the discontinuous
fibers 110 and to blow a plurality of natural keratin fibers 120
into the spaces between the discontinuous fibers 110. The
meltblowing machine 240 is for providing a curtain of semi-molten
meltblown fibers 245. The import channel 250 is for directing the
airflow 225 with the discontinuous fibers 110 and the natural
keratin fibers 120 to the curtain of semi-molten meltblown fibers
245, such that the semi-molten meltblown fibers 130 bond the
discontinuous fibers 110 and the natural keratin fibers 120 to form
a continuous bonding web structure.
[0035] The carding machine 210 is a machine that can disentangle,
clean and intermix the discontinuous fibers 110. In the present
embodiment, the carding machine 210 includes a cylinder carding
cloth. In use, the cylinder carding cloth which rotates at high
speeds can catch the discontinuous fibers 110 and move the
discontinuous fibers 110 to a place adjacent to the feeding channel
230 where the discontinuous fibers 110 and the natural keratin
fibers 120 are mixed. The specifications of the cylinder carding
cloth depend on the required mixing uniformity. In the present
embodiment, the density of the cylinder carding cloth may range
from about 3 p/in to about 120 p/in. The angle of the cylinder
carding cloth may vary from about 27.degree. to about 80.degree..
The angle of the cylinder carding cloth may affect the properties
of the discontinuous fibers 110 which may be broken up by the
cylinder carding cloth.
[0036] The air source 220 may be a blower. The flowing rate of the
airflow 225 may vary from about 1 m/s to about 60 m/s.
[0037] As shown in FIG. 2, the feeding channel 230 is connected to
a place below the cylinder carding cloth, i.e. the carding machine
210, such that the natural keratin fibers 120 are not caught and
broken up by the cylinder carding cloth, i.e. the carding machine
210. In the case that some of the natural keratin fibers 120 need
to be broken up in manufacturing the nonwoven fabric 100, the
feeding channel 230 may be connected to a place above the cylinder
carding cloth, i.e. the carding machine 210. By such an
arrangement, the cylinder carding cloth, i.e. the carding machine
210, can catch the natural keratin fibers 120, and some of the
natural keratin fibers 120 may be broken up by the cylinder carding
cloth, i.e. the carding machine 210. Any one of ordinary skill in
the art should be able to determine the detail structure of the
feeding channel 230 according to actual requirements.
[0038] The feeding rate of the discontinuous fibers 110 depend on
the required weight ratio. In the present embodiment, the feeding
rate of the discontinuous fibers 110 may range from about 1 m/min
to about 3 m/min. The number and distribution of the natural
keratin fibers 120 depend on the gaps of the cylinder carding
cloth, i.e. the carding machine 210, and the rate of the airflow
225.
[0039] Whether the discontinuous fibers 110 and the natural keratin
fibers 120 are broken up by the cylinder carding cloth, i.e. the
carding machine 210, almost all of the discontinuous fibers 110 and
the natural keratin fibers 120 can be blown into the curtain of
semi-molten meltblown fibers 245. Even if a very small part of the
discontinuous fibers 110 and the natural keratin fibers 120 is
caught on the cylinder carding cloth, i.e. the carding machine 210,
this part of the discontinuous fibers 110 and the natural keratin
fibers 120 will be used in the next turn of the cylinder, and thus
the number of void if any will be minimumized to undetectable.
[0040] The semi-molten meltblown fibers 130 bond the discontinuous
fibers 110 and the natural keratin fibers 120 at a place ranging
from about 1 cm to about 50 cm below the die of the meltblowing
machine 240 after the discontinuous fibers 110 and the natural
keratin fibers 120 are blown into the curtain of semi-molten
meltblown fibers 245. Since the meltblown fibers 130 are
semi-molten at this time, the semi-molten meltblown fibers 130 can
stick to the discontinuous fibers 110 and the natural keratin
fibers 120 and also encompass them together before solidifying. In
this way, the discontinuous fibers 110, the natural keratin fibers
120, and the meltblown fibers 130 are firmly bonded together to
form a continuous bonding web structure with good abrasion and
pilling resistance. The process air pressure of the meltblowing
machine 240 may range from about 5 psi to about 15 psi.
[0041] As shown in FIG. 2, the apparatus 200 for manufacturing the
nonwoven fabric 100 may further include a collecting device 260.
The collecting device 260 is for collecting the continuous bonding
web structure formed by the discontinuous fibers 110, the natural
keratin fibers 120, and the meltblown fibers 130 to form a fabric
roll. In the present embodiment, the collecting device 260 may be a
conveyor belt, a roller, a vacuum pump, or any combination thereof.
Furthermore, the vertical distance between the die of the
meltblowing machine 240 and the collecting device 260 may range
from about 10 cm to about 50 cm.
[0042] Another aspect of the present invention is a method for
manufacturing a nonwoven fabric 100. The method for manufacturing
the nonwoven fabric 100 includes the following steps: (The steps
are not recited in the sequence in which the steps are performed.
That is, unless the sequence of the steps is expressly indicated,
the sequence of the steps is interchangeable, and all or part of
the steps may be simultaneously, partially simultaneously, or
sequentially performed.)
[0043] (1) processing a plurality of discontinuous fibers 110 by a
carding machine 210;
[0044] (2) directing airflow 225 to blow a plurality of natural
keratin fibers 120 into the spaces between the discontinuous fibers
110; and
[0045] (3) directing the airflow 225 with the discontinuous fibers
110 and the natural keratin fibers 120 to a curtain of semi-molten
meltblown fibers 245, such that the semi-molten meltblown fibers
130 bond the discontinuous fibers 110 and the natural keratin
fibers 120 to form a continuous bonding web structure.
[0046] In one or more embodiments of the present invention, the
method for manufacturing the nonwoven fabric 100 may further
include the following steps:
[0047] (4) collecting the continuous bonding web structure formed
by the discontinuous fibers 110, the natural keratin fibers 120,
and the meltblown fibers 130 to form a continuous fabric roll with
some physical strength.
[0048] In one or more embodiments of the present invention, the
method for manufacturing the nonwoven fabric 100 may further
include the following steps:
[0049] (2.5) carding the discontinuous fibers 110 and the natural
keratin fibers 120 by an air carding machine before directing the
airflow 225 with the discontinuous fibers 110 and the natural
keratin fibers 120 to the curtain of semi-molten meltblown fibers
245.
[0050] That is, the discontinuous fibers 110 and the natural
keratin fibers 120 are carded by the air carding machine before
blown into the curtain of semi-molten meltblown fibers 245. In this
way, the discontinuous fibers 110 and the natural keratin fibers
120 can be mixed more uniformly, and therefore the quality of the
nonwoven fabric 100 is improved.
[0051] The air carding machine is a sub-element of the carding
machine 210 which can card and mix the discontinuous fibers 110 and
the natural keratin fibers 120 uniformly.
[0052] In one or more embodiments of the present invention, the
step (3) may includes:
[0053] (3.1) directing the airflow 225 with the carded
discontinuous fibers 110 and the carded natural keratin fibers 120
to the curtain of semi-molten meltblown fibers 245, such that the
semi-molten meltblown fibers 130 bond the discontinuous fibers 110
and the natural keratin fibers 120 to form a continuous bonding web
structure.
WORKING EXAMPLE
[0054] A series of tests were run to determine that the
aforementioned apparatus and method could manufacture the required
nonwoven fabrics. The parameters described before are not repeated
hereinafter, and only further information is supplied to actually
perform the series of tests.
[0055] In the following working examples 1-3, the nonwoven fabrics
were manufactured by the apparatus of FIG. 2. The specifications
and manufacturing parameters are listed in the following table 1.
In the following working examples 1-3, the discontinuous fibers
were made of polyethylene terephthalate (PET), the natural keratin
fibers were 650 fill power down, and the meltblown fibers were made
of polypropylene (PP).
TABLE-US-00001 TABLE 1 Specifications and Manufacturing Parameters
of Working Example 1-3 Working Working Working Example 1 Example 2
Example 3 Feeding Rate of Natural 12.3 11.6 6.8 Keratin Fibers (Hz)
Distribution Airflow of 60 50 40 Natural Keratin Fibers (Hz)
Feeding Rate of 20.6 18.3 10.1~12.5 Discontinuous Fibers (Hz)
Rotational Speed of 60 50 40 Carding Machine (Hz) Flowing Rate of
Airflow 3.3~5.3 2.6~2.9 1.9~2.1 (m/s) Feeding Distance (cm).sup.1
18 10 5 Feeding Height (cm).sup.2 25 18 10 Note 1: The feeding
distance is the horizontal distance between the outlet of the
feeding channel and the middle axis of the curtain of semi-molten
meltblown fibers. Note 2: The feeding height is the vertical
distance between the bottom edge of the outlet of the feeding
channel and the die of the meltblowing machine.
[0056] In the nonwoven fabrics manufactured according to the
specifications and manufacturing parameters listed in the table 1,
the weight ratios of the meltblown fibers, the discontinuous
fibers, and the natural keratin fibers are listed in the following
table 2.
TABLE-US-00002 TABLE 2 Contents of Nonwoven Fabrics of Working
Example 1-3 Working Working Working Example 1 Example 1 Example 1
Weight Ratio.sup.3 1.0:1.3:2.7 1.0:1.1:2.2 1.0:1.1:1.2 Note 3: The
weight ratio is the weight of the meltblown fibers:the weight of
the discontinuous fibers:the weight of the natural keratin
fibers.
[0057] The nonwoven fabrics of the working examples 4-5 and the
comparative examples 1-3 were compared in the following table 3.
The nonwoven fabrics of the working examples 4-5 were manufactured
by the apparatus of FIG. 2. The nonwoven fabric of the comparative
example 1 contained the meltblown fibers only. The nonwoven fabric
of the comparative example 2 contained the meltblown fibers and the
discontinuous fibers only. The nonwoven fabric of the comparative
example 3 contained the meltblown fibers and the natural keratin
fibers only. In the nonwoven fabrics of the working examples 4-5
and the comparative examples 1-3, the discontinuous fibers 110 were
made of polyethylene terephthalate (PET), the natural keratin
fibers 120 were 650 fill power down, and the meltblown fibers 130
were made of polypropylene (PP). Other specifications and
manufacturing parameters of the working examples 4-5 and the
comparative examples 1-3 were the same.
TABLE-US-00003 TABLE 3 Comparison of Working Examples 4-5 and
Comparative Examples 1-3 Fluffy Softness- Base Weight (g/m.sup.2)
Thickness (cm) Rate Stiffness Average Uniformity Average Uniformity
(cm.sup.3 /g) (cm) Comparative Example 51.6 90% 0.38 78% 7.3 2.5 1
Comparative Example 189.5 89% 1.58 95% 8.3 2.6 2 Comparative
Example 63.8 93% 1.52 91% 23.8 2.5 3 Working Example 4 101.6 94%
2.96 97% 29.1 2.8 Working Example 5 85.8 92% 1.55 94% 18.0 2.7
[0058] As listed in the table 3, the uniformities of the base
weights of the nonwoven fabrics of the working examples 4-5 were
larger than 90%, specifically from 92% to 94%. Since the nonwoven
fabrics of the working examples 4-5 had the discontinuous fibers,
the fluffy rates of the nonwoven fabrics of the working examples
4-5 were from 12 cm.sup.3/g to 30 cm.sup.3/g, specifically from
18.0 cm.sup.3/g to 29.1 cm.sup.3/g, and the softnesses-stiffnesses
of the nonwoven fabrics of the working examples 4-5 were less than
3 cm, specifically from 2.7 cm to 2.8 cm. These data were better
than that of the comparative examples 1-3.
[0059] The nonwoven fabrics of the working example 6 and the
comparative examples 4-6 were compared in the following tables 4-5.
The nonwoven fabrics of the working example 6 were manufactured by
the apparatus of FIG. 2. The nonwoven fabric of the comparative
example 4 contained the meltblown fibers only. The nonwoven fabric
of the comparative example 5 contained the meltblown fibers and the
discontinuous fibers only. The nonwoven fabric of the comparative
example 6 were 3M.TM. Thinsulate.TM.. In the nonwoven fabrics of
the working example 6 and the comparative examples 4-6, the
discontinuous fibers were made of polyethylene terephthalate (PET),
the natural keratin fibers were 650 fill power down, and the
meltblown fibers were made of polypropylene (PP). Other
specifications and manufacturing parameters of the working example
6 and the comparative examples 4-6 were the same.
TABLE-US-00004 TABLE 4 Comparison of Working Example 6 and
Comparative Examples 4-6 Insulation Heat per Unit Heat Transfer
Thermal Thermal Thickness Preservation Coefficient Resistance
Resistance (.degree. F. (CLO/cm) Rate (%) (W/m.sup.2 .degree. C.)
(m.sup.2 .degree. C./W) h ft.sup.2/Btu) Comparative 0.94-1.3 65.3
0.0350 0.2026 1.1508 Example 4 Comparative 1.72 78.2 0.0317 0.1291
0.7333 Example 5 Comparative 1.7 60 0.0341 0.3471 1.9710 Example 6
Working 2.0-2.4 80.7 0.0310 0.0966 0.5485 Example 6
TABLE-US-00005 TABLE 5 Comparison of Working Example 6 and
Comparative Examples 4-6 Compressional Resilience (%)
Diameter(.mu.m) Comparative 75% 0.9-3.3(meltblown fibers) Example 4
Comparative 88% 0.9-3.3(meltblown fibers) Example 5
15.3(discontinuous fibers) Comparative 89% 1.7~6.0(meltblown
fibers) Example 6 25.6(discontinuous fibers) Working 92%
0.9-3.3(meltblown fibers) Example 6 15.3(discontinuous fibers)
[0060] As listed in the tables 4-5, since the nonwoven fabric of
the working example 6 had down, in comparison with the comparative
example 6, the insulation per unit thickness increases by from 17%
to 41%, the heat preservation rate increases by 34%, and the
compressional resilience increases by 3%.
[0061] All the features disclosed in this specification (including
any accompanying claims, abstract, and drawings) may be replaced by
alternative features serving the same, equivalent or similar
purpose, unless expressly stated otherwise. Thus, unless expressly
stated otherwise, each feature disclosed is one example only of a
generic series of equivalent or similar features.
[0062] Any element in a claim that does not explicitly state "means
for" performing a specified function, or "step for" performing a
specific function, is not to be interpreted as a "means" or "step"
clause as specified in 35 U.S.C. .sctn.112, 6th paragraph. In
particular, the use of "step of" in the claims is not intended to
invoke the provisions of 35 U.S.C. .sctn.112, 6th paragraph.
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