Abstract A method of making nonwoven fabrics from one or more strands of rayon tow wherein at least one strand is continuously fed to a cutter which severs the strand into short bundles, preferably from about 0.2 to about 0.4 inch in length. The bundles of fibers are partially separated and dispersed as they are moved to an enclosed chamber by a blower. An air knife directs air jets transversely to the direction of fiber flow in the enclosed chamber in order to completely separate the individual fibers whereupon they are uniformly deposited in random fashion on a wire. The nonwoven fabric is completed by the conventional steps of spraying a binder composition on the fibers followed by drying.
A method of continuously making a uniform nonwoven web as claimed in claim 1 wherein said fiber bundles are cut to a length of from 0.2 to 0.4 inch.
Claim 2
Independent Claim
161 words
A method of continuously making a uniform nonwoven web comprising the steps of: a. feeding at least one strand of rayon tow into a cutter at a substantially uniform rate, b. cutting said strand into short fiber bundles having a length of from 0.1 to 0.5 inch, c. dispersing said cut bundles randomly into individual fibers in a zone of high air shear, said zone of high air shear including an air knife comprising a slot mounted in the wall of a chamber through which the fiber bundles are passed prior to deposition on said wire and injecting air through said slot at substantial velocity to completely separate the individual fibers from one another, d. depositing said individual fibers uniformly on the surface of a wire screen, and e. spraying a binder on said fibers supported on said wire screen, and drying said binder to bond said fibers into a uniform nonwoven fabric having substantially uniform tensile strength in all directions.
Claim 3
Dependent Claim
29 words
A method of continuously making a uniform nonwoven web as claimed in claim 3 wherein said fiber bundles are cut to a length of from 0.2 to 0.4 inch.
Claim 4
Dependent Claim
44 words
A method of continuously making a uniform nonwoven web as claimed in claim 3 including the intermediate step of passing the fiber bundles through a centrifugal blower to substantially separate the individual fibers by contact with the rough peripheral inside surface of said blower.
Claim 5
Dependent Claim
29 words
A method of continuously making a uniform nonwoven web as claimed in claim 5 wherein said fiber bundleS are cut to a length of from 0.2 to 0.4 inch.