Laminated structural body having unidirectionally arranged strands sandwiched between two web layers, and method of and apparatus for efficiently manufacturing such laminated structural body

• US 20010051484A1
• Filed: 06/01/2001
• Published: 12/13/2001
• Est. Priority Date: 06/09/2000
• Status: Active Grant

• Current Assignee: Nippon Petrochemicals Co., Ltd. (ENEOS Holdings, Inc.), Polymer Processing Research Institute Limited
• Original Assignee: Nippon Petrochemicals Co., Ltd. (ENEOS Holdings, Inc.), Polymer Processing Research Institute Limited
• Inventors: Ishida, Takashi, Murakami, Shuichi, Yazawa, Hiroshi, Ohta, Toshio, Katoh, Tadayoshi
• Granted Patent: US 6,673,186 B2
• Time in Patent Office: Days
• US Class Current: 442/327
• CPC Class Codes: B32B 5/02 characterised by structural features of a fibrous or filamentary layer layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02
• CPC Class Codes: D04H 13/00 Other non-woven fabrics
• CPC Class Codes: D04H 3/07 otherwise than in a plane, e.g. in a tubular way
• CPC Class Codes: Y10T 156/1002 with permanent bending or reshaping or surface deformation of self sustaining lamina
• CPC Class Codes: Y10T 156/1049 Folding only
• CPC Class Codes: Y10T 156/1051 by folding
• CPC Class Codes: Y10T 442/60 Nonwoven fabric [i.e., nonwoven strand or fiber material]
• CPC Class Codes: Y10T 442/607 Strand or fiber material is synthetic polymer
• CPC Class Codes: Y10T 442/609 Cross-sectional configuration of strand or fiber material is specified
• CPC Class Codes: Y10T 442/61 Cross-sectional configuration varies longitudinally along strand or fiber material

Abstract

A laminated structural body is manufactured by laminating unidirectionally arranged strands and a web such that two layers of the web sandwich the strands therebetween. A cylindrical web is delivered in a direction parallel to a central axis thereof. A polymer liquid is discharged from a spinning head, which is disposed in the cylindrical web and rotated about the central axis of the cylindrical web, toward an inner surface of the cylindrical web to spin strands of the discharged polymer liquid. The spun strands are arranged in a direction substantially parallel to the circumferential direction of the cylindrical web and laminated on the inner surface of the cylindrical web. The cylindrical web with the strands laminated thereon is folded flatwise to sandwich the strands between the two folded layers of the web.

Claims

1. A laminated structural body of a web shape comprising a laminated body with a layer of strands laminated on the inner surface of a tubular nonwoven fabric, said laminated body being folded flatwise, said strands being arranged transversely of the laminated structural body between folded layers of the nonwoven fabric.

2. A laminated structural body according to

claim 1

, wherein said strands are made of a thermoplastic elastomer, said nonwoven fabric having an elongation of 100% or higher in the transverse direction of the laminated structural body.

3. A laminated structural body according to

claim 1

, wherein said adjacent strands are spaced from each other.

4. A laminated structural body according to

claim 1

, wherein said nonwoven fabric has fibers arranged longitudinally and stretched longitudinally.

5. A method of manufacturing a laminated structural body having two web layers with unidirectionally arranged strands sandwiched therebetween, comprising the steps of:

delivering a cylindrically curved web in a direction parallel to a central axis thereof in a state where said web is kept in a cylindrical shape;

discharging a polymer liquid from a spinning head, which is disposed in said cylindrical web and rotated about the central axis of the cylindrical web, toward an inner surface of said cylindrical web to spin strands of the discharged polymer liquid and laminate the strands on the inner surface of said cylindrical web; and

folding flatwise said cylindrical web with the strands laminated thereon to sandwich said strands between the two folded layers of the web.

6. An apparatus for manufacturing a laminated structural body having two web layers with unidirectionally arranged strands sandwiched therebetween, comprising:

a tube forming member for curving a web in a direction perpendicular to a longitudinal direction of the web to shape said web into a cylindrical web;

delivery means for delivering said cylindrical web in a direction parallel to a central axis thereof;

a cylindrical guide for supporting said web movably to keep said web curved as the cylindrical web while the web is being delivered by said delivery means;

a spinning head disposed in said cylindrical web supported by said cylindrical guide and rotatable about a central axis of said cylindrical guide, for discharging a polymer liquid toward an inner surface of said cylindrical web to spin strands and laminating the strands on the inner surface of said cylindrical web; and

folding means for folding flatwise said cylindrical web with the strands laminated thereon to sandwich said strands between the two folded layers of the web.

7. An apparatus according to

claim 6

, wherein said folding means comprises a pair of pinch rollers for sandwiching said cylindrical web therebetween to fold the cylindrical web flatwise.

8. An apparatus according to

claim 6

, wherein said folding means has the function of delivering said cylindrical web in a direction parallel to a central axis thereof.

9. An apparatus according to

claim 6

, wherein said spinning head has a plurality of nozzles which discharges the polymer liquid so that the spun strands are spaced from each other on the inner surface of said cylindrical web.