CA1321512C - Method of making a storable handleable fibrous mat - Google Patents
Method of making a storable handleable fibrous matInfo
- Publication number
- CA1321512C CA1321512C CA000585039A CA585039A CA1321512C CA 1321512 C CA1321512 C CA 1321512C CA 000585039 A CA000585039 A CA 000585039A CA 585039 A CA585039 A CA 585039A CA 1321512 C CA1321512 C CA 1321512C
- Authority
- CA
- Canada
- Prior art keywords
- fibers
- fleece
- cellulose fibers
- fibrous mat
- thermoplastic
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 8
- 239000000835 fiber Substances 0.000 claims abstract description 78
- 229920003043 Cellulose fiber Polymers 0.000 claims abstract description 39
- 229920001169 thermoplastic Polymers 0.000 claims abstract description 30
- 239000004416 thermosoftening plastic Substances 0.000 claims abstract description 30
- 239000011230 binding agent Substances 0.000 claims abstract description 29
- 229920000728 polyester Polymers 0.000 claims abstract description 15
- 235000013311 vegetables Nutrition 0.000 claims abstract description 13
- 239000000203 mixture Substances 0.000 claims abstract description 10
- 238000004080 punching Methods 0.000 claims abstract description 8
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 claims abstract description 4
- 229920001568 phenolic resin Polymers 0.000 claims abstract description 4
- 239000005011 phenolic resin Substances 0.000 claims abstract description 4
- 238000000034 method Methods 0.000 claims description 11
- 229920001187 thermosetting polymer Polymers 0.000 claims description 11
- 238000002844 melting Methods 0.000 claims description 3
- 230000008018 melting Effects 0.000 claims description 3
- 239000000155 melt Substances 0.000 claims description 2
- 210000003666 myelinated nerve fiber Anatomy 0.000 claims 1
- 239000002344 surface layer Substances 0.000 description 4
- 239000007767 bonding agent Substances 0.000 description 3
- 239000010410 layer Substances 0.000 description 3
- 238000003892 spreading Methods 0.000 description 3
- 238000005056 compaction Methods 0.000 description 2
- 238000001035 drying Methods 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 238000005470 impregnation Methods 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 229920003002 synthetic resin Polymers 0.000 description 2
- 239000000057 synthetic resin Substances 0.000 description 2
- 229920000742 Cotton Polymers 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 239000012209 synthetic fiber Substances 0.000 description 1
- 229920002994 synthetic fiber Polymers 0.000 description 1
- 239000012815 thermoplastic material Substances 0.000 description 1
Classifications
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/425—Cellulose series
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
- B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
- B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
- B27N3/02—Manufacture of substantially flat articles, e.g. boards, from particles or fibres from particles
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4326—Condensation or reaction polymers
- D04H1/435—Polyesters
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
- D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
- D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
- D04H1/488—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation in combination with bonding agents
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
- D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
- D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
- D04H1/645—Impregnation followed by a solidification process
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Chemical & Material Sciences (AREA)
- General Chemical & Material Sciences (AREA)
- Dispersion Chemistry (AREA)
- Mechanical Engineering (AREA)
- Life Sciences & Earth Sciences (AREA)
- Manufacturing & Machinery (AREA)
- Wood Science & Technology (AREA)
- Forests & Forestry (AREA)
- Nonwoven Fabrics (AREA)
- Sealing Material Composition (AREA)
- Laminated Bodies (AREA)
- Dry Formation Of Fiberboard And The Like (AREA)
Abstract
ABSTRACT OF THE DISCLOSURE:
In order to ensure, in a method of making a storable handleable fibrous mat composed of cellulose fibers and thermoplastic fibers, in particular polyester fibers, and/or natural fibers of vegetable origin, and containing a duroplastic binder on synthetic base, which fibrous mat is capable of being molded into dimensionally stable workpieces in a subsequent operation under the influence of heat and pressure and by curing and setting of the duroplastic binder, uniform properties over the cross sectional area, - the cellulose fibers are impregnated with a solution of the duroplastic binder, preferably a phenolic resin solution, and are dried, - the dried cellulose fibers are mixed in a dry state with thermoplastic fibers, such as polyester fibers, and/or with natural fibers of vegetable origin, - a fleece is formed from the mixture of the cellulose fibers and thermoplastic fibers and/or natural fibers of vegetable origin, and - the formed fleece is compacted by needle-punching in a needle-punching machine.
In order to ensure, in a method of making a storable handleable fibrous mat composed of cellulose fibers and thermoplastic fibers, in particular polyester fibers, and/or natural fibers of vegetable origin, and containing a duroplastic binder on synthetic base, which fibrous mat is capable of being molded into dimensionally stable workpieces in a subsequent operation under the influence of heat and pressure and by curing and setting of the duroplastic binder, uniform properties over the cross sectional area, - the cellulose fibers are impregnated with a solution of the duroplastic binder, preferably a phenolic resin solution, and are dried, - the dried cellulose fibers are mixed in a dry state with thermoplastic fibers, such as polyester fibers, and/or with natural fibers of vegetable origin, - a fleece is formed from the mixture of the cellulose fibers and thermoplastic fibers and/or natural fibers of vegetable origin, and - the formed fleece is compacted by needle-punching in a needle-punching machine.
Description
The invention relates to a method of making a storable handleable fibrous mat composed of cellulose fibers and thermoplastic fibers, in particular polyester fibers, and/or natural fibers of vegetable origin, and containing a thermosetting plastic binder (hereinafter also referred to as a duroplastic binder) on a synthetic base, which fibrous mat is capable of being molded into dimensionally stable workpieces in a subsequent operation under the influence of heat and pressure and by curing and setting of the duroplastic binder.
During the molding operation, the duroplastic binder cures and sets under the influence of heat and pressure and the plastic fibers form heat-sealed connections between the fibers, which also set upon cooling, thus yielding a smooth surface.
It is known (DE-A - 32 39 732) to form a handleable fibrous mat of the above described kind of heating a fibrous fleece of cellulose fibers and of thermoplastic fibers as well as, if desired, of additional thermoplastic materials or of a duroplastic binder in a manner that the thermoplastic fibers soften to their tack point, whereby the fibers are fixed to one another at their points of contact by bonding or adhesion and the fibrous mat is pre-compacted.
During the compaction of the fibrous fleece by heating the thermoplastic fibers to their tack point, but not to melting, a fibrous fleece is obtained, which has properties ~trongly varying over its cross sectional area, the more so as the fibrous fleece is heated most intensively in the surface layers. If bonding of the central layers is sought, it is no longer ensured that the surface layers will still B
have fibrous structures and that the fibrous mat will be flexible enough for further handling.
With the fibrous mat according to DE-A 32 39 732, the binders that are responsible for the setting of the fibrous mat merely are admixed with the fibers, no uniform setting, thus, being ensured. In particular, there may result regions in which binders are present to an insufficient extent such that the finished workpiece does not exhibit the same strength at every point.
A method of producing a fibrous mat, furthermore, is known from DE-B - 1 054 416. According to that document, a mixture of cellulose fibers and synthetic fibers is processed to a fibrous fleece which is compacted by applying bonding agents and subsequent drying and compressing. In doing so, the fibers of the surface layers adhere to one another at their points of contact such that the fibrous fleece is stabilized and may be subjected to further processing.
This known method has disadvantages, which are to be seen in that the application of bonding agents on the surface of a fibrous fleece is cumbersome to carry out, requiring subsequent drying. In addition, the fibrous fleece exhibits strength properties that vary strongly over its cross sectional area, because an impregnation of the fibrous fleece with bonding agents is provided only on the surface layers thereof. Complete impregnation involves an even more complex secondary treatment, at which the fibrous fleece not yet dried must be treated with the respective care.
The compaction of the compressed workpiece, according to DE-B - 1 054 416, is effected by introducing synthetic resin powder into the cavity oE the press molding the fibrous mat.
In order to obtain a regularly compacted workpiece, the synthetic resin powder is to be introduced into the press in a uniformly thick layer, which, however, is very difficult to realize, if at all, in the case of complicated shapes of the workpiece.
The invention aims at avoiding these disadvantages and difficulties and has as its object to provide a method of making the initially described fibrous mat, which yields a homogenously compacted fibrous mat having uniform properties over its cross sectional area and which is operable at low energy expenditures. In addition, the manufacture of regularly compacted workpieces from this fibrous mat is to be guaranteed.
In accordance with the invention there is provided a method of making a storable handleable fibrous mat composed of cellulose fibers and further fibers selected from thermoplastic fibers, and natural fibers of vegetable origin, and containing a thermosetting plastic binder on a synthetic base, which fibrous mat is capable of being molded into dimensionally stable workpieces in a subsequent operation under the influence of heat and pressure and by curing and setting of said binder, wherein the following measures are applied in combination:
the cellulose fibers are impregnated with a solution of the thermosetting plastic binder and are dried, the dried cellulose fibers are mixed in a dry state with said further fibers, a fleece is formed from the mixture of the cellulose fibers and said further fibers, and the formed fleece is compacted by needle-punching in a needle-punching machine.
The invention also provides a fibrous mat, comprising cellulose fibers and further fibers selected from thermoplastic fibers and/or natural fibers of vegetable origin, and a thermosetting plastic binder on a synthetic base, wherein the $
cellulose fibers are impregnated with a solution of said binder and are connected with said further fibers by mechanical intertwining without melting.
If further processing of the fibrous mat involves a particularly extensive conversion of the fibrous mat, the mixture of cellulose fibers and thermoplastic fibers and/or natural fibers of vegetable origin preferably is needled onto a thin carrier fleece of thermoplastic fibers.
A particularly uniform fibrous mat, preferably, may be produced by forming a fleece of impregnated cellulose fibers and a fleece of thermoplastic fibers and/or natural fibers of vegetable origin, which fleeces are mixed in a cylinder, by forming a further fleece from the mixture and by needling the same onto a thin carrier fleece of thermoplastic fibers.
For particularly high stresses to be exerted on the fibrous mats, the cellulose fibers and thermoplastic fibers and/or natural fibers of vegetable origin, suitably, are additionally mechanically connected with a thin carrier fleece of thermoplastic fibers.
An article molded from a fibrous mat according to the invention by the application of heat and pressure is characterized in that the cellulose fibers, thermoplastic fibers and/or natural fibers of vegetable origin are embedded in a set melt of duroplastic binder and are interlinked by this melt.
Advantageously, the cellulose fibers are interlaced with the carrier fleece and with the set melt of duroplastic binder, the article, thus, having a particularly high strength and a highly stressable surface.
Moreover, an article of this type exhibits a high dimensional stability and high flexural stress values.
The method according to the invention will now be explained in more detail by way of the accompanying drawings, wherein Figs. 1 and 2 are each a process diagram for the manufacture of a fibrous mat according to the invention;
Fig. 3 is an isometric view of an article produced of a fibrous mat according to the invention;
Fig. 4 shows this article sectioned along line IV-IV
of Fig. 3; and Fig. 5 is a detailed section through this article in a strongly enlarged view.
According to Fig. 1, shreds 1 are processed into cellulose fibers 3 by defibration in a defibrator 2. The cellulose fibers are impregnated with wax 4 and a phenolic resin solution 5. Subsequently, the impregnated cellulose fibers ~ are dried in a tubular drier 7 and are pressed to bales 9 in a press 8.
Thermoplastic fibers 10, i.e. polyester fibers, are disintegrated from polyester fiber bales 11 and are transported to a fiber spreading machine 13 via an 0 intermediate bunker 12. The fiber spreading machine 13 spreads the polyester fibers 10 onto a conveying belt 14.
Cellulose fibers formed by the disintegration of the bales 9 are spread onto this layer of polyester fibers by means of two additional fiber spreading machines 15, 16.
The sandwich thus formed is pre-mixed in a blender 17 and is further mixed in a fine blender 18. The mixture 19 is transported to a fleece laying machine 20, in which a fibrous fleece 21 having a predetermined weight is formed.
This fibrous fleece 21 is applied onto a thin polyester fleece 22 and is needle-punched thereto in a needle-punching machine 23. Subsequently, the fibrous mat 24 made in this way is cut to predetermined formats in a cutting means 25 and is stapled in a stapling means 26.
The fibrous fleece is readily handleable and, nevertheless, soft and flexible such that there will be no difficulties when processing the same into a molded article. If natural fibers of vegetable origin (e.g., cotton) are used instead of the thermoplastic fibers 10, or if such natural fibers admixed with thermoplastic fibers are used, this will also result in a soft and flexible fibrous fleece.
According to the method illustrated in Fig. 2, the preparation of the shreds 1 to impregnated cellulose fibers 6 and that of the polyester fibers 10 are effected in the same manner as with the method illustrated in Fig. l; yet, the formation of the fibrous fleece is different. The cellulose fibers 6 are fed to the fleece laying machine 20 via a conveying belt 14. The polyester fibers 10 get to a separate fleece laying machine 28 via a conveying belt 27.
0 In this way, a separate fibrous fleece 29, 30 is each formed by the cellulose fibers and by the polyester fibers.
The two fibrous fleeces 29, 30 are united and mixed in a cylinder 31. A further fleece 21 is formed from this mixture and is applied onto a thin polyester fleece 22. In the consecutively arranged needle-punching machine 23, the fibrous fleece 21 is needle-punched to the thin polyester fleece 22, which, again, results in a readily handleable, yet sufficiently moldable fibrous mat 24.
Articles are produced from the fibrous mats 24 by compression under the application of heat and pressure.
Such an article 32 is, for instance, illustrated in Figs. 3 and 4. It constitutes a door panel for a passenger car. As is apparent from Fig. 4, this door panel 32 has approximately the same wall thickness over the entire cross sectional area.
In Fig. 5, a detailed section through the article 32 is illustrated on a greatly enlarged scale. The cellulose fibers 6 embedded in a set melt 33 of duroplastic binder are visible. The external limitation of the article 32, on one side 34, is formed by a carrier fleece 22 of thermoplastic fibers 35, which is connected with the cellulose fibers 6 not only mechanically, but the cellulose fibers 6 are interlaced with the carrier fleece 22 and the set melt 33 of duroplastic binder penetrated into the carrier fleece 22 at the pressing operation, to form a rigid durable and dimensionally stable structure.
Thermoplastic fibers 36 or natural fibers, if used in addition to the thermoplastic fibers 36 or instead of these thermoplastic fibers 36, are embedded in the set binder.
During the molding operation, the duroplastic binder cures and sets under the influence of heat and pressure and the plastic fibers form heat-sealed connections between the fibers, which also set upon cooling, thus yielding a smooth surface.
It is known (DE-A - 32 39 732) to form a handleable fibrous mat of the above described kind of heating a fibrous fleece of cellulose fibers and of thermoplastic fibers as well as, if desired, of additional thermoplastic materials or of a duroplastic binder in a manner that the thermoplastic fibers soften to their tack point, whereby the fibers are fixed to one another at their points of contact by bonding or adhesion and the fibrous mat is pre-compacted.
During the compaction of the fibrous fleece by heating the thermoplastic fibers to their tack point, but not to melting, a fibrous fleece is obtained, which has properties ~trongly varying over its cross sectional area, the more so as the fibrous fleece is heated most intensively in the surface layers. If bonding of the central layers is sought, it is no longer ensured that the surface layers will still B
have fibrous structures and that the fibrous mat will be flexible enough for further handling.
With the fibrous mat according to DE-A 32 39 732, the binders that are responsible for the setting of the fibrous mat merely are admixed with the fibers, no uniform setting, thus, being ensured. In particular, there may result regions in which binders are present to an insufficient extent such that the finished workpiece does not exhibit the same strength at every point.
A method of producing a fibrous mat, furthermore, is known from DE-B - 1 054 416. According to that document, a mixture of cellulose fibers and synthetic fibers is processed to a fibrous fleece which is compacted by applying bonding agents and subsequent drying and compressing. In doing so, the fibers of the surface layers adhere to one another at their points of contact such that the fibrous fleece is stabilized and may be subjected to further processing.
This known method has disadvantages, which are to be seen in that the application of bonding agents on the surface of a fibrous fleece is cumbersome to carry out, requiring subsequent drying. In addition, the fibrous fleece exhibits strength properties that vary strongly over its cross sectional area, because an impregnation of the fibrous fleece with bonding agents is provided only on the surface layers thereof. Complete impregnation involves an even more complex secondary treatment, at which the fibrous fleece not yet dried must be treated with the respective care.
The compaction of the compressed workpiece, according to DE-B - 1 054 416, is effected by introducing synthetic resin powder into the cavity oE the press molding the fibrous mat.
In order to obtain a regularly compacted workpiece, the synthetic resin powder is to be introduced into the press in a uniformly thick layer, which, however, is very difficult to realize, if at all, in the case of complicated shapes of the workpiece.
The invention aims at avoiding these disadvantages and difficulties and has as its object to provide a method of making the initially described fibrous mat, which yields a homogenously compacted fibrous mat having uniform properties over its cross sectional area and which is operable at low energy expenditures. In addition, the manufacture of regularly compacted workpieces from this fibrous mat is to be guaranteed.
In accordance with the invention there is provided a method of making a storable handleable fibrous mat composed of cellulose fibers and further fibers selected from thermoplastic fibers, and natural fibers of vegetable origin, and containing a thermosetting plastic binder on a synthetic base, which fibrous mat is capable of being molded into dimensionally stable workpieces in a subsequent operation under the influence of heat and pressure and by curing and setting of said binder, wherein the following measures are applied in combination:
the cellulose fibers are impregnated with a solution of the thermosetting plastic binder and are dried, the dried cellulose fibers are mixed in a dry state with said further fibers, a fleece is formed from the mixture of the cellulose fibers and said further fibers, and the formed fleece is compacted by needle-punching in a needle-punching machine.
The invention also provides a fibrous mat, comprising cellulose fibers and further fibers selected from thermoplastic fibers and/or natural fibers of vegetable origin, and a thermosetting plastic binder on a synthetic base, wherein the $
cellulose fibers are impregnated with a solution of said binder and are connected with said further fibers by mechanical intertwining without melting.
If further processing of the fibrous mat involves a particularly extensive conversion of the fibrous mat, the mixture of cellulose fibers and thermoplastic fibers and/or natural fibers of vegetable origin preferably is needled onto a thin carrier fleece of thermoplastic fibers.
A particularly uniform fibrous mat, preferably, may be produced by forming a fleece of impregnated cellulose fibers and a fleece of thermoplastic fibers and/or natural fibers of vegetable origin, which fleeces are mixed in a cylinder, by forming a further fleece from the mixture and by needling the same onto a thin carrier fleece of thermoplastic fibers.
For particularly high stresses to be exerted on the fibrous mats, the cellulose fibers and thermoplastic fibers and/or natural fibers of vegetable origin, suitably, are additionally mechanically connected with a thin carrier fleece of thermoplastic fibers.
An article molded from a fibrous mat according to the invention by the application of heat and pressure is characterized in that the cellulose fibers, thermoplastic fibers and/or natural fibers of vegetable origin are embedded in a set melt of duroplastic binder and are interlinked by this melt.
Advantageously, the cellulose fibers are interlaced with the carrier fleece and with the set melt of duroplastic binder, the article, thus, having a particularly high strength and a highly stressable surface.
Moreover, an article of this type exhibits a high dimensional stability and high flexural stress values.
The method according to the invention will now be explained in more detail by way of the accompanying drawings, wherein Figs. 1 and 2 are each a process diagram for the manufacture of a fibrous mat according to the invention;
Fig. 3 is an isometric view of an article produced of a fibrous mat according to the invention;
Fig. 4 shows this article sectioned along line IV-IV
of Fig. 3; and Fig. 5 is a detailed section through this article in a strongly enlarged view.
According to Fig. 1, shreds 1 are processed into cellulose fibers 3 by defibration in a defibrator 2. The cellulose fibers are impregnated with wax 4 and a phenolic resin solution 5. Subsequently, the impregnated cellulose fibers ~ are dried in a tubular drier 7 and are pressed to bales 9 in a press 8.
Thermoplastic fibers 10, i.e. polyester fibers, are disintegrated from polyester fiber bales 11 and are transported to a fiber spreading machine 13 via an 0 intermediate bunker 12. The fiber spreading machine 13 spreads the polyester fibers 10 onto a conveying belt 14.
Cellulose fibers formed by the disintegration of the bales 9 are spread onto this layer of polyester fibers by means of two additional fiber spreading machines 15, 16.
The sandwich thus formed is pre-mixed in a blender 17 and is further mixed in a fine blender 18. The mixture 19 is transported to a fleece laying machine 20, in which a fibrous fleece 21 having a predetermined weight is formed.
This fibrous fleece 21 is applied onto a thin polyester fleece 22 and is needle-punched thereto in a needle-punching machine 23. Subsequently, the fibrous mat 24 made in this way is cut to predetermined formats in a cutting means 25 and is stapled in a stapling means 26.
The fibrous fleece is readily handleable and, nevertheless, soft and flexible such that there will be no difficulties when processing the same into a molded article. If natural fibers of vegetable origin (e.g., cotton) are used instead of the thermoplastic fibers 10, or if such natural fibers admixed with thermoplastic fibers are used, this will also result in a soft and flexible fibrous fleece.
According to the method illustrated in Fig. 2, the preparation of the shreds 1 to impregnated cellulose fibers 6 and that of the polyester fibers 10 are effected in the same manner as with the method illustrated in Fig. l; yet, the formation of the fibrous fleece is different. The cellulose fibers 6 are fed to the fleece laying machine 20 via a conveying belt 14. The polyester fibers 10 get to a separate fleece laying machine 28 via a conveying belt 27.
0 In this way, a separate fibrous fleece 29, 30 is each formed by the cellulose fibers and by the polyester fibers.
The two fibrous fleeces 29, 30 are united and mixed in a cylinder 31. A further fleece 21 is formed from this mixture and is applied onto a thin polyester fleece 22. In the consecutively arranged needle-punching machine 23, the fibrous fleece 21 is needle-punched to the thin polyester fleece 22, which, again, results in a readily handleable, yet sufficiently moldable fibrous mat 24.
Articles are produced from the fibrous mats 24 by compression under the application of heat and pressure.
Such an article 32 is, for instance, illustrated in Figs. 3 and 4. It constitutes a door panel for a passenger car. As is apparent from Fig. 4, this door panel 32 has approximately the same wall thickness over the entire cross sectional area.
In Fig. 5, a detailed section through the article 32 is illustrated on a greatly enlarged scale. The cellulose fibers 6 embedded in a set melt 33 of duroplastic binder are visible. The external limitation of the article 32, on one side 34, is formed by a carrier fleece 22 of thermoplastic fibers 35, which is connected with the cellulose fibers 6 not only mechanically, but the cellulose fibers 6 are interlaced with the carrier fleece 22 and the set melt 33 of duroplastic binder penetrated into the carrier fleece 22 at the pressing operation, to form a rigid durable and dimensionally stable structure.
Thermoplastic fibers 36 or natural fibers, if used in addition to the thermoplastic fibers 36 or instead of these thermoplastic fibers 36, are embedded in the set binder.
Claims (10)
1. A method of making a storable handleable fibrous mat composed of cellulose fibers and further fibers selected from thermoplastic fibers, and natural fibers of vegetable origin, and containing a thermosetting plastic binder on a synthetic base, which fibrous mat is capable of being molded into dimensionally stable workpieces in a subsequent operation under the influence of heat and pressure and by curing and setting of said binder, wherein the following measures are applied in combination:
- the cellulose fibers are impregnated with a solution of the thermosetting plastic binder and are dried, - the dried cellulose fibers are mixed in a dry state with said further fibers, - a fleece is formed from the mixture of the cellulose fibers and said further fibers, and - the formed fleece is compacted by needle-punching in a needle-punching machine.
- the cellulose fibers are impregnated with a solution of the thermosetting plastic binder and are dried, - the dried cellulose fibers are mixed in a dry state with said further fibers, - a fleece is formed from the mixture of the cellulose fibers and said further fibers, and - the formed fleece is compacted by needle-punching in a needle-punching machine.
2. A method as set forth in claim 1, wherein the mixture of cellulose fibers and said further fibers is needled onto a thin carrier fleece of thermoplastic fibers.
3. A method as set forth in claim 1 or 2, wherein a fleece of impregnated cellulose fibers and a fleece of said further fibers are formed, which fleeces are mixed in a cylinder, and a further fleece is formed from the mixture and is needled onto a thin carrier fleece of thermoplastic fibers.
4. A method as set forth in claim 1 or claim 2, wherein said thermoplastic fibers are polyester fibers.
5. A method as set forth in claim 1 or claim 2, wherein said thermosetting plastic binder is a phenolic resin solution.
6. A method as set forth in claim 3, wherein said thermoplastic fibers are polyester fibers, and wherein said thermosetting plastic binder is a phenolic resin solution.
7. A fibrous mat, comprising cellulose fibers and further fibers selected from thermoplastic fibers and/or natural fibers of vegetable origin, and a thermosetting plastic binder on a synthetic base, wherein the cellulose fibers are impregnated with a solution of said binder and are connected with said further fibers by mechanical intertwining without melting.
8. A fibrous mat according to claim 7, wherein said cellulose fibers and said further fibers are additionally mechanically connected with a thin carrier fleece of thermoplastic fibers.
9. An article molded from a fibrous mat according to claim 7 or 8 by the application of heat and pressure, wherein the cellulose fibers, and the further fibers are embedded in a set melt of thermosetting plastic binder and are interlinked by this melt.
10. An article according to claim 9, wherein the cellulose fibers are interlaced with the carrier fleece and with the set melt of thermosetting plastic binder.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| ATA3268/87 | 1987-12-11 | ||
| AT0326887A AT387798B (en) | 1987-12-11 | 1987-12-11 | METHOD FOR PRODUCING A STORAGEABLE, HANDLABLE FIBER MAT, AND FIBER MAT MADE BY THE PROCESS |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1321512C true CA1321512C (en) | 1993-08-24 |
Family
ID=3547957
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000585039A Expired - Fee Related CA1321512C (en) | 1987-12-11 | 1988-12-06 | Method of making a storable handleable fibrous mat |
Country Status (10)
| Country | Link |
|---|---|
| CN (1) | CN1008752B (en) |
| AT (1) | AT387798B (en) |
| CA (1) | CA1321512C (en) |
| CS (1) | CS275642B6 (en) |
| ES (1) | ES2009426A6 (en) |
| PL (1) | PL159294B1 (en) |
| PT (1) | PT89196B (en) |
| WO (1) | WO1989005366A1 (en) |
| YU (1) | YU45065B (en) |
| ZA (1) | ZA889242B (en) |
Families Citing this family (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE4139226A1 (en) * | 1991-08-22 | 1993-03-11 | Pelz Ernst Empe Werke | FIBER COMPOSITE MATERIAL ON THE BASIS OF NATURAL FIBER PLANTS AND A METHOD FOR THE CONTINUOUS PRODUCTION AND FURTHER PROCESSING OF COMPRESSED PARTS |
| AU4040293A (en) * | 1992-04-16 | 1993-11-18 | Heraklith Baustoffe Aktiengesellschaft | Process for producing insulating boards |
| ES2106230T3 (en) * | 1992-07-09 | 1997-11-01 | Dierig Holding Ag | NON-WOVEN FABRIC OF NATURAL FIBERS AND USES OF THE SAME. |
| AT398438B (en) * | 1992-07-17 | 1994-12-27 | Kuehnsdorfer Gmbh | METHOD FOR THE FLOW-DYNAMIC PRODUCTION OF DEFORMABLE FIBER MATS OF HIGH TENSILE STRENGTH, AND DEVICE FOR THE PRODUCTION THEREOF |
| DE4225840C1 (en) * | 1992-08-05 | 1994-04-28 | Rockwool Mineralwolle | Process for producing mineral wool slabs and device for carrying out the process |
| AT405195B (en) * | 1998-06-24 | 1999-06-25 | Wolfinger Eduard Franz Mag | Treatment of natural raw materials for the manufacture of insulants |
| DE10151368A1 (en) * | 2001-10-17 | 2003-05-08 | Sai Automotive Sal Gmbh | Fiber mat, molded part made therefrom and process for its production |
| EP2093318B1 (en) * | 2008-02-22 | 2012-12-12 | ISOWOOD Holding GmbH | Flexible composite material, method for its manufacture and application |
Family Cites Families (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2959509A (en) * | 1955-08-15 | 1960-11-08 | American Felt Co | Needled felt |
| JPS58220721A (en) * | 1982-06-18 | 1983-12-22 | Mitsui Mokuzai Kogyo Kk | Moldig mat and manufacture thereof |
-
1987
- 1987-12-11 AT AT0326887A patent/AT387798B/en not_active IP Right Cessation
-
1988
- 1988-12-02 ES ES8803687A patent/ES2009426A6/en not_active Expired
- 1988-12-05 WO PCT/AT1988/000107 patent/WO1989005366A1/en unknown
- 1988-12-06 CA CA000585039A patent/CA1321512C/en not_active Expired - Fee Related
- 1988-12-08 YU YU2227/88A patent/YU45065B/en unknown
- 1988-12-09 ZA ZA889242A patent/ZA889242B/en unknown
- 1988-12-09 PT PT89196A patent/PT89196B/en not_active IP Right Cessation
- 1988-12-09 CS CS888146A patent/CS275642B6/en not_active IP Right Cessation
- 1988-12-09 PL PL1988276317A patent/PL159294B1/en unknown
- 1988-12-10 CN CN88108479A patent/CN1008752B/en not_active Expired
Also Published As
| Publication number | Publication date |
|---|---|
| CN1008752B (en) | 1990-07-11 |
| YU45065B (en) | 1991-06-30 |
| ES2009426A6 (en) | 1989-09-16 |
| PL276317A1 (en) | 1989-07-10 |
| YU222788A (en) | 1990-04-30 |
| ZA889242B (en) | 1989-08-30 |
| CN1034403A (en) | 1989-08-02 |
| PT89196A (en) | 1989-12-29 |
| PL159294B1 (en) | 1992-12-31 |
| WO1989005366A1 (en) | 1989-06-15 |
| ATA326887A (en) | 1988-08-15 |
| PT89196B (en) | 1995-05-04 |
| AT387798B (en) | 1989-03-10 |
| CS275642B6 (en) | 1992-03-18 |
| CS8808146A2 (en) | 1989-12-13 |
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| Date | Code | Title | Description |
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| MKLA | Lapsed |