PLEATED TEXTILE PRODUCTS AND A MACHINE FOR THEIR PRO DUCTION

If the requested thickness and/or mechanical properties of a product are beyond technological possibility of manufacturing tefabrics, the requested thickness can be obtained by pleating thin fabrics.

Purpose

In the vertical pleating the individual pleats are arranged side by side close to each other and the fabric surfaces consist of the single pleats. The vertical pleating is suitable for quite a number of applications because there is possible to obtaiproduct thickness with lower material consumption and the initial compression resistance is also higher. In accordance with tintended application there can be distinguished three types of pleats.

Types of vertical pleats

The U shape pleat, the width of which is constant within the whole pleat height, has been used for manufacturing mattresses, noise and/or thermal insulation products because of relatively high pleat density. An example is the end use in the wellSTRUTO technology.

The Λ shape pleat, the width of which increases continuously from the top to the bottom, has been generally production of filters. Thus, the filtration area can be enlarged.

Types of vertical pleats

The third pleat type has a drop shape, e.g. as shown in Fig.1.pleat is extending continuously to its widest part wherefrom it is narrowing again up to its narrowest part where the neighbouring pleats are formed. This drop shape increases friction between single layers when multilayer products are manufactured and preserves their separation in the vertical direction. Thus, the cavities are possible to be formed across thproducts which may decrease the product density and influence its deformation and insulation properties The conditions for

STRUTO technology.

products which may decrease the product density and influence its deformation and insulation properties The conditions for forming the described pleat shape are specific and given by the stiffness of the pleated layers, product height, pleat count length unit and structure fixation.

Figure 1: Pleat of drop shape

The schematic diagram of a device for the vertical pleating of thin nonwoven textiles (0,3 to1,8 mm) that has been adapted in

Device for vertical pleating of nonwovens

The schematic diagram of a device for the vertical pleating of thin nonwoven textiles (0,3 to1,8 mm) that has been adapted inmanufacturing products in thickness of 4 to 7 mm is shown in Fig.2. The device consists of two basic assemblies; in the firstformed by means of a forming gear set. A conveyor being moved at a control speed passes through the forming gear set. In the pleated structure is fixed.

Waves maker

Quasi-yarns maker

Output

Figure 2: Schematic diagram of a device for manufacturing products being vertically pleated from thin nonwoven fabrics

For the product structure fixation, i.e. the vertically formed pleats of the identical height and defined wave number (pleat number per

Surface fixation

and defined wave number (pleat number per length unit), quasi-yarns have been used [3]. The individual fixation sections are arranged in sliding blocks and abrasive particles are their working elements. The surface fixation by means of quasi-yarns in conjunction with a by means of quasi-yarns in conjunction with a suitable number of pleats and suitable bending rigidity of the nonwoven fabric being pleated is the necessary condition for the forming of the above mentioned drop shape pleats (Fig.1).

Parameters and their relations

Figure 4: Machine prototype for manufacturing vertically pleated

Thickness of the product T and tooth penetration of the forming gears P can be estimated as follows, where a is given by the forming gear construction.

Parameters and their relations

Types of products

The initial intention was to use the products most of all in the automotive industry. There was intended to replace the polymaterials “cover textile fabric – polyurethane foam”. They were intended for forming “a sandwich composite core” for vehicle cei

Application

materials “cover textile fabric – polyurethane foam”. They were intended for forming “a sandwich composite core” for vehicle ceinoise insulation in various vehicle parts. Later on, various industrial branches were added, the product tests were targeted filtration (cartridge filters), environment-friendly end uses, e.g. oil and emulsion sorption etc. The discussions with prospectdevelopment of specific products for the above mentioned end uses have not been finished yet.

How it is possible to influence filtration efficiency by an additional layer inserted into the product during its processing Example of application – filter

How it is possible to influence filtration efficiency by an additional layer inserted into the product during its processing shown in Fig. 6 and 7 where the results of the particle size measurement are given. In manufacturing the test samples there wspun-jet fabric (Fig.6) and three layers – spun-jet, melt-blown and spun-jet fabrics (Fig.7).

. Figure 6 Filter made from two Figure 7 Filter Figure 6 Filter made from two layers of spun-jet nonwoven

Figure 7 Filterthree layers

PLEATED TEXTILE PRODUCTS AND A MACHINE FOR THEIR PRO DUCTION

If the requested thickness and/or mechanical properties of a product are beyond technological possibility of manufacturing textile

In the vertical pleating the individual pleats are arranged side by side close to each other and the fabric surfaces consist of top parts of the single pleats. The vertical pleating is suitable for quite a number of applications because there is possible to obtain an even product thickness with lower material consumption and the initial compression resistance is also higher. In accordance with the

The U shape pleat, the width of which is constant within the whole pleat height, has been used for manufacturing mattresses, noise and/or thermal insulation products because of relatively high pleat density. An example is the end use in the well-known

shape pleat, the width of which increases continuously from the top to the bottom, has been generally used in the production of filters. Thus, the filtration area can be enlarged.

The third pleat type has a drop shape, e.g. as shown in Fig.1.The pleat width changes with its height in such a way that the pleat is extending continuously to its widest part wherefrom it is narrowing again up to its narrowest part where the neighbouring pleats are formed. This drop shape increases friction between single layers when multilayer products are manufactured and preserves their separation in the vertical direction. Thus, the cavities are possible to be formed across the products which may decrease the product density and influence its deformation and insulation properties The conditions for products which may decrease the product density and influence its deformation and insulation properties The conditions for forming the described pleat shape are specific and given by the stiffness of the pleated layers, product height, pleat count per

The schematic diagram of a device for the vertical pleating of thin nonwoven textiles (0,3 to1,8 mm) that has been adapted inits specific design, i.e. for

Device for vertical pleating of nonwovens

The schematic diagram of a device for the vertical pleating of thin nonwoven textiles (0,3 to1,8 mm) that has been adapted inits specific design, i.e. for manufacturing products in thickness of 4 to 7 mm is shown in Fig.2. The device consists of two basic assemblies; in the firstassembly the pleats are formed by means of a forming gear set. A conveyor being moved at a control speed passes through the forming gear set. In the second assembly the formed

maker

Input

products being

In Fig.4 there is shown a configuration of the machine model for manufacturing the vertically pleated textile fabrics 4 – 7 mm thick and about 250 mm wide. Such a fabrics 4 – 7 mm thick and about 250 mm wide. Such a textile product consists of thin vertically pleated (0,3 – 1,8 mm) nonwoven fabrics. Currently it is possible to process the semi-product, which has the mass per unit area 20 – 100 g/m2, and manufacture the product of 300 – 900 g/m2. The machine model [4] consists of mirror similar blocks (see machine model [4] consists of mirror similar blocks (see Fig.2), which are able to be set up mutually and continuously. The forming gears are driven in one part only; the delivery conveyors are driven in both blocks of the machine.Machine prototype for manufacturing vertically pleated textile fabrics

1

222

222

22

−

+

+

−=

k

kTa

ka

PT and tooth penetration of the forming gears P can be

2

22

22

22

22= T

k

Pa

ka

kP −

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The initial intention was to use the products most of all in the automotive industry. There was intended to replace the polyurethane foam in composite polyurethane foam”. They were intended for forming “a sandwich composite core” for vehicle ceilings and doors, for polyurethane foam”. They were intended for forming “a sandwich composite core” for vehicle ceilings and doors, for

noise insulation in various vehicle parts. Later on, various industrial branches were added, the product tests were targeted most of all for the liquid friendly end uses, e.g. oil and emulsion sorption etc. The discussions with prospective customers on the

development of specific products for the above mentioned end uses have not been finished yet.

How it is possible to influence filtration efficiency by an additional layer inserted into the product during its processing by the new technology there is How it is possible to influence filtration efficiency by an additional layer inserted into the product during its processing by the new technology there is shown in Fig. 6 and 7 where the results of the particle size measurement are given. In manufacturing the test samples there were pleated two layers of a

jet fabrics (Fig.7).There is a machine model for manufacturing the products 4 – 7

mm thick being vertically pleated from thin nonwoven fabrics.The product samples made in accordance with the described

. Filter made from

The product samples made in accordance with the described method show at least as good parameters as do the products currently offered on the market.The product parameters can be influenced by pleating more layers into so called multilayer or combined products.

Filter made from three layers