CA2166185A1 - Fibrous material batts - Google Patents
Fibrous material battsInfo
- Publication number
- CA2166185A1 CA2166185A1 CA002166185A CA2166185A CA2166185A1 CA 2166185 A1 CA2166185 A1 CA 2166185A1 CA 002166185 A CA002166185 A CA 002166185A CA 2166185 A CA2166185 A CA 2166185A CA 2166185 A1 CA2166185 A1 CA 2166185A1
- Authority
- CA
- Canada
- Prior art keywords
- sliver
- bonding agent
- mat
- batts
- fibrous material
- 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.)
- Abandoned
Links
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
- D04H1/58—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
- D04H1/42—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
- D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
- D04H1/43835—Mixed fibres, e.g. at least two chemically different fibres or fibre blends
-
- 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
- D04H1/4266—Natural fibres not provided for in group D04H1/425
-
- 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
- D04H1/4374—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 using different kinds of webs, e.g. by layering webs
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Dispersion Chemistry (AREA)
- General Chemical & Material Sciences (AREA)
- Nonwoven Fabrics (AREA)
- Preliminary Treatment Of Fibers (AREA)
- Chemical Or Physical Treatment Of Fibers (AREA)
- Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
Abstract
Fibrous material batts are produced from a mixture of natural and synthetic fibres. A sliver (10) of the fibres is fed through a lapping device (11) onto a moving conveyor to form a continuous mat. The sliver is sprayed with a bonding agent and other optional substances during lapping. The mat is then compressed to a required thickness before curing the bonding agent, and is then cut to form batts of a low density. Resilience and fire retardance properties may be imparted to the fibrous material by including an octaborate salt among the substances sprayed with the bonding agent.
Description
WO 95/00691 21~ 5 PCT/NZ94/00067 FIBROUS MATERL~L BATTS
FIELD OF THE INVENTION ~ ~
This invention relates to the m~n~lf~ctllre of fibrous material mats or batts, in particular but not solely to low density batts for thermal ins~ tion or padtling The 5 invention also relates to other properties of these batts, such as fire resistance and r~cilience to crushing.
BACKGROUND OF THE INVENTION
A method of forming resin impregnated fibre batts is disclosed in US Patent No. 4,678,822. The resin is an acrylic self cross-linking polymer cont~ining fire and 10 smoke retardants and a pesticide. The fibres may be natural and/or synthetic in origin and are often waste m~teJi~l~
The materials are r~ndomly dispersed in a sliver which is sprayed with the resinduring a co~ lous folding process known as lapping. The sliver is lapped up to arequired th~ rn~s~ on a moving conveyer, and the reslllting mat is cured at around 150C
15 and cut into batts having a density of around 25 kg/m3.
This method and other similar methods now in use have high production costs due to the q~l~nl;L;es of materials required and the conditions under which m~mlf~ctllnng takes place. The relatively high density batts also give an undesirably high thermal cQn~ ctivity for a given thickness. Lower density products would be cheaper and less 20 conductive but are not yet available from existing sources.
The textile industry incorporates various natural andtor synthetic fibre materials in a wide range of products. These materials are often treated for fire resistance by absorption of inorganic salts such as borates and phosphates from aqueous solution, and/or by spraying with resin compositions which con~aill these salts or other chemicals 25 such as metal oxides or halogenated organic compounds.
A variety of natural and synthetic resins are available. By themselves most are dangerously fl~mm~hle until the various salts and other compounds are admLxed insolution to form water/resin emulsions. The final compositions may then impart fire, insect, fungus and rodent re~i~Lallce as well as resilience, cohesion and strength to the 30 fibrous materials. They should also be stable and non-toxic.
Boric acid (H3BO3) and sodium tetraborate or borax (Na2B4O7)impart many of the desired properties to the fibres and to the resins with boron being the important component. However, their use has been lln~ti~f~ctory to some extent due to problems with high pH and low solubility in water. Generally both the aqueous solutions in which 35 the material is immersed and the resin compositions with which they are sprayed cannot ~lG~ 5 PCT/N~g 41 o o o 6 7 REC~1VE~ t O FFR t995 contain sufficient conce~ alions of boron. They have also been lm~ti~f~ctory with regard to stiffn~ss of the treated m~teri~ls.
SUMMARY OF THE INVENTION
Itisanobjectofthepl~selllinventiontoprovidefor...~....l~ctllre of fibrousm?,t~
S batts having ill~r~vt;d physical properties, or at least to provide the public with a useful choice.
The invention involves several aspe.ils relating to prodllction of the improved batts.
A f~le sliver of fibrous m~teli~l is contimlously formed from a mass of natural and/or synthetic fibres such as found in waste wool. The sliver is lapped into a lightweight mat 10 which is carried on a moving conveyor. A bonding agent and optionally other s~lbst~nces are sprayed onto the sliver in a fine mist as lapping takes place back and forth across the conveyor. Control may be exerted over the thickness of the mat by vaIying the lapping-and conveying speeds. The structure of the mat is then fixed by curing.
Spraying takes place on ~ltçrn~te sides of the sliver from a pair of spray booms15 which preferably oscillate with the sliver. Each boom may be turned off briefly at the point of closest approach of the sliver. This enables precise control over the eventual density of batts into which the mat will be cut. It is generally desired that the batts have - a density of less than 15 kg/m3, and preferably 8 to 12 kg/m3.
The bonding agent which is sprayed onto the sliver is typically a resin em~ ion 20 c~ g the optional ~ubsl~ces in an aqueous solution. Batts being ~ r~ctured for therm~l in~ tion must be fire resist~nt and one of the optional subst~nces should be an octaborate salt having a conce~llalion of up to around 30% by weight.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred embodim~nt will be described as an e~r~mple of the invention with 25 respect to the drawings of which:
Figure 1 sc~ tically shows api)a.alus for ..~ .,rflcturing fibrous m~t~ri~l batts, from one side, Figllre 2 shows the ap~alus from above with an e~r~g~e~aled indic~tion of the lapping operation, and Figure 3 shows an end view of the lapping and spraying operations.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to these drawings it will be evident that the invention can be employed when m~kin~ mats and batts from a range of natural and synthetic m~/tel`i~l~;7 including animal or plant fibres and acrylics, polyesters or polyamides. Natural wool is preferred 35 due to its ready availability and lo~ng characteristics. It will also be appreciated ~at the A~hENDED SHEET
~n~lAI I
21661~5 PCT/NZ9 4 / O 0 0 6 7 RECEIY~D t O FEB l995 fibrous ~ h ~ products can be put to a wide range of uses inCllltling therrn~l in~ul~tion and st~lffing for various objects.
Figure 1 shows sliver 10 of fibrous m~teri~l passing dowllwards through a lapping device 11. The sliver is formed continuously from wool or a wool/synthetic mix, 5 prerelably at least 50% by weight of wool, which may be scoured or cleaned by a CO~ n,ial process and possibly pr~llealcd for fire resist~nce. Processes for treating the bulk m~teri~l and forminp the sliver are well known and will be not be described fi~ther.
The sliver itselfhas a f~agile structure up to around 1 cm thick and perhaps 2 m in width.
The lapping device inçl~l-les sliver control çlem~ntc 30 and spray booms 31 which 10 will be described later. The device oscillates back and forth across a moving conveyor ~
12 onto which the sliver is folded, to create a continllous mat 13 of fibrous m~teri~l The fibre bonding agent sprayed onto the sliver from booms 31 thoroughly impregn~tes th~
mat, which is typically 10 to 20 cm thick. The conveyor passes through a bath 14 which removes any ove,~prd~ed bonding agent.
Figure 2 shows mat 13 from above, with an ex~e~aled zigzag structNre caused by the relative motion of the lapping device 11 and conveyor 12. In practice the zigzag is veIy much finer due to the lapping device moving rather more quickly than the conveyor - in the directions indicated. The multilayer structure of the mat has also been considerably exaggelated in Figure 1.
As shown in both Figures 1 and 2 the mat 13 is carried from conveyor 12 to a space 15 between parallel conveyors 16 and 17. The space is adjustable, by lowering or raising conveyor 16, so that the mat can be col-lplessed to a greater or lesser degree in obtaining a ~e~luil~d thi~l~n~ss The conveyors contact both sides of the mat, which is still wet from the spraying operation, through a non-sticking mesh surface. This also holds the mat in 25 place during air blowing.
Conveyors 16 and 17 carry the mat into an oven 20 which circulates hot air as indicated to dry and cure the bonding agent. A heal.,r/r~ 21 blows hot air up through conveyor 17 and out of the oven ~hrough an eYh~llst 22. Heat is eYch~n~ed to incoming air which passes down through conveyor 16 from inlet 23. The upwa~ds moving air is 30 typically at a lel~p~alu~e of up to 120C and ~lef~bly heats the mat to a temperalu~e of l~t~cen 70 and 100C. The dowl.w~s moving air has a le~ e~ e of between 50 to 60C.
The mat 13 is finally cut at a guillotine device 25 after curing and drying. This cleates batts of a required thickness and low density accor~ g to various parameters 35 which may be varied during the overall .~ ct~ g process. For eY~mple, to create lUUENDED SHEET
R E C E I \~E ~ J~ 8 F~ g~
FIELD OF THE INVENTION ~ ~
This invention relates to the m~n~lf~ctllre of fibrous material mats or batts, in particular but not solely to low density batts for thermal ins~ tion or padtling The 5 invention also relates to other properties of these batts, such as fire resistance and r~cilience to crushing.
BACKGROUND OF THE INVENTION
A method of forming resin impregnated fibre batts is disclosed in US Patent No. 4,678,822. The resin is an acrylic self cross-linking polymer cont~ining fire and 10 smoke retardants and a pesticide. The fibres may be natural and/or synthetic in origin and are often waste m~teJi~l~
The materials are r~ndomly dispersed in a sliver which is sprayed with the resinduring a co~ lous folding process known as lapping. The sliver is lapped up to arequired th~ rn~s~ on a moving conveyer, and the reslllting mat is cured at around 150C
15 and cut into batts having a density of around 25 kg/m3.
This method and other similar methods now in use have high production costs due to the q~l~nl;L;es of materials required and the conditions under which m~mlf~ctllnng takes place. The relatively high density batts also give an undesirably high thermal cQn~ ctivity for a given thickness. Lower density products would be cheaper and less 20 conductive but are not yet available from existing sources.
The textile industry incorporates various natural andtor synthetic fibre materials in a wide range of products. These materials are often treated for fire resistance by absorption of inorganic salts such as borates and phosphates from aqueous solution, and/or by spraying with resin compositions which con~aill these salts or other chemicals 25 such as metal oxides or halogenated organic compounds.
A variety of natural and synthetic resins are available. By themselves most are dangerously fl~mm~hle until the various salts and other compounds are admLxed insolution to form water/resin emulsions. The final compositions may then impart fire, insect, fungus and rodent re~i~Lallce as well as resilience, cohesion and strength to the 30 fibrous materials. They should also be stable and non-toxic.
Boric acid (H3BO3) and sodium tetraborate or borax (Na2B4O7)impart many of the desired properties to the fibres and to the resins with boron being the important component. However, their use has been lln~ti~f~ctory to some extent due to problems with high pH and low solubility in water. Generally both the aqueous solutions in which 35 the material is immersed and the resin compositions with which they are sprayed cannot ~lG~ 5 PCT/N~g 41 o o o 6 7 REC~1VE~ t O FFR t995 contain sufficient conce~ alions of boron. They have also been lm~ti~f~ctory with regard to stiffn~ss of the treated m~teri~ls.
SUMMARY OF THE INVENTION
Itisanobjectofthepl~selllinventiontoprovidefor...~....l~ctllre of fibrousm?,t~
S batts having ill~r~vt;d physical properties, or at least to provide the public with a useful choice.
The invention involves several aspe.ils relating to prodllction of the improved batts.
A f~le sliver of fibrous m~teli~l is contimlously formed from a mass of natural and/or synthetic fibres such as found in waste wool. The sliver is lapped into a lightweight mat 10 which is carried on a moving conveyor. A bonding agent and optionally other s~lbst~nces are sprayed onto the sliver in a fine mist as lapping takes place back and forth across the conveyor. Control may be exerted over the thickness of the mat by vaIying the lapping-and conveying speeds. The structure of the mat is then fixed by curing.
Spraying takes place on ~ltçrn~te sides of the sliver from a pair of spray booms15 which preferably oscillate with the sliver. Each boom may be turned off briefly at the point of closest approach of the sliver. This enables precise control over the eventual density of batts into which the mat will be cut. It is generally desired that the batts have - a density of less than 15 kg/m3, and preferably 8 to 12 kg/m3.
The bonding agent which is sprayed onto the sliver is typically a resin em~ ion 20 c~ g the optional ~ubsl~ces in an aqueous solution. Batts being ~ r~ctured for therm~l in~ tion must be fire resist~nt and one of the optional subst~nces should be an octaborate salt having a conce~llalion of up to around 30% by weight.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred embodim~nt will be described as an e~r~mple of the invention with 25 respect to the drawings of which:
Figure 1 sc~ tically shows api)a.alus for ..~ .,rflcturing fibrous m~t~ri~l batts, from one side, Figllre 2 shows the ap~alus from above with an e~r~g~e~aled indic~tion of the lapping operation, and Figure 3 shows an end view of the lapping and spraying operations.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to these drawings it will be evident that the invention can be employed when m~kin~ mats and batts from a range of natural and synthetic m~/tel`i~l~;7 including animal or plant fibres and acrylics, polyesters or polyamides. Natural wool is preferred 35 due to its ready availability and lo~ng characteristics. It will also be appreciated ~at the A~hENDED SHEET
~n~lAI I
21661~5 PCT/NZ9 4 / O 0 0 6 7 RECEIY~D t O FEB l995 fibrous ~ h ~ products can be put to a wide range of uses inCllltling therrn~l in~ul~tion and st~lffing for various objects.
Figure 1 shows sliver 10 of fibrous m~teri~l passing dowllwards through a lapping device 11. The sliver is formed continuously from wool or a wool/synthetic mix, 5 prerelably at least 50% by weight of wool, which may be scoured or cleaned by a CO~ n,ial process and possibly pr~llealcd for fire resist~nce. Processes for treating the bulk m~teri~l and forminp the sliver are well known and will be not be described fi~ther.
The sliver itselfhas a f~agile structure up to around 1 cm thick and perhaps 2 m in width.
The lapping device inçl~l-les sliver control çlem~ntc 30 and spray booms 31 which 10 will be described later. The device oscillates back and forth across a moving conveyor ~
12 onto which the sliver is folded, to create a continllous mat 13 of fibrous m~teri~l The fibre bonding agent sprayed onto the sliver from booms 31 thoroughly impregn~tes th~
mat, which is typically 10 to 20 cm thick. The conveyor passes through a bath 14 which removes any ove,~prd~ed bonding agent.
Figure 2 shows mat 13 from above, with an ex~e~aled zigzag structNre caused by the relative motion of the lapping device 11 and conveyor 12. In practice the zigzag is veIy much finer due to the lapping device moving rather more quickly than the conveyor - in the directions indicated. The multilayer structure of the mat has also been considerably exaggelated in Figure 1.
As shown in both Figures 1 and 2 the mat 13 is carried from conveyor 12 to a space 15 between parallel conveyors 16 and 17. The space is adjustable, by lowering or raising conveyor 16, so that the mat can be col-lplessed to a greater or lesser degree in obtaining a ~e~luil~d thi~l~n~ss The conveyors contact both sides of the mat, which is still wet from the spraying operation, through a non-sticking mesh surface. This also holds the mat in 25 place during air blowing.
Conveyors 16 and 17 carry the mat into an oven 20 which circulates hot air as indicated to dry and cure the bonding agent. A heal.,r/r~ 21 blows hot air up through conveyor 17 and out of the oven ~hrough an eYh~llst 22. Heat is eYch~n~ed to incoming air which passes down through conveyor 16 from inlet 23. The upwa~ds moving air is 30 typically at a lel~p~alu~e of up to 120C and ~lef~bly heats the mat to a temperalu~e of l~t~cen 70 and 100C. The dowl.w~s moving air has a le~ e~ e of between 50 to 60C.
The mat 13 is finally cut at a guillotine device 25 after curing and drying. This cleates batts of a required thickness and low density accor~ g to various parameters 35 which may be varied during the overall .~ ct~ g process. For eY~mple, to create lUUENDED SHEET
R E C E I \~E ~ J~ 8 F~ g~
batts having a density of 10 kg/m3 from a sliver formed at 50 kg/hr, a 1 m wide mat may be conveyed at 50 m/hr, and co~ ,essed to a thic~ness of 10 cm.
Surpri~ingly good ins~ tive properties have been obtained from batts having a density less than 15 kg/m3 and pl~rel~bly between about 8 and 12 kg/m3. This represents 5 an o~tinlu~ volume ratio of air to fibre. At higher d~nciti5s fibre and resin consumption are unnecess~rily high and the in~nl~tion is also re~l~ced A comp~ricon of one sample with the example in US 4,678,822 is as follows.
Thickness Density Tnslll~tion Thermal mm kglm "R" value Conductivity m2/C/W W/m2/C
-. 8.2 1.71 0.052 _~
54 25 1.34 0.040 From these results it can be seen that a thickish mat of low density according to the 15 invention gives better in~ tion than a conv~ntion~l mat of hi~h density. As ~e ~ickness was less than double while the density was less than one third a considerable saving in production m~t~ri~lc can be made.
Figure 3 shows the lapper in more detail to have a pair of control booms 30 and a pair of spray booms 31. It moves from side to side as indicated and the sides of the sliver 20 10 are finely and ~lt~rn~tely sprayed with a resin em~ ion to hold the s~ucture of the mat, and other ~,b~ es to provide certain propc~ies of resilience and ret~rdance. The spray booms are ~ltern~tely switched off for brief periods when the sliver is closest~ to obtain economic and even distribution of resin.
Spraying takes place ~l~relàbly with the resin at a ~ per~ e up to about 50C and 25 generally l~t~ ,n about 25 and 40 C. This assists evaporation of l,loislure prior to curing and avoids need of elaborate radiative or other drying means which have been proposed previously.
Curing takes place in ~e oven ~ ,ferdl)ly at a ~ 't less ~an about 120C and generally between about 70 and 100C. Higher curing lem~ &llueS are usually of no 30 advantage and may be detnment~l to some fibres and resins.
The resin emnl~iQn norm~lly incl~ldes various fire and smoke retardants, pesticides, filn~ci~les and the like in the form of an aqueous solution. A ~llrfflct~nt such as sold by F~ctm~n Chemicals Ltd of the United States, under ~he trade mark TEXANOL, may also be added. Resins suitable for the low lenlpe.&lule curing are plefelably acrylic polymer AMENDED SHEET
IDCA/~
Surpri~ingly good ins~ tive properties have been obtained from batts having a density less than 15 kg/m3 and pl~rel~bly between about 8 and 12 kg/m3. This represents 5 an o~tinlu~ volume ratio of air to fibre. At higher d~nciti5s fibre and resin consumption are unnecess~rily high and the in~nl~tion is also re~l~ced A comp~ricon of one sample with the example in US 4,678,822 is as follows.
Thickness Density Tnslll~tion Thermal mm kglm "R" value Conductivity m2/C/W W/m2/C
-. 8.2 1.71 0.052 _~
54 25 1.34 0.040 From these results it can be seen that a thickish mat of low density according to the 15 invention gives better in~ tion than a conv~ntion~l mat of hi~h density. As ~e ~ickness was less than double while the density was less than one third a considerable saving in production m~t~ri~lc can be made.
Figure 3 shows the lapper in more detail to have a pair of control booms 30 and a pair of spray booms 31. It moves from side to side as indicated and the sides of the sliver 20 10 are finely and ~lt~rn~tely sprayed with a resin em~ ion to hold the s~ucture of the mat, and other ~,b~ es to provide certain propc~ies of resilience and ret~rdance. The spray booms are ~ltern~tely switched off for brief periods when the sliver is closest~ to obtain economic and even distribution of resin.
Spraying takes place ~l~relàbly with the resin at a ~ per~ e up to about 50C and 25 generally l~t~ ,n about 25 and 40 C. This assists evaporation of l,loislure prior to curing and avoids need of elaborate radiative or other drying means which have been proposed previously.
Curing takes place in ~e oven ~ ,ferdl)ly at a ~ 't less ~an about 120C and generally between about 70 and 100C. Higher curing lem~ &llueS are usually of no 30 advantage and may be detnment~l to some fibres and resins.
The resin emnl~iQn norm~lly incl~ldes various fire and smoke retardants, pesticides, filn~ci~les and the like in the form of an aqueous solution. A ~llrfflct~nt such as sold by F~ctm~n Chemicals Ltd of the United States, under ~he trade mark TEXANOL, may also be added. Resins suitable for the low lenlpe.&lule curing are plefelably acrylic polymer AMENDED SHEET
IDCA/~
6 6 ~ ~ ~ PCT/~Z !~ 4 / O ~99;~
RECEI ED 1 0~
emulsion types with low film forming prope-lies during spraying and high self cross-linkin~ properties during curing.
One especially advantageous addition to the fibre bonding agents has been found in a range of inorganic octaborate salts, particularly sodium octaborate (Na2B80l3).
S A sodium octaborate product (tetrahydrate) is m~rkete-l by United States Borax and Chemical Corporation under the trade marks TIMBOR and F-BOR These have been used exclusively for preservation of timber in the past.
A suitable resin is m~rkete~l by A C Hatrick (NZ) Limited under the trade mark ACROCRYL. It has not been used sllccessrl~lly with boric acid or borax in the past and 10 compositions of this kind have been dis egarded due to the unfavourable chçmic~1 -reactions which occur. Other salts and resins may also be suitable but those mentioned are the most cheaply and widely available at plesent.
A composition of TIMBOR dissolved in water and ACROCRYL forms an emulsion which gives surI-ri~ing1y good fire resi~nre and rçsi1i~n~ to treated m~teri~1~. There are 15 no problems with pH or low solubility as occurs with other well known boron chemicals which have been tried in the pæt. It also covers and adheres to fibre surfaces particularly well, and has a m~rke~ shelf life stability so need not be used immediately after prep~a~ion. The resin is an acrylic cross-linked variety which is cured at around 70 to 100C once applied.
20 ~ Pr~fe"~ d n~ s for spraying onto a fibrous m~teri~1 sliver during lapping have been found to co~ e a resin çmn1cion with up to 30% by weight of resin solids and up to 30% by weight of an octaborate salt. Most pref~ably lS to 25% by weight of resin solids and l0 to 25% of so~linm octaborate tetrahydrate.
A co...p~ orl oftec~mic~1 data on boric acid, borax and sodium octaborate indicates 25 rather better water solubility characteri~cs for octaborate compounds (l/l9, l/16 and 1/11 g/ml respectively). Further, the pH of an octaborate solution drops to near neutral as concentration increases and no ullfavoulable reactions occur with the m~teri~l~ or resins. This allows a high concc~ on of boron in purely aqueous solutions for immersion of Il~A~ , and in resin emn1~innc which may be sprayed onto the m~tçri~
O~1tct~ndin~ results have been achieved in e~ t~ c~n~ll)cte~l to date using resin compositions on woollen webs or blocks for inq11~tion. An emulsion compricin,~ 20%
ACROCRYL, 18% TIMBOR and the b~1~n~ water by weight was sprayed onto woollen fibres which were then lofted and cured. The resl11tin~. webs were effectively fire resistant wi~ desirable qu~lities of high stiffness and low toxicity with fungicidal and insecticidal 35 properties also.
AMENDED SHEEr
RECEI ED 1 0~
emulsion types with low film forming prope-lies during spraying and high self cross-linkin~ properties during curing.
One especially advantageous addition to the fibre bonding agents has been found in a range of inorganic octaborate salts, particularly sodium octaborate (Na2B80l3).
S A sodium octaborate product (tetrahydrate) is m~rkete-l by United States Borax and Chemical Corporation under the trade marks TIMBOR and F-BOR These have been used exclusively for preservation of timber in the past.
A suitable resin is m~rkete~l by A C Hatrick (NZ) Limited under the trade mark ACROCRYL. It has not been used sllccessrl~lly with boric acid or borax in the past and 10 compositions of this kind have been dis egarded due to the unfavourable chçmic~1 -reactions which occur. Other salts and resins may also be suitable but those mentioned are the most cheaply and widely available at plesent.
A composition of TIMBOR dissolved in water and ACROCRYL forms an emulsion which gives surI-ri~ing1y good fire resi~nre and rçsi1i~n~ to treated m~teri~1~. There are 15 no problems with pH or low solubility as occurs with other well known boron chemicals which have been tried in the pæt. It also covers and adheres to fibre surfaces particularly well, and has a m~rke~ shelf life stability so need not be used immediately after prep~a~ion. The resin is an acrylic cross-linked variety which is cured at around 70 to 100C once applied.
20 ~ Pr~fe"~ d n~ s for spraying onto a fibrous m~teri~1 sliver during lapping have been found to co~ e a resin çmn1cion with up to 30% by weight of resin solids and up to 30% by weight of an octaborate salt. Most pref~ably lS to 25% by weight of resin solids and l0 to 25% of so~linm octaborate tetrahydrate.
A co...p~ orl oftec~mic~1 data on boric acid, borax and sodium octaborate indicates 25 rather better water solubility characteri~cs for octaborate compounds (l/l9, l/16 and 1/11 g/ml respectively). Further, the pH of an octaborate solution drops to near neutral as concentration increases and no ullfavoulable reactions occur with the m~teri~l~ or resins. This allows a high concc~ on of boron in purely aqueous solutions for immersion of Il~A~ , and in resin emn1~innc which may be sprayed onto the m~tçri~
O~1tct~ndin~ results have been achieved in e~ t~ c~n~ll)cte~l to date using resin compositions on woollen webs or blocks for inq11~tion. An emulsion compricin,~ 20%
ACROCRYL, 18% TIMBOR and the b~1~n~ water by weight was sprayed onto woollen fibres which were then lofted and cured. The resl11tin~. webs were effectively fire resistant wi~ desirable qu~lities of high stiffness and low toxicity with fungicidal and insecticidal 35 properties also.
AMENDED SHEEr
Claims (19)
1. A method of manufacturing fibrous material batts comprising: forming a sliver of dispersed fibrous material lapping the sliver into a moving multilayer mat, spraying the sliver with a fibre bonding agent during lapping, curing the bonding agent on the moving mat, and cutting the mat to form batts of required dimensions and density, characterised in that alternate sides of the sliver are sprayed during lapping, by a pair of spray booms which oscillate with the sliver.
2. A method according to claim 1 further comprising compressing the moving mat to a required thickness after lapping.
3. A method according to claim 1 wherein the spray from each boom is briefly turned off at a turning point of each oscillation when the sliver is closest to the boom.
4. A method according to claim 1 wherein the fibrous material comprises at least 50%
by weight of wool.
by weight of wool.
5. A method according to claim 1 wherein the batts have a density of less than 15 kg/m3.
6. A method according to claim 1 wherein the batts have a density of between 8 and 12 kg/m3.
7. A method according to claim 1 wherein the fibre bonding agent comprises a resin emulsion having less than 30% by weight of resin solids.
8. A method according to claim 1 wherein the fibre bonding agent comprises a resin emulsion having from 15 to 25% by weight of resin solids.
9. A method according to claim 1 wherein the fibre bonding agent comprises an aqueous resin emulsion or solution having less than 30% by weight of an octaborate salt.
10. A method according to claim 1 wherein the fibre bonding agent comprises an aqueous resin emulsion or solution having from 10 to 25% by weight of sodium octaborate tetrahydrate.
11. A method according to claim 1 wherein the spraying takes place with the fibre bonding agent at a temperature of less than 50°C.
12. A method according to claim 1 wherein the spraying takes place with the fibre bonding agent at a temperature of from 25 to 40°C.
13. A method according to claim 1 wherein the curing takes place at a temperature of less than 120°C.
14. A method according to claim 1 wherein the curing takes place at a temperature of from 70 to 100°C.
15. A fibrous material mat or batt formed according to the method of any one of the preceding claims, and having a density of less than 15kg/m3.
16. A fibrous material mat or batt formed according to the method of any one of claims 1 to 14, and having a bonding agent incorporating an octaborate salt.
17. Apparatus for manufacturing fibrous material batts comprising lapping means which forms a sliver of fibrous material into a moving multilayer mat, spraying means which delivers a fibre bonding agent to alternating sides of the sliver during lapping, curing means which heats the bonding agent on the moving mat after lapping of the sliver, and cutting means which severs the mat into batts of required dimensions and density.
18. Apparatus according to claim 17 further comprising compressing means which reduces the moving mat to a required thickness.
19. Apparatus according to claim 17 wherein the spraying means comprises a pair of spray booms which oscillate with the sliver during lapping.
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| NZ248004 | 1993-06-28 | ||
| NZ24800493 | 1993-06-28 | ||
| NZ248456 | 1993-08-20 | ||
| NZ24845693 | 1993-08-20 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2166185A1 true CA2166185A1 (en) | 1995-01-05 |
Family
ID=26651201
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002166185A Abandoned CA2166185A1 (en) | 1993-06-28 | 1994-06-28 | Fibrous material batts |
Country Status (8)
| Country | Link |
|---|---|
| EP (1) | EP0706588B1 (en) |
| JP (1) | JPH09501741A (en) |
| AT (1) | ATE186342T1 (en) |
| AU (1) | AU683898B2 (en) |
| CA (1) | CA2166185A1 (en) |
| DE (1) | DE69421532T2 (en) |
| DK (1) | DK0706588T3 (en) |
| WO (1) | WO1995000691A1 (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE19513815C2 (en) * | 1995-04-12 | 1998-02-19 | Schiller & Partner Gmbh Ingeni | Device for producing finished nonwovens |
Family Cites Families (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4045398A (en) * | 1975-11-24 | 1977-08-30 | Monsanto Company | Resole resin binder composition |
| US4678822A (en) * | 1984-06-21 | 1987-07-07 | Maxwell Victor Lane | Resin impregnated fibre batt |
| JPH01148206A (en) * | 1987-12-04 | 1989-06-09 | Asahi Glass Co Ltd | Carpet |
| US5240766A (en) * | 1992-04-01 | 1993-08-31 | Hollingsworth & Vose Company | Gasket material |
-
1994
- 1994-06-28 AT AT94919022T patent/ATE186342T1/en not_active IP Right Cessation
- 1994-06-28 CA CA002166185A patent/CA2166185A1/en not_active Abandoned
- 1994-06-28 DK DK94919022T patent/DK0706588T3/en active
- 1994-06-28 JP JP7502678A patent/JPH09501741A/en not_active Withdrawn
- 1994-06-28 WO PCT/NZ1994/000067 patent/WO1995000691A1/en active IP Right Grant
- 1994-06-28 EP EP94919022A patent/EP0706588B1/en not_active Expired - Lifetime
- 1994-06-28 AU AU70103/94A patent/AU683898B2/en not_active Ceased
- 1994-06-28 DE DE69421532T patent/DE69421532T2/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| DE69421532D1 (en) | 1999-12-09 |
| DK0706588T3 (en) | 2000-05-08 |
| WO1995000691A1 (en) | 1995-01-05 |
| AU7010394A (en) | 1995-01-17 |
| ATE186342T1 (en) | 1999-11-15 |
| EP0706588A1 (en) | 1996-04-17 |
| DE69421532T2 (en) | 2000-05-25 |
| JPH09501741A (en) | 1997-02-18 |
| EP0706588B1 (en) | 1999-11-03 |
| AU683898B2 (en) | 1997-11-27 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| FZDE | Discontinued |