Patent GB-1003058-A (GB)
Title: A method and apparatus for producing nonwoven fabrics
Inventor: KALWAITES FRANK
IPC: D04H1/736
Filed: 1963-02-21
Abstract: 1,003,058. Fibrous fabrics; paper-making apparatus; paper. JOHNSON & JOHNSON. Feb. 21, 1963, No. 7020/63. Headings D1R, D2A and D2B. A foraminous non-woven fabric 9<SP>1</SP> is produced from a layer 9 of wet irregularly arranged fibres by penetrating the layer 9 with a group of needles, prongs or like tapered implements 26 arranged in a predetermined pattern and brushing the fibre accumulating zones between the needles 26 to move the rearranged fibres so that they lie in a relaxed, tensionless condition. The fibrous layer 9 is carried into the machine by a conveyer 8 and if not self-sustaining is carried on a permeable carrier web. The layer 9 passes between a roll 11 dipping into water in a pan 15 and a vertically-adjustable roll 12 to effect wetting thereof. The layer 9 is then moved into contact with the sharp ends of the needles 26 arranged in a predetermined pattern on the peripheral surface of a rotating cylinder 25 secured to a shaft 23. The needles or prongs 26 may have rounded, flat or pointed ends and are preferably each formed with a cylindrical body and a tapered conical section. The layer.9 is impaled onto the needles 26 by a soft-bristle brush 27 which is curved slightly to conform to the surface of the cylinder 25. The brush 27 can pivot slightly about a joint 30 and is mounted on a rod 32, Fig. 4, secured to a strap 39 carried by bearings 40 on a disc 37 eccentrically mounted on a rotating shaft 35 so that the rod 32 is reciprocated. The reciprocatory motion of the brush 27 is confined to a path normal to the cylinder surface by the rod 32 sliding in a guide 44. The layer 9 is then engaged by the soft bristles of rotating brushes 46, 47, 48, 49, the brushes 47, 49 being driven in the same direction as and the brushes 46, 68 in the opposite direction to the cylinder 25 from the shaft 23 by belts 58, 59, 60, 61, Fig. 6. The rotating shaft 50, 51, 52, 53 of each of the brushes 46, 47, 48, 49 is oscillated longitudinally. As the shaft 23 rotates it rotates a shaft 72, Figs. 2 and 7, through worms 69, 71 and rotates four cams 74 eccentrically mounted on the shaft 72. As each cam 74 moves outwardly it presses against a follower roller 81 to move the upper end of a lever 78 and the shaft 50, 51, 52 or 53 inwardly against the action of a compression spring 84. As each cam 74 moves inwardly the spring 84 pushes the shaft 50, 51, 52 or 53 outwardly to complete the oscillation of the shaft. The resulting non-woven fabric 9<SP>1</SP> passes between doffing rolls 86, 87, one of which is preferably driven;and passes onto a conveyer 10 to carry the fabric to a suitable adhesive bonding or drying area. Specified fibres are rayon and cotton and any of the starting materials described in Specifications 836,396, 836,397 and 816,673 may be used. Fibres specified in these specifications are cotton, flax, wood, silk, wool, jute, asbestos, ramie, rag, abaca, viscose rayon, cupra-ammonium rayon, ethyl cellulose, cellulose acetate, polyamide, polyester, acrylic, polyethylene, vinylidene chloride, polyvinyl chloride, polyurethane or vinyl chloride-acrylonitril copolymer, alone or in combination with one another. The textile-like fibres preferably average at least <SP>1</SP>/ 4  inch in length.