CA2158421C - Apparatus for making nonwoven fabrics having raised portions - Google Patents

Apparatus for making nonwoven fabrics having raised portions Download PDF

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Publication number
CA2158421C
CA2158421C CA002158421A CA2158421A CA2158421C CA 2158421 C CA2158421 C CA 2158421C CA 002158421 A CA002158421 A CA 002158421A CA 2158421 A CA2158421 A CA 2158421A CA 2158421 C CA2158421 C CA 2158421C
Authority
CA
Canada
Prior art keywords
pattern
support member
macro
sized
topographical
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
CA002158421A
Other languages
French (fr)
Other versions
CA2158421A1 (en
Inventor
William A. James
William G. F. Kelly
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Johnson and Johnson Consumer Inc
Original Assignee
McNeil PPC Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by McNeil PPC Inc filed Critical McNeil PPC Inc
Priority to CA002513621A priority Critical patent/CA2513621C/en
Publication of CA2158421A1 publication Critical patent/CA2158421A1/en
Application granted granted Critical
Publication of CA2158421C publication Critical patent/CA2158421C/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/36—Removing material
    • B23K26/38—Removing material by boring or cutting
    • B23K26/382—Removing material by boring or cutting by boring
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/492—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet
    • D04H1/495—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet for formation of patterns, e.g. drilling or rearrangement
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H18/00—Needling machines
    • D04H18/04—Needling machines with water jets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/30—Organic material
    • B23K2103/38—Fabrics, fibrous materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/50—Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness

Abstract

A topographical support member and a method of forming a topographical support member for use in producing nonwoven fabrics with raised portions, especially intaglio and slub type portions. The topographical support member comprises a body having a top surface including a first micro-sized topographical pattern and a pattern of apertures extending through the body. At least one macro-sized region recessed below the top surface is provided. The micro-sized pattern produces a background portion of the fabric and the macro-sized recessed regions produce the raised portions of the fabric. Multiple levels may be provided in the macro-sized region to produce multiple level raised portions.

Claims (26)

1. A method for forming a topographical support member for producing nonwoven fabrics having at least one raised portion, said method comprising the steps of:
a) providing a workpiece;
b) forming a first micro-sized topographical pattern on a top surface of the workpiece;
c) forming a plurality of openings through said workpiece; and d) superimposing on said workpiece at least one macro-sized region recessed from said top surface.
2. The method of claim 1 wherein said recessed surface has a second micro-sized topographical pattern.
3. The method of claim 2 wherein said first and second topographical patterns are the same pattern.
4. The method of claim 1 wherein the step of forming the first topographical pattern includes laser drilling the top surface of said workpiece.
5. The method of claim 4 wherein said step of laser drilling includes moving a laser beam in a series of raster scan lines over the surface of the workpiece.
6. The method of claim 4 wherein the step of superimposing at least one macro-sized region includes laser ablating to a predetermined depth below said top surface.
7. The method of claim 6 wherein said laser ablating step including moving a laser beam in a series of raster scan lines over the top surface of the workpiece.
8. The method of claim 1 wherein said step of superimposing at least one macro-sized region includes the step of forming at least two of said regions at differing depths below the top surface.
9. The method of claim 1 wherein the step of superimposing at least one macro-sized region includes the step of forming a major surface recessed a first depth below the top surface and at least one minor surfaces recessed at depths different from said first depth.
10. The method of claim 9 wherein one minor surface is formed surrounding said major surface, said minor surface being recessed at a depth below said first depth, the width of said minor surface being substantially less than that of said major surface.
11. The method of claim 1 wherein steps (b) and (c) are performed by the steps of:
a) focusing a laser beam such that the focal point is below the top surface of said workpiece; and b) drilling with said laser beam a predetermined pattern of tapered apertures through said workpiece thereby forming an array of peaks and valleys surrounding each aperture on the top surface of the resulting support member.
12. The method of claim 11 wherein the center line to center line spacing of adjacent apertures is less than the major diameter of a conical top portion of each adjacent aperture.
13. The method of claim 12 wherein said array of peaks and valleys surrounding the pattern of tapered apertures is configured to provide a tricot-like nonwoven fabric.
14. A topographical support member for producing a nonwoven fabric comprising:
a) a body having a top surface including a first micro-sized topographical pattern;
b) a pattern of apertures extending through said body; and c) at least one macro-sized region recessed below said top surface.
15. The support member of claim 14 wherein said at least one macro-sized region has a second micro-sized topographical pattern on a top surface of said region.
16. The support member of claim 15 wherein said first and second topographical patterns are the same pattern.
17. The support member of claim 14 wherein said at least one macro-sized region includes a major surface recessed a first depth below the top surface and at least one minor surfaces recessed at depths different from said first depth.
18. The support member of claim 17 wherein said macro-sized region includes one minor surface surrounding said major surface, said minor surface being recessed at a depth below said first depth, the width of said minor surface being substantially less than the width of said major surface.
19. The support member of claim 14 wherein said first micro-sized topographical pattern includes a pattern of a plurality of peaks and valleys, each of said apertures having a conical top portion surrounded by a cluster of said peaks and valleys.
20. The support member of claim 19 wherein the center line to center line spacing of adjacent apertures is less than the major diameter of the conical top portion of each adjacent aperture.
21. The support member of claim 20 wherein said pattern of the plurality of peaks, valleys and apertures being configured to produce a tricot-like nonwoven fabric.
22. The support member of claim 19 wherein said at least one macro-sized region includes a pattern of a plurality of peaks and valleys surrounding each aperture which is the same as said first micro-sized topographical pattern.
23. The support member of claim 14 wherein said first topographical pattern includes a repeating pattern of peaks and valleys and wherein the cross-sectional width of said macro-sized region is greater than the spacing between the repeat of said repeating pattern.
24. The support member of claim 14 wherein said pattern of apertures is a matrix and wherein the cross-sectional width of said macro-sized region is greater than the spacing between the apertures in said matrix.
25. The support member of claim 14 wherein said first topographical pattern includes a repeating pattern of peaks and valleys and wherein the cross-sectional width of said macro-sized region is at least two times greater than the spacing between the repeat of said repeating pattern.
26. The support member of claim 14 wherein said pattern of apertures is a matrix and wherein the cross-sectional width of said macro-sized region is at least two times greater than the spacing between the aperture in said matrix.
CA002158421A 1994-09-16 1995-09-15 Apparatus for making nonwoven fabrics having raised portions Expired - Fee Related CA2158421C (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CA002513621A CA2513621C (en) 1994-09-16 1995-09-15 Apparatus for making nonwoven fabrics having raised portions

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US08/308,017 US5674587A (en) 1994-09-16 1994-09-16 Apparatus for making nonwoven fabrics having raised portions
US08/308,017 1994-09-16

Related Child Applications (1)

Application Number Title Priority Date Filing Date
CA002513621A Division CA2513621C (en) 1994-09-16 1995-09-15 Apparatus for making nonwoven fabrics having raised portions

Publications (2)

Publication Number Publication Date
CA2158421A1 CA2158421A1 (en) 1996-03-17
CA2158421C true CA2158421C (en) 2006-10-10

Family

ID=23192181

Family Applications (1)

Application Number Title Priority Date Filing Date
CA002158421A Expired - Fee Related CA2158421C (en) 1994-09-16 1995-09-15 Apparatus for making nonwoven fabrics having raised portions

Country Status (8)

Country Link
US (4) US5674587A (en)
EP (1) EP0705933B1 (en)
JP (1) JP3739448B2 (en)
CN (2) CN1064728C (en)
CA (1) CA2158421C (en)
DE (1) DE69520861T2 (en)
FI (1) FI954357A (en)
TW (1) TW328975B (en)

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JPH08176945A (en) 1996-07-09
CA2158421A1 (en) 1996-03-17
CN1132276A (en) 1996-10-02
DE69520861D1 (en) 2001-06-13
FI954357A0 (en) 1995-09-15
CN1064728C (en) 2001-04-18
EP0705933A3 (en) 1997-10-01
JP3739448B2 (en) 2006-01-25
CN1277274A (en) 2000-12-20
TW328975B (en) 1998-04-01
USRE38105E1 (en) 2003-05-06
US5906786A (en) 1999-05-25
US5822833A (en) 1998-10-20
EP0705933B1 (en) 2001-05-09
DE69520861T2 (en) 2001-09-13
US5674587A (en) 1997-10-07
CN1253621C (en) 2006-04-26
EP0705933A2 (en) 1996-04-10
FI954357A (en) 1996-03-17

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