Fabric Comprising Shaped Conductive Monofilament Used in the Production of Non-Woven Fabrics

Abstract

In an apparatus for the production of a non-woven web, structure, or article using a spun-bonding process in combination with a forming fabric which is woven having flat CMD yarns, flat MD yarns or both with some or all of such yarns being conductive so as to dissipate static electricity.

1 . An apparatus for the production of a nonwoven fabric produced by way of a spun-bonding or melt-blowing process whereby a spinneret produces a curtain of fibers and a process-air blower blows process air onto the curtain of fibers to deposit the fibers upon a forming fabric to create a nonwoven web, article, or structure, the improvement comprising:
 a forming fabric for use in combination with said apparatus, wherein the curtain of fibers is deposited upon the forming fabric to create the nonwoven web, article, or structure, wherein the forming fabric is woven and includes flat cross machine direction yarns or flat machine direction yarns so as to reduce a volume of air in the forming fabric and improve surface roughness of the forming fabric in comparison to that of a similarly woven forming fabric woven from only round cross-sectional shaped yarns such that a same distance between each of the flat yarns in the weave forms a receptacle consisting of less empty space than the same distance in the weave formed by each of the round monofilaments, thereby reducing air disturbance in the fabric and air leakage between a top press roll of the apparatus and the fabric surface or through the fabric thickness during the spun-bonding or melt-blowing process whilst providing a desired permeability,   wherein said flat cross machine direction yarns or flat machine direction yarns are conductive and include parallel sides with a thickness to width ratio being from 1/1 to 1/5, and   wherein the apparatus in combination with the forming fabric has an improved reduction of air leakage.   
     
     
         2 . The invention in accordance with  claim 1  wherein the forming fabric includes flat cross machine direction yarns and flat machine direction yarns. 
     
     
         3 . The invention in accordance with  claim 2  wherein said flat cross machine direction yarns and flat machine direction yarns are conductive. 
     
     
         4 . The invention in accordance with  claim 1  wherein said flat cross machine direction yarns and flat machine direction yarns include parallel sides with a thickness to width ratio being from 1/1 to 1/5. 
     
     
         5 . A method for the production of a nonwoven fabric comprising the steps of:
 providing a spun-bonding or melt-blowing apparatus whereby a spinneret produces a curtain of fibers and a process-air blower blows process air onto the curtain of fibers to deposit the fibers upon a forming fabric to create a nonwoven web, structure, or article; and   using in combination with said apparatus a forming fabric, wherein the curtain of fibers is deposited upon the forming fabric to create the nonwoven web, article, or structure, wherein the forming fabric is woven and includes flat cross machine direction yarns or flat machine direction yarns so as to reduce a volume of air in the forming fabric and improve surface roughness of the forming fabric in comparison to that of a similarly woven forming fabric woven from only round cross-sectional shaped yarns such that a same distance between each of the flat yarns in the weave forms a receptacle consisting of less empty space than the same distance in the weave formed by each of the round monofilaments, thereby reducing air disturbance in the fabric and air leakage between a top press roll of the apparatus and the fabric surface or through the fabric thickness during the spun-bonding or melt-blowing process whilst providing a desired permeability,   wherein said flat cross machine direction yarns or flat machine direction yarns are conductive and include parallel sides with a thickness to width ratio being from 1/1 to 1/5   wherein when the apparatus when used in combination with the forming fabric has an improved reduction of air leakage.   
     
     
         6 . The method in accordance with  claim 5  wherein the forming fabric includes flat cross machine direction yarns and flat machine direction yarns. 
     
     
         7 . The method in accordance with  claim 6  wherein said flat cross machine direction yarns and flat machine direction yarns are conductive.