Cross-lapping

It is a continuous web transfer m/c. The web is

layered from side to side onto a lower conveyor or
bottom lattice, which runs perpendicular to the in-
feed web to form a diagonally stratified batt,
wadding or fleece, which typically consists of 4–>15
layers depending on requirements.
Commercially, cross-lapped batt weights range
from about 50 g/m2 to over 1500 g/m2 depending on
fibre properties and the web weight per unit area.
 Cross-lapping

Cross lapping enables the production of batts much

wider than the initial web fed from the carding
machine which is limited to <5 m and is more usually
about 2.5 m.

More commonly, horizontal cross-lappers are used

consisting of a number of interacting conveyor
aprons that operate in conjunction with traversing
carriages and drive rollers.
 Cross-lapping
The carding machine delivers the web to the
infeed conveyor, which transports it onto the top
sheet or belt assembly.

The carriages reciprocate as the web is

transported within the belts.

The exiting web is then layered concertina-fashion

onto a lower conveyor which runs perpendicular to
the in-feed direction.
Cross-lapper
Cross-lapper
Double aprons are now used to sandwich the web
and control its motion through the machine. Short
web path cross-lappers allow higher lapping speeds
and minimise the turning of the web in the
conveyors. This minimizes the introduction of web
irregularities.
The concept of a carriage has changed from that
of a heavily constructed unit within a distinctive
framework, to a lighter mechanism incorporating a
relatively simple series of rollers in which the web
may be turned only once during its passage through
the cross-lapper.
Recent developments in cross-lapping technology
have primarily focused on increasing speeds.

Modern cross-lappers include sophisticated drive

control systems. The input width of a cross-lapper is
the same as the card, which feeds it and is typically
2.5 m wide. The output of the cross-lapper is not
restricted by the width of the card.
Profiling cross-lappers

To counteract the batt weight variation across the

width due to cross-lapping, profiling cross-lappers
are used. Although the term profiling has become
somewhat generic, it was first introduced by Asselin.

Profiling cross-lappers manipulate the web between

the conveyors by controlled drafting and
condensation (or web storage) as well as control web
laydown to produce batts with specified cross-
machine weight profiles.
Batt drafting
A batt drafter is used to increase the fibre orientation in the
machine direction after the formation of a cross-lapped batt.

This is particularly important in applications such as

geotextiles where uniformly isotropic tensile properties and
burst strength may be required.

Batt drafters normally consist of a series of nipped roller

drafting units extending the full width of the machine, the
surface speed of each set of rollers increases from the input to
the output to control the draft and the maximum draft may be
in the range 30–260%.
Batt drafting
Needle punched fabric drafters are also used after or between
successive needle looms to manipulate fibre orientation in the
fabric.

Typically, drafts of 20–60% are applied to fabrics in widths up

to 7.4 m. Whilst draft is principally applied to manipulate the
MD/CD strength it also influences other structural features
such as density, thickness and permeability.

Although drafting can produce MD/CD ratios approximating

to 1 it is frequently associated with an increase in weight
variation.
Vertically lapped web formation
Vertically lapped (perpendicular-laid) nonwovens are gaining
acceptance in an increasing number of applications.

Such fabrics are used as foam replacement materials in the

automotive industry, depth filtration media and thermal
insulation.

Various methods of corrugating webs to form perpendicular-laid

fabrics have been devised over the years and all produce a
concertina-like, three-dimensional structure, which after
bonding exhibits high recovery from compression.
Vertically lapped web formation

A carded web, which normally contains a proportion of

thermoplastic fibre, typically a bicomponent, is formed into a
series of vertical folds that are stabilized by through-air thermal
bonding.

Blends may be composed of thermoplastic synthetic fibres,

reclaimed waste materials and natural fibres such as cotton and
wool.
 Rotary Lapper
A reciprocating lapping device is used to continuously
consolidate the carded web into a vertically folded batt
immediately prior to through-air bonding.

A proportion of low-melt thermoplastic fibre in the blend

enables thermal bonding of the structure either in its basic
lapped form or in conjunction with a scrim or support fabric,
which can be introduced before the oven. Thereafter the Struto
fabric is cooled and subsequently wound.
 Rotary Lapper
The first rotary and reciprocating lappers originated at the
University of Liberec. Whilst the rotary lapper leads to
significantly higher production rates than the reciprocating
version used by the Struto system, the latter produces a more
pronounced z-directional fold orientation, which is
approximately perpendicular to the fabric plane.