Method and apparatus for controlling flow in a drum

• US 20020070471A1
• Filed: 12/08/2000
• Published: 06/13/2002
• Est. Priority Date: 12/10/1999
• Status: Abandoned Application

• Current Assignee: Innovent, Inc. (Standex Engraving, LLC)
• Original Assignee: Innovent, Inc. (Standex Engraving, LLC)
• Inventors: Lee, George, Bontaites, George J. Jr.
• Application Number:
  US09/733,147
• Publication Number:
  US 20020070471A1
• Time in Patent Office: Days
• US Class Current: 264/40.3
• CPC Class Codes: A61F 13/15626 Making fibrous pads without outer layers
• CPC Class Codes: B29C 2948/926 Flow or feed rate
• CPC Class Codes: B29C 2948/92923 Calibration, after-treatment or cooling zone
• CPC Class Codes: B29C 48/05 Filamentary, e.g. strands
• CPC Class Codes: B29C 48/92 Measuring, controlling or regulating
• CPC Class Codes: D04H 1/56 in association with fibre formation, e.g. immediately following extrusion of staple fibres
• CPC Class Codes: D04H 1/72 the fibres being randomly arranged
• CPC Class Codes: D04H 1/76 otherwise than in a plane, e.g. in a tubular way
• CPC Class Codes: D04H 3/02 characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
• CPC Class Codes: D04H 3/07 otherwise than in a plane, e.g. in a tubular way
• CPC Class Codes: D04H 3/16 with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion

Abstract

A method of manufacturing a non-woven material uses a contoured honeycomb drum with an outer microporous surface, more particularly with a contoured outer surface, for the manufacture of contoured non-woven fibrous materials. The method can use spunbonded, melt blown, or electro-static spun techniques for depositing solidifying filaments on the microporous surface such that the non-woven material conforms to the contour of the drum. The drum facilitates continuous production of non-woven articles with three-dimensional shapes such as surgical masks or pleated air filters. Airflow through the drum can be controlled with an internal adjustable manifold with independent valves to obtain non-woven material articles of various configurations and properties. In addition, efficiency can be improved by including turning vanes. Vacuum or pressure can be applied.

Claims

1. A manifold spanning a sector of a drum across at least a portion of a width thereof, the manifold comprising at least two chambers independently regulatable with respect to at least one of pressure and flow.

2. The invention according to claim 1 wherein the manifold comprises an inner tube located inside of a shell, the shell further comprising a plate to prevent airflow from leaking around the inner tube.

3. The invention according to claim 2 wherein the inner tube comprises a plurality of ports to provide fluidic communication between the inner tube and the shell.

4. The invention according to claim 3 wherein the inner tube further comprises a plurality of valves in communication with the plurality of ports to regulate at least one of pressure in and flow through the manifold.

5. The invention according to claim 2 wherein the shell further comprises a frame forming an aperture.

6. The invention according to claim 5 further comprising a honeycomb panel disposed within the frame aperture.

7. The invention according to claim 5 further comprising at least one flow turning vane disposed between the inner tube and the frame aperture.

8. The invention according to claim 2 wherein the shell further comprises at least one partition thereby defining the at least two independently regulatable chambers.

9. A drum for forming non-woven articles, the drum comprising:

a generally tubular honeycomb member having an outer surface forming a contour; and

a manifold spanning a sector on the drum across a width therefore, the manifold subdivided into at least two chambers independently regulatable with respect to pressure.

10. The invention according to claim 9 wherein the drum further comprises a microporous layer covering at least a portion of the contour.

11. The invention according to claim 9 further comprising a frame for rotatably supporting the drum.

12. The invention according to claim 9 wherein the manifold comprises an inner tube located inside of a shell, the shell further comprising a plate to prevent airflow from leaking around the inner tube.

13. The invention according to claim 12 wherein the inner tube comprises a plurality of ports to provide fluidic communication between the inner tube and the shell.

14. The invention according to claim 13 wherein the inner tube further comprises a plurality of valves in communication with the plurality of ports to regulate at least one of pressure in and flow through the manifold.

15. The invention according to claim 12 wherein the shell further comprises a frame forming an aperture.

16. The invention according to claim 15 further comprising a honeycomb panel disposed within the frame aperture.

17. The invention according to claim 15 further comprising at least one flow turning vane disposed between the inner tube and the frame aperture.

18. The invention according to claim 12 wherein the shell further comprises at least one partition thereby defining the at least two independently regulatable chambers.

20. The method of claim 19 wherein the pressure applied is a negative pressure.

21. The method of claim 19 wherein the pressure applied is a positive pressure.

22. The method according to claim 19 wherein the manifold comprises an inner tube located inside of a shell, the shell further comprising a plate to prevent airflow from leaking around the inner tube.

23. The method according to claim 22 wherein the inner tube comprises a plurality of ports to provide fluidic communication between the inner tube and the shell.

24. The method according to claim 23 wherein the inner tube further comprises a plurality of valves in communication with the plurality of ports to regulate at least one of pressure in and flow through the manifold.

25. The method according to claim 22 wherein the shell further comprises a frame forming an aperture

26. The method according to claim 25 wherein the shell further comprises a honeycomb panel disposed within the frame aperture.

27. The method according to claim 25 wherein the shell further comprises at least one flow turning vane disposed between the inner tube and the frame aperature.

28. The method according to claim 22 wherein the shell further comprises at least one partition thereby defining the at least two independently regulatable chambers.

30. The method according to claim 29 wherein the drum further comprises a microporous layer covering at least a portion of the contour.

31. The method according to claim 29 wherein the pressure applied to the manifold is a negative pressure to conform the solidifying elements to the contour.

32. The method according to claim 29 wherein the pressure applied to the manifold is a positive pressure to facilitate removing the fibrous material from the drum.

19. A method of independently regulating at least one of pressure and flow spanning a sector of a drum across at least a portion of a width thereof, the method comprising:

providing a drum comprising a manifold spanning a sector of the drum across at least a portion of a width thereof, the manifold subdivided into at least two chambers independently regulatable with respect to at least one of pressure and flow; and

applying a pressure to the manifold to achieve at least one of a desired pressure and flow profile across the sector of the drum.

29. A method of forming a non-woven article comprising the steps of:

providing a drum comprising;

a generally tubular honeycomb member having an outer surface forming a contour; and

a manifold spanning a sector of the drum across at least a portion of a width thereof, the manifold subdivided into at least two chambers independently regulatable with respect to at least one of pressure and flow;

applying pressure to the manifold;

depositing solidifying filaments on the outer surface to form a non-woven fibrous material substantially matching at least a portion of the contour; and

removing the fiberous material from the drum.

33. A non-woven article produced according to the method of claim 29.