US 2006/0065348 A1 · Apparatus and method for fiber fusing a surface of woven and non-woven fabrics

Abstract

An apparatus and method for producing a non-woven fabric made from a web having a combination of synthetic and/or blend of synthetic and natural fibers by fiber fusing or melting one or more surfaces with a flame or high heat from a burner heat source to eliminate or reduce the use of latex or other binders and low melt fibers. A first burner is positioned opposite a first roll around which the web passes, and the first burner applies a flame or heats the first surface. A second burner appropriately displaced from the first burner is positioned opposite a second roller around which the web passes and the second burner applies a flame or heats a second surface of the web. A blade or alternately a cylindrical assembly is positioned adjacent to each burner for flattening the melted fibers. An air nozzle is positioned immediately adjacent to each roller for cooling the entire width of a web as the web is heated to accomplish the melting of the predetermined necessary fibers without adversely affecting other fibers in the web.

Claims31

Dependent claims

An apparatus for fiber fusing a surface of a fabric comprising:

(a) a first roll positioned in said apparatus for receiving a fabric web and moving said fabric web around a portion of said first roll;
(b) a second roll positioned below and spaced apart from said first roll for receiving said web and moving said web around a portion of said second roll for exiting said apparatus;
and
(c) a first burner, positioned adjacent to a side of and directed at said first roll which said web passes around a portion thereof, for applying a flame or heat to fibers of said web.

1 more element

A method of fiber fusing a surface of a fabric web comprising the steps of:

(a) providing a first roll for receiving said fabric web and moving said fabric web around a portion of said first roll;
(b) positioning a second roll below and spaced apart from said first roll to receive said web and moving said web around a portion of said second roll for exiting said apparatus;
(c) applying a flame or heat from a first burner to fibers of said web, said first burner being positioned adjacent to a side of said first roll which said web passes around;
(d) applying a flame or heat from a second burner to fibers of said web, said second burner being positioned adjacent to a side of said second roll which said web passes around;
(e) flattening melted fibers after said web passes by said first burner with first means positioned below said first roll and in contact with said web;
(f) flattening melted fibers after said web passes by said second burner with second means positioned below said second roll and in contact with said web;
(g) providing a first air source extending across a face of said web and positioned adjacent to said first roll for cooling said face of said web;
(h) providing a second air source extending across a face of said web and positioned adjacent to said roll for cooling said face of said web;
and
(i) turning on said first burner when fusing a first surface of said web, and turning on said second burner when fusing a second surface of said web.

7 more elements

Dependencies are inferred from the claim text.

Apparatus and method for fiber fusing a surface of woven and non-woven fabrics

Life of this patent

Apparatus and method for fiber fusing a surface of woven and non-woven fabrics

Life of this patent

Abstract

Claims31