U.S. patent number 3,737,950 [Application Number 05/161,627] was granted by the patent office on 1973-06-12 for apparatus to produce a plane padding web.
This patent grant is currently assigned to Societe Rhodiaceta. Invention is credited to Robert Bolliand, Claude Saligny.
United States Patent |
3,737,950 |
Bolliand , et al. |
June 12, 1973 |
APPARATUS TO PRODUCE A PLANE PADDING WEB
Abstract
Method and apparatus for making padding web is disclosed,
wherein uncut, highly crimped, tensioned tow is passed through a
series of rollers. The rollers are arranged in at least two sets of
pairs, the rollers of each pair rotating at different peripheral
velocities. The ratio of peripheral velocities is higher for the
upstream pair of rollers. The upper rollers of the two pairs
rotates faster than the lower rollers thereof. The padding web
produced is suitable for stuffing articles such as bed covers,
sleeping bags, anoraks, and the like.
Inventors: |
Bolliand; Robert (Lyon,
FR), Saligny; Claude (Lyon, FR) |
Assignee: |
Societe Rhodiaceta (Paris,
FR)
|
Family
ID: |
9058940 |
Appl.
No.: |
05/161,627 |
Filed: |
July 12, 1971 |
Foreign Application Priority Data
|
|
|
|
|
Jul 10, 1970 [FR] |
|
|
7026734 |
|
Current U.S.
Class: |
28/282; 28/220;
976/DIG.46; 28/246 |
Current CPC
Class: |
D02J
1/18 (20130101); D04H 3/011 (20130101); D04H
3/02 (20130101); F16L 55/10 (20130101) |
Current International
Class: |
D02J
1/00 (20060101); D02J 1/18 (20060101); D04H
3/02 (20060101); F16L 55/10 (20060101); D01d
011/02 () |
Field of
Search: |
;19/65T,66T
;28/71.3 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Newton; Dorsey
Claims
We claim:
1. Apparatus for making a padding web, said apparatus comprising,
in combination,
a. an upstream pair of rollers comprising an upper upstream roller
and a lower upstream roller, said rollers being parallel to one
another;
b. a downstream pair of rollers comprising an upper downstream
roller and a lower downstream roller, said downstream rollers being
parallel to one another and substantially parallel to said upstream
rollers;
c. first feeding means to feed continuous filaments through said
upstream rollers in the direction from said upstream rollers to
said downstream rollers and second feeding means to feed said
continuous filaments through said downstream rollers; and
d. rotating means to rotate each roller in the direction of
movement of said filaments, with the periphery of each roller of
each pair of rollers moving at a different speed from the other
roller of the pair, the upstream pair of rollers having a higher
ratio of peripheral speeds than the downstream pair of rollers, and
the upper rollers having a higher peripheral speed than the lower
rollers, whereby in operation the differential rotation of the
rolls of each pair of rollers spreads said filaments.
2. Apparatus as claimed in claim 1, wherein said second feeding
means includes a set of holding roller means to feed continuous
filaments to said downstream pair of rollers.
3. Apparatus as claimed in claim 1, wherein said second feeding
means includes arched bar spreaders.
4. Apparatus as claimed in claim 1, wherein said first feeding
means and said second feeding means includes arched bar
spreaders.
5. Apparatus as claimed in claim 1, wherein the surface of each
roller is smooth.
6. Apparatus as claimed in claim 1, further including means to vary
the distance between the rollers of each pair of rollers.
7. Apparatus as claimed in claim 1, wherein said first feeding
means includes arched bar spreaders.
Description
BACKGROUND OF THE INVENTION
The prior art has used natural materials, such as down, animal hair
or feathers, for stuffing articles. However, such natural materials
are expensive and have numerous practical disadvantages,
particularly as regards cleaning. The prior art has proposed to use
synthetic fibers for padding uses, with the fibers being used as
such or in the form of flock or sheets. However, such synthetic
fibers tend to agglomerate and to penetrate the coverings
containing same after a certain time of usage, and especially,
above all, after washings.
French patent 1,418,403 describes a process of opening and
spreading a tow of continuous crimped filaments, by passing the
filaments between two rollers, at least one of which is grooved,
with spreading of the filaments to 1.5 to 6 times the original
width thereof on curved bars or on air spreaders.
French patent 1,540,268 describes a process for making dense and
wavy padding webs by passing tow between two rubbing rollers having
different peripheral speeds. The mat obtained is heavily
corrugated, generally with the corrugation fixed, by means of
subsequent application of a resin. The end products produced by
such a process have an irregular appearance, because the
corrugations are readily apparent, and this appearance is
unacceptable for certain applications, in particular for quilting.
The products produced by this process are also too heavy to permit
their use in light weight articles.
In order to avoid the visible corrugations produced using the
process of the aforesaid French patent 1,540,268, it has been
proposed in our U.S. patent application Ser. No. 32,778, filed Apr.
28, 1970, now U.S. Pat. No. 3,696,185, to produce mats having a
relatively flat external surface by using two pairs of smooth
rollers with the upper roller of the first pair of rollers having a
higher peripheral speed that the lower roller of the pair, and the
upper roller of the second pair of rollers having a lower
peripheral speed that the lower roller of the pair. The mats
obtained are of very high quality but practical disadvantages have
been found in such a process, particularly as regards the
regulation of the roller velocities and the feed rate.
SUMMARY OF THE INVENTION
The present process for making padding suitable for stuffing
articles includes the steps of feeding tensioned tow through an
upstream pair of parallel rollers comprising an upper upstream
roller and a lower upstream roller, thereafter feeding said tow
through a downstream pair of parallel rollers comprising an upper
downstream roller and a lower downstream roller, wherein said
downstream pair of rollers are substantially parallel to said
upstream pair of rollers, while rotating each roller in the same
direction, relative to the direction of travel of said tow, and at
a different peripheral speed for each roller of each pair of
rollers from the other roller of the pair, the upstream pair of
rollers having a higher ratio of peripheral speeds than the
downstream pair, and the upper rollers of the two pairs having a
higher peripheral speed than the lower rollers. The process is
practiced on apparatus which includes an upstream pair of rollers
comprising an upper upstream roller and a lower upstream roller,
said rollers being parallel to one another, a downstream pair of
rollers comprising an upper downstream roller and a lower
downstream roller, said downstream rollers being parallel to one
another and substantially parallel to said upstream rollers,
feeding means to feed continuous filaments through said rollers in
the direction from said upstream rollers to said downstream
rollers, and rotating means to rotate each roller in the direction
of movement of said filaments, with the periphery of each roller of
each pair of rollers moving at a different speed from the other
roller of the pair, the upstream pair of rollers having a higher
ratio of peripheral speeds than the downstream pair of rollers, and
the upper rollers of the two pairs having a higher peripheral speed
than the lower rollers.
DESCRIPTION OF THE INVENTION
The present invention provides a method of making padding for
stuffing articles comprising feeding tensioned tow through an
upstream pair of rollers and then through a downstream pair of
rollers, each pair of rollers having its respective rollers
rotating at different peripheral speeds, the upstream pair of
rollers having a higher ratio of peripheral speeds than the
downstream pair of rollers, and the upper rollers of the two pairs
of rollers rotating at a higher peripheral speed than the lower
rollers. The padding produced by the present invention is generally
readily compressible and slightly elastic, having a comparatively
flat external surface. Such padding is highly suitable for stuffing
articles such as quilts or other bed covers, sleeping bags, anoraks
and the like. The continuous crimped tow used in the process or/and
apparatus of this invention is a collection of a great number of
continuous filaments with little, if any, twists or interlacing.
Normally tows are merely intermediate products, which are later
transformed to discontinuous fibers by cutting or crushing. In
contrast, in the present invention, the starting tow is not cut.
The tow will be heavily crimped, however, by known means, such as,
for example, by means of a stuffing box.
The tow used may be of any synthetic textile filament, such as
polyamides, including Nylon 6, Nylon 66, Nylon 610, Nylon 11, etc.,
polyolefins, such as polypropylene, vinyl polymers, acrylic
polymers, polyester polymers and the like. Particularly good
results have been achieved with polyester filaments, especially
polyethylene terephalate.
The tow may be under a tension conventional in the art, such as,
e.g. 1 to 5 kg, preferably 1.5 to 2.8 kg. The tow is preferably
opened during processing according to the present invention,
generally by a factor of about 1 to 4 times the original width of
the tow. However, such opening may be unnecessary in certain cases,
depending upon the specific tow used and the intended application
of the padding.
The distance between the smooth rollers of each pair of rollers
conveniently is adjustable. This distance between rollers depends
mainly upon the thickness of the tow of continuous filaments, and
the thickness of the desired padding mat. The spacing may
conveniently vary, for example, between 0 and 1 mm, although
greater spacing will be used in certain situations, i.e. up to 5 mm
and even higher.
In a number of applications the padding produced by the present
process will be treated with a thermosetting resin to enhance the
cohesion of the resulting mat. Such treatment is known to the art,
with the resin generally applied by spraying and then the
resin-treated mat is subjected to a curing operation in order to
cure the resin. In most instances, this curing operation will be a
thermal treatment in a curing oven or the like, although chemical
curing treatments may also be used, such as for instance, passing
the treated mat through an atmosphere of steam or other gas or
liquid.
It will be appreciated that the padding produced according to the
present invention is obtained directly from tows without passing of
the tow through carding machines. The padding webs of the present
invention may be used, in certain applications, as a substitution
for carding webs.
When used in the present specification the term "ratio of
peripheral speeds" refers to the ratio of the peripheral speeds of
the upper and lower rollers of a given pair of rollers, with the
peripheral speed of the roller having the highest peripheral speed
divided by the peripheral speed of the roller having the lowest
peripheral speed. The two pairs of rollers have the upper rollers
having the highest peripheral speed.
The continuous crimp tow feed rate may vary over a wide range but
suitably would be from 10 to 25 meters/minute, preferably 12 to 15
meters/minute.
DESCRIPTION OF THE DRAWING
The invention will be more clearly understood with reference to the
accompanying drawing wherein
FIG. 1 is a schematic diagram of the apparatus of the present
invention and
FIG. 2 is a diagram illustrating the width of the tow at
corresponding stages in the apparatus of FIG. 1.
FIG. 3 is a cross-sectional view of the upstream pair of smooth
rollers 2, illustrating the means of rotation thereof, as well as
the means of adjusting the gap between the rollers.
FIG. 4 is a view of the arched bar spreaders.
As shown in FIG. 1, a tow 1 of continuous, crimped filaments is
removed from a storage bin (not shown) and continuously fed past
arched bar spreaders and stretchers (not shown) and through the
upstream pair of smooth rollers 2. The rollers rotate in opposite
axial directions but in the same direction relative to the
direction of travel of the tow, i.e. both rollers travel in the
direction of the tow. In other words, adjacent portions of the two
rollers constituting each pair of rollers move in the same
direction, which direction is from the upstream pair to the
downstream pair. Spreader 3 located before the first pair of
rollers 2 imparts a good, uniform appearance to the tow.
The axes of the first pair of smooth rollers 2 are parallel, and
the adjustment between the rollers is adjustable. The rollers are
adjusted to a separation which depends mainly upon the thickness of
the tow and also upon the thickness of the padding mat. The surface
of the smooth rollers 2 as well as the smooth rollers 6 is of a
material having a high coefficient of friction, preferably rubber
of 60.degree. - 70.degree. shore hardness. The surface of the
rollers may be of various other materials having similar high
coefficient of friction as known to the art. The ratio of
peripheral speeds of the upper and lower rollers of the upstream
pair of rollers 2 is greater than 5, preferably between 5 and
10.
After passing between upstream pair of rollers 2, the tow then
passes over spreader 4 comprising a series of arched bars, and then
over holding rollers 5, which comprise three drums which serve to
maintain the spread of the mat and control the mat tension. The tow
then passes between the downstream pair of smooth rollers 6, which
have a ratio of peripheral speeds of less than 5 and preferably
between 3 and 5. The spacing of the downstream pair of rollers 6 is
also adjustable and can be varied according to the thickness of the
tow and of the desired mat.
Depending upon the desired width of the mat or padding web desired,
the mat may be passed over an additional spreader 7 which consists
of one or several arched bars. The mat is then passed into a set of
holding rollers 8 and then to a moving belt 9. While on moving belt
9, the mat may be, if necessary, treated with a thermosetting
resin, e.g. by spraying, with the resin-treated mat then being
thermally treated to enhance the cohesion of the resulting mat or
padding web. The upstream pair of rollers 2 comprises an upper
roller 32 and a lower roller 32'. The shaft 33 of upper roller 32
is is supported by bearing 34 which rides in sleeve 35. Bearing 34
is urged upwardly by spring 36 and is adjustable by way of set
screw 37. Roller 32' is driven by variable speed motor 38 through
chain drive 39, and roller 32 is directly driven, through universal
joint 39', by variable speed motor 38'.
The universal joint 39' is used because of the displacement of
roller 32 during adjustment of the gap between rollers 32 and 32'.
Two variable speed motors 38 and 38' are illustrated, and are
greatly preferred, but it will be appreciated that in some
instances one of the rollers may be driven by a constant speed
motor. The transmission of power for motor 38 to roller 32' is
preferably by way of a chain 39 rather than a belt drive in order
to avoid slippage.
In FIG. 4 arched bars 41 are carried by rails 42. The tow 1 is
illustrated passing over one bar 41 and under the next. The bars 41
are retained in rails 42 by adjusting nuts 43, which enable some
rotational adjustment of the arched bars 41.
EXAMPLES
The invention will be understood more readily by reference to the
following example; however, this example is intended to illustrate
the invention and is not to be construed to limit the scope of the
invention.
EXAMPLE 1
A polyethylene terephalate tow of crimped filaments of 110,000
dtex, about 6.7 dtex per strand, was fed to spreader 3 under a
tension of 1.5 kg at a feed rate of 5 meters/minute. The tow, which
had been spread to 3 times its original width, was then fed between
the rollers of upstream pair of rollers 2, with the upper roller
being driven at a peripheral speed of 7.10 meters/minute and the
lower roller at a speed of 1.40 meters/minute. The rollers were
spaced 1/10 mm apart. The tow was then spread over four arched bars
of spreader 4 and through the set of holding cylinders 5, all of
which cylinders or rollers revolved at a speed of 4.80
meters/minute. In the set of holding cylinders 5, the width of the
mat was 33 cm. Holding cylinders 5 served to control the tension
for the passage of the mat between the rollers of downstream pair
of rollers 6.
The mat was passed between the smooth rolls of downstream pair of
rollers 6, with the upper roller thereof rotating at a peripheral
velocity of 5 meters/minute and the lower roller rotating at a rate
of 1.80 meters/minute. The downstream pair of rollers 6 were spaced
1/10 mm apart
The surface of each roller of upstream pair of rollers 2 and
downstream pair of rollers 6 was of rubber of 65.degree. shore
hardness.
The mat was then passed through holding rollers 8, wherein the mat
had a width of 51 cm. The mat was discharged on moving belt 9 at a
rate of 4.50 meters/minute, having a weight about 22 grams per
square meter.
The resulting mat is suitable for padding a variety of articles,
such as anaroks and sleeping bags, for example. The padding web
could also be used for thermal and acoustical insulation, as a
coating support, or as a reinforcing element for plastic materials,
laminants, etc. Depending upon the count (number of filaments) of
the starting tow and the ultimate end use, the mat may be employed
singly, or several mats may be superimposed, before or after the
optional treatment with a thermosetting resin.
* * * * *