Specification
DESCRIPTION:
Technical Field of the Invention
[0001] The present invention generally relates to laminating nonwoven fabric and tubular woven fabric material. More particularly, the present invention relates to a system and a method for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material.
Background of the Invention
[0002] Conventional polypropylene spunbonded webs (which are generically known as polypropylene nonwoven fabrics) represent a class of product, used in textile industry. These conventional polypropylene spunbonded "webs offer a wide range of product characteristics ranging from very light and flexible structure to a heavy and stiff structure.
[0003] Conventionally, polypropylene spunbonded webs are produced by depositing extruded, spun filaments onto a collecting belt in a uniform random manner. Typically, during a web (fabric) laying process the fibers are separated by air jets or electrostatic charges. The spim fiber collecting surface is usually perforated to prevent the air stream from deflecting and carrying the fibers in an uncontrolled manner.
[0004] A conventional process for making polypropylene spunbonded webs includes extrusion of polypropylene fibers from polypropylene granules and partial heating of polypropylene fibers, which melt their surfaces while bonding a plurality of polypropylene fibers, to thereby bring strength and integrity in the web. Typically, polypropylene spunbonded products are used in carpet backing, geotextiles and disposable medical/hygiene products. These polypropylene spunbonded webs lack the adequate strength for packaging and holding heavier goods, which is a disadvantage of polypropylene spunbonded fabrics.
[0005] Typically, a polypropylene woven fabric tube is produced by interlacing two or more sets of polypropylene yams, fibers, rovings or filaments where the elements pass
each other essentially at right angles and one set of elements is parallel to the fabric axis. This fabric has good strength but lacks an aesthetic look and has rough surface for conventional baggage or sacks.
[0006] Typically, a composite of polypropylene spunbonded fabric and tubular woven fabric or sacks can bring good carrying strength, provide an aesthetic look and a smooth surface for conventional baggage or packaging means. This composite polypropylene fabric and tubular woven fabric lamination can be achieved by extrusion. However, for making the composite of polypropylene spunbonded fabric and tubular woven fabric, precision in manufacturing is difficult in order to get a rectangular, square and a cognizant shape.
[0007] Conventionally sacks or bags are made by cutting composite fabric in to predetermined dimensions. This lacks the ability in making a precision cut of composite fabric and further involves increased wastage of composite fabric to get desired size for a sack or a bag. Conventional sacks made from composite fabric have no uniformity at edges and posses fewer load bearing capacity due to the presence of polypropylene tubular woven fabric at the inner side of sack edges, which is a disadvantage.
[0008] Hence, there is need for a system and a method to enable a fabric lamination so as to minimize fabric material wastage by enabling a high precision in manufacturing process of laminating the fabrics.
Summary of the Invention
[0009]A system and a method of laminating a tubular woven fabric with a nonwoven fabric are disclosed. According to a first aspect of the invention, a method of laminating a tubular woven fabric with a nonwoven fabric includes unwinding the nonwoven fabric from a first unwinding stand. The step of unwinding the nonwoven fabric from the first unwinding stand includes a step of unwinding a polypropylene nonwoven fabric from the first unwindmg stand
[0010] According to the first aspect, the method of laminating a tubular woven fabric with a nonwoven fabric includes unwinding the tubular woven fabric from a second imwinding stand responsive to the unwinding the nonwoven fabric, the nonwoven fabric configured to be wider than the tubular woven fabric. The step of unwinding the tubular woven fabric from the second unwinding stand includes a step of unwinding a polypropylene tubular woven fabric from the second unwinding stand.
[0011] According to the first aspect, the method of laminating a tubular woven fabric with a nonwoven fabric includes aligning the tubular woven fabric with a center position of the nonwoven fabric for enabling a uniform edge formation on a nonwoven fabric surface for compensating for size variations occurred while manufacturing the tubular woven fabric to thereby generate a first laminated stage of a composite fabric including the tubular woven fabric laminated with the nonwoven fabric, whereby the dimensions of the first laminated stage are predetermined according to a holding capacity parameter of the composite fabric.
[0012] According to the first aspect, the method of laminating a tubular woven fabric with a nonwoven fabric includes laminating the nonwoven fabric with the tubular woven fabric through an adhesive. The step of laminating the nonwoven fabric with the tubular woven fabric through a polypropylene adhesive includes a step of conducting extrusion lamination on a first side of the composite fabric to generate the first laminated stage.
[0013] According to the first aspect, the method of laminating a tubular woven fabric with a nonwoven fabric where in the step of conducting extrusion lamination on a first side of the first composite fabric includes applying a combination of polypropylene glue in a major proportion, low density polymer glue in a minor proportion and rolling a glued combination of the nonwoven fabric and the tubular woven fabric through a pair of lamination rollers.
[0014] According to the first aspect, the method of laminating a tubular woven fabric with a nonwoven fabric includes laminating the tubular woven fabric with the nonwoven
fabric for generating a second laminated stage of the composite fabric, to thereby generate a laminated enclosure configuration of the composite fabric further including at least one of a tubular configuration woven sack, a carrying article, bag and the like. The step of laminating the tubular woven fabric with the nonwoven fabric for generating a second laminated stage of the composite fabric includes a step of conducting an extrusion lamination on a second side of the composite fabric to thereby generate the second laminated stage, whereby the second laminated stage includes a symmetrical configuration in accordance with the first laminated stage of the composite fabric. The step of the conducting an extrusion lamination on a second side of the composite fabric to thereby generate the second laminated stage comprising a step of polypropylene nonwoven fabric material unwinding from a third unwinding stand. The step of polypropylene nonwoven fabric material unvmiding from a third unwinding stand includes a step of laminating the second side of the composite fabric with polypropylene nonwoven fabric material whereby a base material on the second side is the tubular woven fabric. The step of laminating the second side of the composite fabric with polypropylene nonwoven fabric material includes a step of applying polypropylene adhesive between: the base material on the second side of the composite fabric and the polypropylene nonwoven fabric material.
[0015] According to a second aspect, a method for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material is disclosed. The method for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material includes unwinding the woven sack tube material from a first unwinding stand, the woven sack tube material comprising a polypropylene tubular woven fabric.
[0016] According to the second aspect, a method for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material includes unwinding the nonwoven fabric material from a second unwinding stand responsive to the unwinding the woven sack tube material, the nonwoven fabric
material configured to be wider than the woven sack tube material, and the nonwoven fabric material comprising a polypropylene spunbonded fabric.
[0017] According to the second aspect, a method for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material includes aligning the woven sack tube material with a center position of the nonwoven fabric material for minimizing abruptness on an edge formed on the first laminated combination.
[0018] According to the second aspect, a method for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material includes laminating the nonwoven fabric material with the woven sack tube material through an adhesive for generating a first laminated combination thereby generating a partially laminated composite fabric.
[0019] According to the second aspect, a method for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material includes unwinding a polypropylene spunbonded fabric material fi'om a third unwinding stand whereby a width of the polypropylene spunbonded material is equal to a width of the nonwoven fabric material.
[0020] According to the second aspect, a method for laminating a woven sack tube material wdth a nonwoven fabric material for generating a sandwiched composite fabric material includes aligning the first laminated combination parallel to the polypropylene spunbonded fabric material as unwinding to thereby enable minimal abruptness on an edge formed on a polypropylene spunbonded surface for a second laminated combination to be formed.
[0021] According to the second aspect, a method for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material includes laminating the woven sack tube material on the partially laminated
composite fabric with the polypropylene spimbonded fabric material through an adhesive for generating the second laminated combination to produce a completely laminated composite fabric in a configuration enclosing a volume between the first laminated combination and the second laminated combination.
[0022] According to the second aspect, a method for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material configured for a holding means. Further includes a step of sealing while compensating a variation occurred in manufacturing woven sack tube material to thereby generate a desired size of the holding means whereby the sealing includes at least one of an edging, a bonding and a binding of the nonwoven fabric material with the adhesive and a step of printing on an external surface of the completely laminated composite fabric while retaining volume between the first laminated combination and the second laminated combination.
[0023] According to a third aspect, a system for laminating a woven sack tube material with a nonwoven fabric material for generating a sandv^dched composite fabric material is disclosed. The system for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material includes a first unwinding stand for unwinding the woven sack tube material.
[0024] According to the third aspect, the system for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material includes a second unwinding stand for unwinding the nonwoven fabric material responsive to the unwinding the woven sack tube material, the nonwoven fabric material configured to be wider than the woven sack tube material.
[0025] According to the third aspect, the system for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material includes at least one first aligner for aligning the woven sack tube material with
a center position of the nonwoven fabric material for minimizing abruptness on an edge formed on the first laminated combination.
[0026] According to the third aspect, the system for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material includes a first extruder for enabling an extrusion of an adhesive for laminating the woven sack tube material and the nonwoven fabric material. The adhesive for laminating the woven sack tube material and the nonwoven fabric material is a polypropylene adhesive further including at least one of glue, a sealing material, and a thermoplastic filament
[0027] According to the third aspect, the system for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material includes at least one pair of a first lamination rollers for laminating the woven sack tube material and the nonwoven fabric material vvith the adhesive material for generating a first laminated combination thereby generating a partially laminated composite fabric, whereby the nonwoven fabric material comprising a polypropylene spunbonded fabric material and the woven sack tube material comprising a polypropylene woven sack tube fabric material. The pair of lamination rollers includes a nip roll and a chill roll.
[0028] According to the third aspect, the system for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material includes a third unwinding stand for unwinding a polypropylene spun bonded fabric material where by a width of the polypropylene spunbonded material is equal to a width of the nonwoven fabric material.
[0029] According to the third aspect, the system for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material includes at least one second aligner for aligning the first laminated combination
parallel to the polypropylene spunbonded fabric material as unwinding to thereby enable minimal abruptness on an edge formed on a polypropylene spunbonded surface for a second laminated combination to be formed.
[0030] According to the third aspect, the system for laminating a woven sack tube material with a noiiwoven fabric material for generating a sandwiched composite fabric material includes a second extruder for enabling an extrusion of an adhesive for laminating the composite fabric and the polypropylene spun bonded fabric material.
[0031] According to the third aspect, the system for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material includes at least one pair of a second lamination rollers for laminating the composite fabric and the polypropylene spun bonded fabric material for generating the second laminated combination to produce a completely laminated composite fabric in a configuration enclosing a volume between the first laminated combination and the second laminated combination. Both pair of lamination rollers includes a nip roll and a chill roll.
[0032] According to the third aspect, the system for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material includes a rewinding stand for winding the composite fabric.
[0033] According to the third aspect, the system for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material includes at least one of a colorless fabric and a colored fabric.
[0034] According to the third aspect, the system for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material configured to hold and pack material further includes at least one of the gazette rectangular, gazette square shape.
[0035] According to the third aspect, the system for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material where woven sack tube material includes a parameter in range of 100 denier to 3000 denier and variable mesh size.
[0036] Accordmg to the third aspect, the system for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material where the polypropylene spunbonded fabric material includes a variable grams per square meter (GSM) parameter.
Brief Description of the Drawings
[0037] Other objects and advantages of the present invention will become apparent to those skilled in the art upon reading the following detailed description of the preferred embodiments, in conjunction with the accompanying drawings, wherein like reference numerals have been used to designate like elements, and wherein:
[0038] FIG.l is a diagram depicting an extrusion lamination process of polypropylene nonwoven fabric and polypropylene tubular woven fabric.
[0039] FIG.2 is a diagram depicting a double extrusion lamination process of polypropylene nonwoven fabric and polypropylene tubular woven fabric.
[0040] FIG. 3 is a block diagram depicting an extrusion lamination process of polypropylene nonwoven fabric and polypropylene tubular woven fabric.
[0041] FIG.4 is a diagram depicting a sack made from a final composite fabric according to an exemplary aspect of the present invention.
[0042] FIG.5 is a diagram depicting a top view of a sack made from final composite fabric.
uetaiied Ueseription of the Invention
[0043] Exemplary embodiments of the present invention are directed to a system and a method of laminating a tubular woven fabric with a nonwoven fabric. A system and a method of laminating a tubular woven fabric with a nonwoven fabric are disclosed. According to a first aspect of the invention, a method of laminating a tubular woven fabric with a nonwoven fabric includes unwinding the nonwoven fabric from a first unwinding stand. The step of unwinding the nonwoven fabric from the first unwinding stand includes a step of unwinding a polypropylene nonwoven fabric from the first unwinding stand
[0044] According to the first aspect, the method of laminating a tubular woven fabric with a nonwoven fabric includes unwinding the tubular woven fabric from a second unwinding stand responsive to the unwinding the nonwoven fabric, the nonwoven fabric configured to be wider than the tubular woven fabric. The step of unwinding the tubular woven fabric from the second unwinding stand includes a step of unwinding a polypropylene tubular woven fabric from the second unwinding stand.
[0045] According to the first aspect, the method of laminating a tubular woven fabric with a nonwoven fabric includes aligning the tubular woven fabric with a center position of the nonwoven fabric for enabling a uniform edge formation on a nonwoven fabric surface for compensating for size variations occuned while manufacturing the tubular woven fabric to thereby generate a first laminated stage of a composite fabric including the tubular woven fabric laminated with the nonwoven fabric, whereby the dimensions of the first laminated stage are predetermined according to a holding capacity parameter of the composite fabric.
[0046] According to the first aspect, the method of laminating a tubular woven fabric with a nonwoven fabric includes laminating the nonwoven fabric with the tubular woven fabric through an adhesive. The step of laminating the nonwoven fabric with the tubular
woven fabric through a polypropylene adhesive includes a step of conducting extrusion lamination on a first side of the composite fabric to generate the first laminated stage.
[0047] According to the first aspect, the method of laminating a tubular woven fabric with a nonwoven fabric where in the step of conducting extrusion lamination on a first side of the first composite fabric includes applying a combination of polypropylene glue in a major proportion, low density polymer glue iii a minor proportion and rolling a glued combination of the nonwoven fabric and the tubular woven fabric through a pair of lamination rollers.
[0048] According to the first aspect, the method of laminating a tubular woven fabric with a nonwoven fabric includes laminating the tubular woven fabric with the nonwoven fabric for generating a second laminated stage of the composite fabric, to thereby generate a laminated enclosure configuration of the composite fabric further including at least one of a tubular configuration woven sack, a carrying article, bag and the like. The step of laminating the tubular woven fabric with the nonwoven fabric for generating a second laminated stage of the composite fabric includes a step of conducting an extrusion lamination on a second side of the composite fabric to thereby generate the second laminated stage, whereby the second laminated stage includes a symmetrical configuration in accordance with the first laminated stage of the composite fabric. The step of the conducting an extrusion lamination on a second side of the composite fabric to thereby generate the second laminated stage comprising a step of polypropylene nonwoven fabric material unwinding from a third unwinding stand. The step of polypropylene nonwoven fabric material unwinding from a third unwinding stand includes a step of laminating the second side of the composite fabric with polypropylene nonwoven fabric material whereby a base material on the second side is the tubular woven fabric. The step of laminating the second side of the composite fabric with polypropylene nonwoven fabric material includes a step of applying polypropylene adhesive between the base material on the second side of the composite fabric and the polypropylene nonwoven fabric material.
[0049] According to a second aspect, a method for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material is disclosed. The method for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material includes unwinding the woven sack tube material from a first unwinding stand, the woven sack tube material comprising a polypropylene tubular woven fabric.
[0050] According to the second aspect, a method for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material includes unwinding the nonwoven fabric material from a second unwinding stand responsive to the unwinding the woven sack tube material, the nonwoven fabric material configured to be wider than the woven sack tube material, and the nonwoven fabric material comprising a polypropylene spunbonded fabric.
[0051] According to the second aspect, a method for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material includes aligning the woven sack tube material with a center position of the nonwoven fabric material for minimizing abruptness on an edge formed on the first laminated combination.
[0052] According to the second aspect, a method for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material includes laminating the nonwoven fabric material with the woven sack tube material through an adhesive for generating a first laminated combination thereby generating a partially laminated composite fabric.
[0053] According to the second aspect, a method for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material includes unwinding a polypropylene spunbonded fabric material from a third unwinding stand whereby a width of the polypropylene spunbonded material is equal to a width of the nonwoven fabric material.
[0054] According to the second aspect, a method for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material includes aligning the first laminated combination parallel to the polypropylene spunbonded fabric material as unwinding to thereby enable minimal abruptness on an edge formed on a polypropylene spunbonded surface for a second laminated combination to be formed.
[0055] According to the second aspect, a method for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material includes laminating the woven sack tube material on the partially laminated composite fabric with the polypropylene spunbonded fabric material through an adhesive for generating the second laminated combination to produce a completely laminated composite fabric in a configuration enclosing a volume between the first laminated combination and the second laminated combination.
[0056] According to the second aspect, a method for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material configured for a holding means. Further includes a step of sealing while compensating a variation occurred in manufacturing woven sack tube material to thereby generate a desired size of the holding means whereby the sealing includes at least one of an edging, a bonding and a binding of the nonwoven fabric material with the adhesive and a step of printing on an external surface of the completely laminated composite fabric while retaining volume between the first laminated combination and the second laminated combination.
[0057] According to a third aspect, a system for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material is disclosed. The system for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material includes a first unwinding stand for xanwinding the woven sack tube material.
[0058] According to the third aspect, the system for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material includes a second unwinding stand for unwinding the nonwoven fabric material responsive to the unwinding the woven sack tube material, the nonwoven fabric material configured to be wider than the woven sack tube material.
[0059] According to the third aspect, the system for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material includes at least one first aligner for aligning the woven sack tube material with a center position of the nonwoven fabric material for minimizing abruptness on an edge formed on the first laminated combination.
[0060] According to the third aspect, the system for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material includes a first extruder for enabling an extrusion of an adhesive for laminating the woven sack tube material and the nonwoven fabric material. The adhesive for laminating the woven sack tube material and the nonwoven fabric material is a polypropylene adhesive fiirther including at least one of glue, a sealing material, and a thermoplastic filament
[0061] According to the third aspect, the system for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material includes at least one pair of a first lamination rollers for laminating the woven sack tube material and the nonwoven fabric material with the adhesive material for generating a first laminated combination thereby generating a partially laminated composite fabric, whereby the nonwoven fabric material comprising a polypropylene spunbonded fabric material and the woven sack tube material comprising a polypropylene woven sack tube fabric material. The pair of lamination rollers includes a nip roll and a chill roll.
[0062] According to the third aspect, the system for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material includes a third unwinding stand for unwinding a polypropylene spun bonded fabric material where by a width of the polypropylene spunbonded material is equal to a width of the nonwoven fabric material.
[0063] According to the third aspect, the system for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material includes at least one second aligner for aligning the first laminated combination parallel to the polypropylene spunbonded fabric material as unwinding to thereby enable minimal abruptness on an edge fonned on a polypropylene spunbonded surface for a second laminated combination to be formed.
[0064] According to the third aspect, the system for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material includes a second extruder for enabling an extrusion of an adhesive for laminating the composite fabric and the polypropylene spun bonded fabric material.
[0065] According to the third aspect, the system for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material includes at least one pair of a second lamination rollers for laminating the composite fabric and the polypropylene spun bonded fabric material for generating the second laminated combination to produce a completely laminated composite fabric in a configuration enclosing a volume between the first laminated combination and the second laminated combination. Both pair of lamination rollers includes a nip roll and a chill roll.
[0066] According to the third aspect, the system for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material includes a rewinding stand for winding the composite fabric.
[0067] According to the third aspect, the system for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material includes at least one of a coloriess fabric and a colored fabric.
[0068] According to the third aspect, the system for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material configured to hold and pack material further includes at least one of the rectangular, square and a gazette shape.
[0069] According to the third aspect, the system for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material where woven sack tube material includes a parameter in range of 100 denier to 3000 denier and variable mesh size.
[0070] According to the third aspect, the system for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material where the polypropylene spunbonded fabric material includes a variable grams per square meter (GSM) parameter. In accordance with an exemplary embodiment of the present invention the system comprising a lamination process in a sub system, further comprising a primary unwinding stand ;a secondary unwinding stand; an aligner; an extruder ands a pair of lamination rollers for generating a completely laminated composite fabric further comprising a symmetrical laminating configuration including a first laminated combination and a second laminated combination.
[0071] Referring to Fig.l is a diagram 100 depicting an extrusion lamination process of polypropylene nonwoven fabric and polypropylene tubular woven fabric. A polypropylene nonwoven fabric unwinds from a primary unwind stand 102 and a polypropylene tubular woven fabric unwinds from a secondary unwind stand 106. Further more a polypropylene extruded from extruder 104 is used as an adhesive for laminating polypropylene nonwoven fabric, and polypropylene tubular woven fabric passmg between a chill roll 110 and a nip roll 108. The lamination process enables to combine the
polypropylene nonwoven fabric and the polypropylene tubular woven fabric. A composite fabricl 14 passing out from the chill roll HO and the nip roll 108 winds to a rewind stand 112.
[0072] The rewinding stand 112 includes composite fabric where one side of polypropylene woven fabric is laminated with polypropylene spunbonded fabric. The rewinding stand 112 is placed manually at unwinding stand 106 in reverse manner in order to enable second side lamination of the composite fabric. The polypropylene nonwoven fabric unwinds from a primary unwind stand 102 and composite fabric unwinds from a secondary imwind stand 106 .The lamination process repeated to generate final composite fabric where both sides of polypropylene tubular woven fabric is laminated.
[0073] Referring to FIG.2 is a diagram 200 depicting an extrusion lamination process of polypropylene nonwoven fabric and polypropylene tubular woven fabric according to an exemplary aspect of the present invention. A polypropylene nonwoven fabric imwinds from a primary unwind stand 202 and a polypropylene tubular woven fabric unwinds from a secondary unwind stand 206. hi accordance with an exemplary embodiment of the present invention, the imwinding of the polypropylene nonwoven fabric and the polypropylene tubular woven fabric from the unwinding stands 202 and 206 occurs simultaneously. Either imwinding of polypropylene nonwoven fabric from unwinding stand 202 or unwinding of polypropylene tubular woven fabric from unwinding stand 206 starts first. The width of polypropylene nonwoven fabric which unwinds from the primary unwind stand 202 is greater than the width of polypropylene tubular woven fabric which is in the form of a sheet unwinding from the secondary unwind stand 206, in accordance with an exemplary embodiment of present invention.
[0074] According to an exemplary embodiment of the present invention, the polypropylene tubular woven fabric is aligned at the center of polypropylene nonwoven fabric sheet using web aligners 222. The polypropylene extruded from extruder 204 is used as an adhesive for laminating polypropylene nonwoven fabric and polypropylene
tubular woven fabric passing between a chill roll 210 and a nip roll 208. The lamination process enables to combine the polypropylene nonwoven fabric and the polypropylene tubular woven fabric to form a composite fabric 224. The polypropylene tubular woven fabric is aligned at the center of polypropylene nonwoven fabric sheet using web aligners 222. The polypropylene tubular woven fabric is not present at the edges of composite fabric 224.
[0075] According to an exemplary embodiment of the present invention, the composite fabric 224 includes the polypropylene tubular woven fabric in the form of a sheet. The outer surface of the nonwoven fabric is lanunated with polypropylene using polypropylene adhesive, for example. The composite fabric 224 passing out from the chill roll 210 and the nip roll 208 is further carried for an extrusion lamination on a second side with polypropylene nonwoven fabric. The polypropylene nonwoven fabric unwinds from tertiary unwinding stand 216. The width of polypropylene nonwoven fabric unwinded from unwinding stand 216 is same as width of polypropylene nonwoven fabric unwinded from unwinding stand 202
[0076] In accordance with an exemplary embodiment of the present invention, the composite fabric 224 passing out from the chill roll 210 and the nip roll 208 is aligned parallel to the polypropylene nonwoven fabric unwinds from tertiary unwinding stand 216, using web aligners 222. Polypropylene extruded from extruder 214 is used as an adhesive for laminating polypropylene nonwoven fabric and composite fabric 224 passing between a chill roll 220 and a nip roll 218. The lamination process enables to combine the polypropylene nonwoven fabric and the composite fabric 224 to form a final composite fabric 226, which includes uniform edges while laminating, wherein the uniform edges pertain to edges in a composite fabric 224, which is a blend of woven fabric (tubular woven fabric) and nonwoven fabric (polypropylene spunbonded fabric).
[0077] According to an exemplary embodiment of the present invention, a final composite fabric 226 includes the polypropylene tubular woven fabric at the inner surface, polypropylene nonwoven fabric at the outer surface and the polypropylene acts
as an adhesive layer for laminating the inner surface and the outer surface , which includes uniform edges while laminating, wherein the uniform edges pertain to edges in a composite fabric 226, which is a blend of woven fabric (tubular woven fabric) and nonwoven fabric (polypropylene spunbonded fabric).
[0078] In accordance with an exemplary embodiment of the present invention, the edges of the final composite fabric 226 are laminated with the polypropylene nonwoven fabric. The edges of the final composite fabric 226 doesn't include tubular woven fabric in order to obtain uniformity and strong binding along the edges and also for increasing load bearing capacity of the sack. The smooth edges helps for enabling an easy feeding of the final composite fabric 226 for offset printing.
[0079] Referring to FIG.3 is a block diagram 300 depicting an extrusion lamination process of polypropylene nonwoven fabric and polypropylene tubular woven fabric. According to an exemplary embodiment of the present invention, at block 302 a polypropylene nonwoven fabric unwinds from a primary unwind stand, at block 306 a polypropylene tubular woven fabric unwinds from a secondary unwind stand and fiirther at block 304 polypropylene extruded from extruder used as an adhesive for laminating polypropylene nonwoven fabric and polypropylene tubular woven fabric passing between a chill roll and a nip roll.
[0080] According to an exemplary embodiment of the present invention, at block 310 one side of polypropylene tubular woven fabric is laminated with polypropylene nonwoven fabric sheet using web aligners. The composite fabric includes the polypropylene tubular woven fabric in the form of a sheet. The outer surface of the nonwoven fabric is laminated with polypropylene using polypropylene adhesive .The width of polypropylene nonwoven fabric which unwinds from the primary unwind stand is greater than the width of polypropylene tubular woven fabric which is in the form of a sheet unwinding from the secondary unwind stand. At block 308 the polypropylene nonwoven fabric unwinds from tertiary unwinding stand.
[0081] In accordance with an exemplary embodiment of the present invention, the width of polypropylene nonwoven fabric unwinding from unwinding stand at block 308 is same as width of polypropylene nonwoven fabric unwinding from unwinding stand at block 302. Polypropylene extruded from extruder at block 312 is used as an adhesive for laminating polypropylene nonwoven fabric and composite fabric passing between the chill roll and the nip roll.
[0082] According to an exemplary embodiment of the present invention, at block 314 the second side of polypropylene tubular woven fabric is laminated with polypropylene non-woven fabric to form a composite fabric passing out from the chill roll and the nip roll is carried for a second side extrusion lamination with polypropylene nonwoven fabric.
[0083] In accordance with an exemplary embodiment of the present invention, the composite fabric passing out from the chill roll and the nip roll is aligned parallel to the polypropylene nonwoven fabric unwinding from tertiary unwinding stand using web aligners. The lamination process enables to combine the polypropylene nonwoven fabric and the composite fabric to form a final composite fabric. At block 316, the final composite fabric of laminated polypropylene nonwoven fabric and the composite fabric is rewinded to a rewind stand. Finally at block 318, the final composite fabric is cut and sealed to desired size and shaped to form a sack, a carrying article, a bag and the like. In accordance with an exemplary embodiment of present invention, a photo sensor is attached to a trimmer machine or slitting machine for avoiding the cutting of the woven sack tube. The trimmer machine enables to cut polypropylene nonwoven fabric at edges at predetermined distance from polypropylene tubular woven fabric using photo sensors.
[0084] In accordance with an exemplary embodiment of the present mvention, the polypropylene used as an adhesive is made from polypropylene granules of any grade. The adhesive includes 1-25% of low density polymer which brings good binding strength. The polypropylene tubular woven fabric has polypropylene grade H030SG, H033MG. The polypropylene tubular woven fabric has deniers in the range of about 100 to about 3000 for example and any mesh size. The polypropylene tubular woven sack can
be any color. According to an exemplary embodiment of the present invention the propylene nonwoven fabric includes a cross, a line or rhombus or a dot shaped webs and variable grams per square meter ranging from 5 to 250 GSM.
[0085] Referring to Fig.4 is a diagram 400 depicting a sack made from a final composite fabric according to an exemplary aspect of the present invention. The composite fabric of sack 402 includes the polypropylene nonwoven fabric on the outer surface, the polypropylene tubular woven fabric in the inner surface and the adhesive layer for laminating the outer surface and the inner surface. The edge 404 includes lamination of polypropylene nonwoven fabric on outer surface using polypropylene adhesive layer. The edge doesn't include the woven fabric.
[0086] Referring to Fig.5 is a diagram 500 depicting a top view of a sack made from final composite fabric. The inner surface is made using the polypropylene tubular woven fabric 502, outer surface with polypropylene nonwoven fabric 504, 506 and a polypropylene adhesive 508 used for laminating the polypropylene woven fabric 502 and polypropylene nonwoven fabric 504, 506. The edge of the sack made from final composite fabric doesn't include a inner polypropylene woven fabric 502. The edge of the sack includes only the lamination of outer polypropylene nonwoven fabric 504 and 506. Polypropylene 508 is used as an adhesive material for laminating polypropylene nonwoven fabric 504 and 506 for example.
[0087] As will be appreciated by a person skilled in the art, the various implementations of the present technique provide a variety of advantages. Firstly, obtaining uniformity and strong binding along the edges of sack. Secondly, increasing load bearing capacity of the sack. Thirdly, the smooth edges help for enabling an easy feeding of the final composite fabric for offset printing.
5. CLAIMS What is claimed is:
1. A method of laminating a tubular woven fabric with a nonwoven fabric, comprising:
unwinding the nonwoven fabric from a first unwinding stand;
unwinding the tubular woven fabric from a second unwinding stand responsive to the unwinding the nonwoven fabric, the nonwoven fabric configured to be wider than the tubular woven fabric;
aligning the tubular woven fabric with a center position of the nonwoven
fabric for enabling a uniform edge formation on a nonwoven fabric surface for
compensating for size variations occurred while manufacturing the tubular woven
fabric to thereby generate a first laminated stage of a composite fabric including
1' the tubular woven fabric laminated with the nonwoven fabric, whereby the
dimensions of the first laminated stage are predetermined according to a holding
capacity parameter of the composite fabric; and
laminating the nonwoven fabric with the tubular woven fabric through an
adhesive.
2. The method as claimed in claim 1, wherein the step of unwinding the nonwoven fabric from the first unwinding stand comprises a step of unwinding a polypropylene nonwoven fabric from the first unwinding stand.
3. The method as claimed in claim 3, wherein the step of unwinding the tubular woven fabric from the second unwinding stand comprises a step of unwinding a polypropylene tubular woven fabric from the second unwinding stand.
4. The method as claimed in claim 1, wherein the step of. laminating the nonwoven fabric with the tubular woven fabric through the adhesive comprising a step of conducting extrusion lamination on a first side of the composite fabric to generate the first laminated stage.
5. The method as claimed in claim 4, wherein the step of conducting
extrusion lamination, on a first side of the first composite fabric comprising:
applying a combination of: polypropylene glue in a major proportion; and low density polymer glue in a minor proportion; and
rolling a glued combination of the nonwoven fabric and the tubular woven fabric through a pair of lamination rollers.
6. The method as claimed in claim 1, comprising laminating the tubular woven fabric with the nonwoven fabric for generating a second laminated stage of the composite fabric, to thereby generate a laminated enclosure configuration of the composite fabric fiirther comprising at least one of: a tubular configuration woven sack; a carrying article; and a bag.
7. The method as claimed in claim 6, wherein the step ofj laminating the tubular woven fabric with the nonwoven fabric for generating a second laminated stage of the composite fabric comprising a step of conducting an extrusion lamination on a second side of the composite fabric to thereby generate the second laminated stage, whereby the second laminated stage includes a symmetrical configuration in accordance with the first laminated stage of the composite fabric.
8. The- method as claimed in claim 7, wherein the step of the conducting an extrusion lamination on a second side of the composite fabric to thereby generate the second laminated stage comprising a step of polypropylene nonwoven fabric material unwinding from a third unwinding stand.
9. The method as claimed in claim 8, wherein the step of polypropylene nonwoven fabric material unwinding fi*om a third unwinding stand comprising a step of laminating the second side of the composite fabric with polypropylene nonwoven fabric material whereby a base material on the second side is the tubular woven fabric.
lU. Ihe method as claimed in claim 9, wherein the step of laminating the second side of the composite fabric with polypropylene nonwoven fabric material comprising a step of applying polypropylene adhesive between: the base material on the second side of the composite fabric; and the polypropylene nonwoven fabric material.
11. A method for laminating a woven sack tube material with a nonwoven fabric material for generating a sandwiched composite fabric material, comprising:
unwinding the woven sack tube material from a first unwinding stand, the woven sack tube material comprising a polypropylene tubular woven fabric;
unwinding the nonwoven fabric material from a second unwinding stand
i;
responsive to the unwinding the woven sack tube material, the npnwoven fabric material configured to be wider than the woven sack tube material, and the nonwoven fabric material comprising a polypropylene spunbonded fabric;
aligning the woven sack tube material with a center position of the
nonwoven fabric material for minimizing abruptness on an edge formed on the
first laminated combination; j
laminating the nonwoven fabric material with the woven sack tube material through an adhesive for generating a first laminated combination thereby generating a partially laminated composite fabric;
unwinding a polypropylene spunbonded fabric material from a third
unwinding stand whereby a width of the polypropylene spunbonded material is
equal to a width of the nonwoven fabric material; f
aligning the first laminated combination parallel to the polypropylene spunbonded fabric material as unwinding to thereby enable minimal abruptness on an edge formed on a polypropylene spunbonded surface for a second laminated combination to be formed; and
laminating the woven sack tube material on the partially laminated composite fabric with the polypropylene spunbonded fabric material through an
adhesive for generating the second laminated combination to produce a completely laminated composite fabric in a configuration enclosing a volume between the first laminated combination and the second laminated combination.
12. The method as claimed in claim 11, wherein the sandwich composite
fabric is configured for a holding means.
1
13. The method as claimed in claims 11 or 12, comprising aistep of sealing while compensating a variation occurred in manufacturing woven sack tube material to thereby generate a desired size of the holding means whereby the sealing including at least one of: an edging; a bonding; and a binding of the nonwoven fabric material with the adhesive.
14. The method as claimed in claim 11, comprising a step of printing on an external surface of the completely laminated composite fabric while retaining volume between the first laminated combination and the second laminated combination.
15. A system for laminating a woven sack tube material with a nonwoven
|I
fabric material for generating a sandwiched composite fabric material comprising:
a first unwinding stand for imwinding the woven sack tube material;
a second unwinding stand for unwinding the nonwoven fabric material responsive to the unwinding the woven sack tube material, the nonwoven fabric material configured to be wider than the woven sack tube material;
at least one first aligner for aligning the woven sack tube material with a center position of the nonwoven fabric material for minimizing abruptness on an edge formed on the first laminated combination;
a first extruder for enabling an extrusion of an adhesive for laminating the woven sack tube material and the nonwoven fabric material; and
at least one pair of a first lamination rollers for laminating the woven sack tube material and the nonwoven fabric material with the adhesive material for
generating a first laminated combination thereby generating a partially laminated composite . fabric, whereby the nonwoven fabric material comprising a polypropylene spunbonded fabric material and the woven sack tube material comprising a polypropylene woven sack tube fabric material.
16. The system as claimed in claim 15, further comprising:
a third unwinding stand for unwinding a polypropylene spun bonded fabric material where by a width of the polypropylene spunbonded material is equal to a width of the nonwoven fabric material;
at least one second aligner for aligning the first laminated combination parallel to the polypropylene spunborided fabric material as unwinding to thereby enable minimal abruptness on an edge formed on a polypropylene spunbonded surface for a second laminated combination to be formed;
a second extruder for enabling an extrusion of an adhesive for laminating the composite fabric and the polypropylene spun bonded fabric material;
at least one pair of a second lamination rollers for laminating the composite fabric and the polypropylene spun bonded fabric material for generating the second laminated combination to produce a completely laminated composite fabric in a configuration enclosing a volume between the first laminated combination and the second laminated combination; and
a rewinding stand for winding the composite fabric.
17. The system as claimed in claimlS, wherein the pair of first lamination rollers comprising a nip roll and a chill roll.
18. The system as claimed in claim 15, wherein the adhesive for laminating the woven sack tube material and the nonwoven fabric material is a polypropylene adhesive further comprising at least one of: a glue; a sealing material; and a thermoplastic filament.
19. The system as claimed in claim 16, wherein the composite fabric includes at least one of: a colorless fabric; a colored fabric.
20. The system as claimed in claim 19, wherein the composite fabric configured to hold and pack material further comprising at least one of the following shape: rectangular; square; and a gazette shape.
21. The system as claimed in claim 15, wherein the woven sack tube material comprising a polypropylene grade woven sack tube further comprising following
I;
parameters: a range of 100 denier to 3000 denier; and a variable mesh size.
22. The system as claimed in claim 15, wherein the polypropylene
spunbonded fabric material comprising a variable grams per square meter (GSM)
parameter.
23. The system as claimed in claim 15, further comprising a lamination process in
a sub system, further comprising:
a primary unwinding stand for unwinding the woven sack tube material;
a secondary unwinding stand for imwinding the nonwoven fabric material responsive to the unwinding the woven sack tube material, the nonwoven fabric material configured to be wider than the woven sack tube material;
at least one first aligner for aligning the woven sack tube|: material with a center position of the nonwoven fabric material for minimizing abruptness on an edge formed on the laminated combination;
an extruder for enabling an extrusion of an adhesive for laminating the woven sack tube material and the nonwoven fabric material; and
a pair of lamination rollers for laminating the woven sapk tube material and the nonwoven fabric material with the adhesive material for generating a first lammated combination thereby generating a partially laminated composite fabric , whereby a second laminated combination is generated symmetrical to the first laminated combination through the lamination process to thereby generate a completely laminated composite fabric.
