CN1068375A - The manufacture method of heat insulator - Google Patents

The manufacture method of heat insulator Download PDF

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Publication number
CN1068375A
CN1068375A CN92105495A CN92105495A CN1068375A CN 1068375 A CN1068375 A CN 1068375A CN 92105495 A CN92105495 A CN 92105495A CN 92105495 A CN92105495 A CN 92105495A CN 1068375 A CN1068375 A CN 1068375A
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China
Prior art keywords
fiber
felt
fibre
temperature
viscose
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CN92105495A
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Chinese (zh)
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P·M·蒙克里夫
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COTTON UNLIMITED Inc
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COTTON UNLIMITED Inc
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Publication of CN1068375A publication Critical patent/CN1068375A/en
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    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-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
    • D04H1/54Non-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 welding together the fibres, e.g. by partially melting or dissolving
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-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
    • D04H1/42Non-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
    • D04H1/4382Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • D04H1/43835Mixed fibres, e.g. at least two chemically different fibres or fibre blends
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-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
    • D04H1/42Non-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
    • D04H1/425Cellulose series
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-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
    • D04H1/42Non-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
    • D04H1/4374Non-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

Abstract

A kind of method and apparatus that is used for production low density heat insulation felt.Felt comprise can be softened and the adhesion felt in the viscose fibre of non-conductive fibre and the spacer insulator fiber so that produce the support fiber of air pocket therein.

Description

The manufacture method of heat insulator
The present invention relates to heat insulator and manufacture method thereof.
More particularly, the method and apparatus that the present invention relates to is used for production low density heat insulation felt, and described heat insulation felt comprises low-density non-conductive fibre and viscose fibre, and viscose fibre can be softened and mutually combine with non-conductive fibre in felt.
On the other hand, the method and apparatus that the present invention relates to is to be used to produce the heat insulation felt of being made by non-conductive fibre, wherein also comprises the support fiber, and this fiber and non-conductive fibre interconnect at interval, to limit the gap air pocket in the non-conductive fibre.
The United States Patent (USP) U.S.Patent No.4 of Lightware woods (Lewellin), 678,822 have described a kind of method that is used to produce viscose fibre heat insulation felt.In the method for Lightware woods (Lenellin), make the fiber guipure with carding machine.The fiber guipure is folded into felt through lapper.When the fiber guipure was folded into felt, a kind of RHOPLEX resin emulsion was sprayed onto on the fiber guipure.The felt of being made by lapper is heated so that dry described resin emulsion.The resin that is sprayed on the felt is very important, because Lightware woods (Lewellin) relies on resin to guarantee that felt keeps the integrality of its size and structure.In its patent, Lightware woods (Lewellin) points out that the heat insulation felt made from his method has two big advantages, the glass mat that this heat insulation felt of the first is not insalubrity, and it two is that the occupied space of this heat insulation felt is littler than glass mat.At last, Lightware woods (Lewellin) points out that also the insulation values of his felt equates with glass fibre.The density of the felt of Lightware woods (Lewellin) approximately is 1.51bs/ft.Resin has increased the density of Lightware woods (Lewellin) felt.
When Lightware woods (Lewellin) is described its heat insulation felt and than existing traditional glass mat many advantages is arranged in its patent, but do not mention the problem of producing a kind of low density heat insulation felt, this low density heat insulation felt need not to spray resin so that the non-conductive fibre in the felt is bonded to together.Obviously, reduce the density of heat insulation felt and need not spray the cost that resin can reduce to produce and use felt.A kind of low-density heat insulation felt only needs less manufactured materials and less cost of transportation.
Therefore, people thirst for obtaining a kind of through improved low density heat insulation felt, and this heat insulation felt need not traditional being used for the resin that the non-conductive fibre of felt is bonded to is together sprayed.
Purpose of the present invention just provides a kind of improved method and apparatus, is used to produce heat insulator and a kind of improved heat insulation felt is provided.
Another object of the present invention provides a kind of improved heat insulation felt, and the density of this heat insulation felt is lower significantly than the density of traditional hot insulation felt.
Another object of the present invention provides a kind of method of improved production heat insulation felt, and this method does not need to use the spraying equipment that together felt is carried out the resin spraying for the non-conductive fibre in the felt is bonded to.
A further object of the invention just provides a kind of improved non-conductive fibre mixture, and this mixture uses corresponding support fiber so that the non-conductive fibre space links, thereby guarantees the gap air pocket between non-conductive fibre.
In addition, a further object of the invention, provide a kind of improved non-conductive fibre mixture that comprises viscose fibre, the softening temperature of described viscose fibre is lower than the fusion temperature of the non-conductive fibre that is in the great majority in felt, described insulation felt be heated to above binder fiber softening temperature, be lower than the fusion temperature of non-conductive fibre, viscose fibre is softening also can be bonded on the non-conductive fibre so that make, and it is mutually combined.
These and other purpose of the present invention and advantage, for a person skilled in the art, will be more obvious by following detailed description with the accompanying drawing.
Fig. 1 is the process description schematic diagram of heat insulation felt making method of the present invention;
Fig. 2 is the process description schematic diagram of the heat insulation felt making method of an alternative embodiment of the present invention;
Fig. 3 and 4 is schematic diagrames of another alternative embodiment of the present invention.
In brief, the invention provides a kind of method that is used to make the heat insulation felt, this method is included in first step of selecting temperature that viscose fibre is mixed with non-conductive fibre, viscose fibre has sticking temperature, when it is in this temperature, viscose fibre softens and is bonded on the non-conductive fibre, non-conductive fibre is to select from one group of synthetic and natural fabric that has than the high fusion temperature of fiber sticking temperature that bonds, in its fusion temperature, have at least a part to melt in the non-conductive fibre, described sticking temperature is higher than 130 and the ratio first selection temperature height; Carry out the blended fiber operation so that form felt in the second selection temperature that is lower than sticking temperature, heat described felt, make its temperature be greater than or equal to sticking temperature and be lower than fusion temperature, so just can make viscose fibre softening and be bonded on the non-conductive fibre, non-conductive fibre is mutually combined together, with, cool off described felt, so that the viscose fibre that sclerosis has been softened.
A kind of method of improved production heat insulation felt is provided in another embodiment of the present invention.This method comprises: (a) select temperature to implement non-conductive fibre is made the step of the fiber guipure with certain selection thickness first, non-conductive fibre is to select from one group of synthetic or natural fabric with certain fusion temperature, in fusion temperature, have the fusing of SI semi-insulation fiber at least, described fusion temperature is higher than first and selects temperature; (b) select temperature that the fiber guipure is transported to be folded on the lapper second and have the felt thicker: (c) select temperature the fiber guipure to be folded into felt than fiber web tape thickness by lapper the 3rd than the thickness of fiber guipure; (d) select temperature that felt is transported to a heater from lapper the 4th and heat, make the temperature of felt be greater than or equal to the selection softening temperature and be lower than described fusion temperature; (e) from selecting a step at least step by (b), (c) and this group of (d) forming, when this step is carried out, viscose fibre is placed on the felt, selecting the softening temperature viscose fibre to soften and be bonded on the non-conductive fibre, this softening temperature greater than 130 °F, less than fusion temperature, and greater than (b), (c) and (d) the selected temperature of step, in (b), (c) and (d) step in the step, select temperature that viscose fibre is placed on the felt at it; (f) by a heater felt is heated, make its temperature be greater than or equal to the softening temperature of selection and be lower than fusion temperature, viscose fibre just can soften and be bonded to and is attached to together on the non-conductive fibre and non-conductive fibre like this; (g) cooling felt is so that make softening viscose fibre sclerosis.
Refer now to accompanying drawing, accompanying drawing does not just limit the scope of the invention for the preferred embodiment of the present invention is described.Fig. 1 illustrates a kind of method of production heat insulation felt, and in Fig. 1, the bale of cotton 1 or other non-conductive fibre or " loosing " fiber are at first packaged and be separated into the fiber of single or little component by funneling baling press 2.Funneling baling press in addition is used to open viscose fibre, supports fiber or other fiber, goes so that these fibers are added or be mixed in the fiber by above-mentioned funneling baling press 2 processing.The fiber that is provided by funneling baling press 2 directly is transported in the mixing opener 4.Viscose fibre, support fiber or other non-conductive fibre and can join with the ratio of any serious hope with the non-conductive fibre 3 that provides by funneling baling press 2 and mix in the opener 4.The fiber of exporting from mix opener 4 is transferred device 5 and is transported in the picker 6.The loose fiber guipure that picker 6 is made is wound into a roll 7, volume 7 is carried and is fed in the revolving flats carding machine 9 by transport 8.Carding machine 9 comprises the feeding roller 10 that has the pin tooth, and described pin tooth removes the fubril bundle on the fiber guipure.Master rotor 11 also has the pin tooth and is used to divest by the fubril bundle on the fiber of feeding roller input.The narrow pecten 12 that is driven by belt passing round 13 has the pin tooth, is used to carry out combing work and removes impurity.Be input to the lapper 16 around doffer 14 operations and by transport 15 from the fiber guipure of master rotor 11 outputs.Lapper 16 is made fiber guipure 15 on the felt of desired thickness.The preferably overlapping lapper of lapper 16, but also can be any traditional lapper.Similarly, carding machine 9, picker 6 mixes opener 4 and baling press 2 and also can be replaced by any traditional device, but these conventional apparatus must be similar with apparatus of the present invention, can implement the operation of the inventive method to non-conductive fibre, support fiber and viscose fibre.The felt of being made by lapper 16 is transported in the bonding baking oven 18 by transport 17, felt is heated to the softening temperature of viscose fibre that is enough to make in the felt.When viscose fibre is softening.Viscose fibre just is bonded on the non-conductive fibre and non-conductive fibre is bondd mutually.Viscose fibre can mix with non-conductive fibre in mixing opener 4, also can be in the process that the fiber guipure is transported to lapper 16 by transport 15 or in the process that folds in lapper 16 and in fiber guipure that handle folded or felt are transported to baking oven 18 by transport 17 process viscose fibre is added on the fiber guipure.Having passed through heat treated felt in baking oven 18 is cooled and is transported on the other work station 20 by transport 19.Work station 20 can or dust by spraying felt is applied fire retardant.Common fire retardant comprises borax (borates), aluminium hydroxide (aluminum hydrate), halogenated hydrocarbon (halogonated hgdrocarbons) and decabrominated dipheny base ether (decabromo diphonsyl dcther), also can add chemical preservative and go mouldy and insect bite preventing on felt.If desired, can be before carding machine 9 be made the fiber guipure any appropriate operation or make the fiber guipure after these fire retardants and chemical preservative are joined on the fiber guipure.
Another working procedure of work station 20 is the cutting felt, and felt can be cut into short section, felt and other any desirable shape and size.
The non-conductive fibre that mixes in the opener 4 that is added into shown in Figure 1 can be selected from following natural fabric, as selecting from cotton fiber, wool fibre, linen fibre, tossa, Angora goat wool fibre, cocoon fiber, ramee, hemp and asbestos fibre, perhaps from following synthetic fiber, select, as from viscose, acetate fiber, nylon fiber, polyester fiber, polyene fiber, polyacrylonitrile fibre, Wei Nilun fiber, poly fiber or other monomer polyacrylonitrile fibre, polyacrylonitrile fibre and polyamide fiber, selecting.Joining the ratio of mixing the non-conductive fibre in the opener 4 can change as required, generally is the scope of percentage by weight 0 to 95%.Mention as top, viscose fibre will be added in the non-conductive fibre and go.Being added to the proportion that mixes the viscose fibre in the opener 4 is 2% to 8% of non-conductive fibre weight.The softening temperature of viscose fibre is all lower than joining the fusion temperature of mixing any non-conductive fibre in the opener 4.When the felt of sending here from lapper 16 passed through baking oven 18, temperature of oven was heated to the softening temperature that is equal to or higher than viscose fibre and the fusion temperature that is lower than non-conductive fibre.Like this, the viscose fibre in the baking oven 18 is with regard to deliquescing and adhere on the non-conductive fibre and arrive together non-conductive fibre is inter-adhesive.In this article, term " softens " and means viscose fibre when being used for viscose fibre and be heated to one and select temperature and begin to lose its hardness deliquescing and/or fusing, be bonded to together thereby adhere on the non-conductive fibre and, be cooled to 78 of room temperatures subsequently again non-conductive fibre.Some viscose fibre just can become before fusing and have " viscosity " and adhere on the non-conductive fibre.And other viscose fibres just can be bonded on the non-conductive fibre after must being melted.The viscose fibre of fusing and softening " viscosity " viscose fibre all comprise the viscose fibre of " softening ".Current best viscose fibre is a polyester fiber.Any other desirable synthetic fiber or natural fabric can both be used as viscose fibre.
The application of known polyester fiber is to be used to link products such as medical liner and women's towel.In this application, polyester fiber forms one deck water barrier.For example, polyester fiber forms the back side at operating room on medical liner.On the DOTEX sanltary towel, polyester partly forms water barrier along the interior adsorption layer of sanitary napkin.This application does not relate to thermal insulation products, does not point out the effect of the polyester viscose fibre of the inventive method yet.
Can be earlier join viscose fibre on the volume 7, perhaps viscose fibre be joined on the fiber guipure making the arbitrary step of process that fiber web takes heating felt in baking oven 18 to by carding machine 9.The fusion temperature of viscose fibre can be in being higher than the inventive method changes in the scope of temperature of machine 4,6 and 16 processing viscose fibres, till felt is placed in the baking oven 18 heating, and the fusion temperature of non-conductive fibre is higher than the softening temperature of viscose fibre, and described softening temperature is 130 °F at least.The softening temperature of viscose fibre be if to be lower than 130 °F will be inappropriate because in summer if be kept at this binding material in the storehouse that does not have air-conditioning or do not have will cause in the compartment of air-conditioning binding material softening or melt.The optimum fusion temperature scope of viscose fibre is 180 °F to 450 °F.Viscose fibre can be the pattern of actual fibers, also can be the powder pattern of being made by fiber, or the powder of being made by the material that is used to make fiber.Add viscose fibre with powder type, particularly in mixing opener 4, add the viscose fibre powder and have many advantages.On the contrary, the most of non-conductive fibre that is included in the felt should be the actual fibers form.Otherwise baling press, mixing opener 4, picker 6 and carding machine 9 etc. can not be processed non-conductive fibre.The length range of viscose fibre is 0.5 to 2.0 inch, preferably 1.5 inches.The 410(Eastman kodak of Eastman Kodak 410) viscose fibre is the best viscose fibre in the invention process.
The length of implementing the used non-conductive fibre of the present invention is 0.5 inch or longer, and its typical length range is 0.5 inch to 1.5 inches long.Non-conductive fibre surpassed for 3.0 dawn, but 3.0 dawn or less preferably, because the heat insulation felt of being produced is quite light.When using cotton fiber, preferably select the cotton fiber in 2.4 to the 3.0 dawn scopes for use.Though carding machine can be produced thicker or thinner fiber guipure, by the fiber guipure that carding machine 9 is produced, preferably 1/16 inch to 3/16 inch of its thickness range.As illustrative method, when using 2.5 meters working width MASTERCARD of Hollingsworth carding machine, the pin tooth of feeding roller 10 is 40 to 50 teeth per square inch, preferably 50 teeth per square inch, its operating angle is 15 ° to 25 ° degree, preferably 20 ° of degree; The pin tooth of master rotor 11 is 300 to 700 tooth scopes per square inch.500 teeth per square inch preferably, its operating angle is 17 ° to 27 ° degree, preferably 22 ° of degree; The pin tooth of doffer 14 is 150 to 250 tooth scopes per square inch, 250 teeth per square inch preferably, and its operating angle is 17 ° to 27 ° degree, preferably 22 ° of degree.If be ready, can use in many carding machine 9 producd fibers guipures feeding lappers 16.Also can or relatively become the net loom to replace carding machine 9 with random web-laying equipment, knot breaker.The air lay function is produced heavier inhomogeneous fiber guipure.The air pocket of the fiber guipure that knot breaker is produced is bigger than the air pocket of the fiber guipure of being produced by carding machine 9.Implementing to use carding machine when of the present invention is best, because carding machine defibre and can produce relatively all reticular fibre guipures that includes the fiber that extends in parallel of even and fine matter respectively.These fibre bundles that extend in parallel account for 80% to 85% of whole fiber guipure weight, or more some more, and the fibre bundle of all the other weight of the fiber guipure then fibre bundle of opposing parallel extension is arranged at an angle and is connected with the fibre bundle that extends in parallel.Therefore, when the fiber guipure of being made by carding machine 9 passes lapper 16, each of the felt that is folded into layer fiber guipure that continue all has one and is parallel to the longitudinal axis that is included in the most fibre bundle that extends in parallel in the fiber guipure, this longitudinal axis is longitudinal axis rotation 20 ° to 60 ° degree, preferably 30 ° of degree of its preceding one deck fiber web belt in felt relatively.
When the fiber guipure of being produced by carding machine 9 was folding by lapper 16, supporting fiber can be diffused on that layer fiber guipure that folded before on that layer fiber guipure that first had folded in that lapper 16 is with cover another layer fiber web.This support fiber is 1/16 inch to 3/8 inch long, preferably 1/8 inch to 1/4 inch long.The effect of supporting fiber is to support spaced apart certain space between the folding adjacent fiber guipure layer that makes in the felt by diffusion.When felt was heated in baking oven 18, the viscose fibre that has softened adhered to and supports on fiber and the non-conductive fibre and they are linked mutually.When on the fiber guipure, applying the support fiber, also can apply extra viscose fibre with supporting fiber, be beneficial to support fiber and mix with non-conductive fibre.Be preferably in the process of lapper 16 folded fibre guipures and be placed on the fiber web belt supporting a fiber, because support like this fiber be easy to rely on lower floor's fiber guipure above, so that lower floor's fiber guipure and above it adjacent that layer fiber guipure separate, thereby form supporting layer.When felt was heated in baking oven 18, supporting layer was connected on the non-conductive fibre, and the support fiber that occupy adjacent two layers fiber web interband keeps a scope between 1/32 inch to 1/8 inch, preferably 1/16 inch space.Insulating materials produced according to the invention has wherein reduced the weight of insulating materials by supporting the space that is positioned at the fiber web interband that fiber produces to increase the volume of insulating materials significantly.If be ready, support fiber and can be placed in to mix in the opener 4 and mixes with long non-conductive fibre, perhaps the arbitrary step in the operation process of the present invention the fiber guipure is made into and leaves carding machine 9 after spreads the support fiber or is applied on the fiber guipure.KODAFIL 435 is a kind of synthetic fiber that can be used as the support fiber, and as cotton fiber, it has 1/8 inch length to 3/8 inch scope.As non-conductive fibre, support fiber and also have a fusing point or fusion temperature, this fusing point or fusion temperature are higher than the softening temperature of the viscose fibre that uses in the heat insulation felt of the present invention.
Fig. 2 illustrates an alternative embodiment of the invention, and wherein the bale of cotton 1 or other non-conductive fibre or " loosing " fiber are at first packaged and be separated into the fibre bundle of single or little component by funneling baling press 2.Funneling baling press in addition is used to open viscose fibre, supports fiber or other fiber, goes so that these fibers are added or be mixed in the fiber that is produced by above-mentioned funneling baling press 2.The fiber that is provided by funneling baling press 2 directly is transported in the mixing opener 4.Viscose fibre, support fiber or other non-conductive fibre and can join with the ratio of any serious hope with the non-conductive fibre 3 that provides by funneling baling press 2 and mix in the opener 4.Be transported to the dispersion funnel 23 of opener 21 by transport 5 from the fiber that mixes output in the opener 4.The fiber 36 of mixing chamber 33 of falling into opener 21 by funnel is by eddy current 37 mixing, the tearing that are produced by a branch of at least input air-flow 22 and separate.Air-flow 22 also can come opening fiber by making fiber impact agitator as shown in opener 4 or grid or some other structure member.Air-flow 22 inlet chambers 33 backs are along the direction inlet chamber 34 of arrow 24 indications.The air-flow 24 of inlet chamber 34 is divided into two-way, and one road air-flow 26 is discharged by steam vent 25, and another road air-flow 28 is discharged by steam vent 38.Hinged air door 27 is covered with steam vent 38.The blended fiber 36 of being brought in the chamber 34 by air-flow 24 is placed in or takes on the rectangle steel plate 31.Vibrating device 32 vibration steel plates 31 are so that compacting concentrates on the fiber 36 on the steel plate 31.Fiber on steel plate 31 has reached enough weight, and conveyer 30 will start outwards being exported by steam vent 38 along the direction of arrow 40 by the fibroplastic felt 29 of compacting.Air-flow 28 also promotes to concentrate on fiber compacting on the steel plate 31 with respect to the pressure of the fiber on the steel plate 31 36.The compacting pressure of air-flow 28 may be exempted the use of vibrating device 32.Other tamping unit also can or separate use with air-flow 28 and vibrating device 32 associatings, so that compacting and blended fiber.Steel plate 31 rests on scale or the Weight apparatus, so that determine to be collected in the weight of the fiber on the steel plate 31.The weight of measuring when Weight apparatus has reached selective value, and then conveyer 30 is started working, and the felt 29 that forms on steel plate 31 is exported chamber 34 in the direction of arrow A.If be ready, conveyer 30 can be the felt of being made by opener 21 the long felt shape output of unidirectional extension continuously.Felt 29 is transferred machine 30 and sends in the baking oven 18 and heat-treat.That exports from baking oven will be cooled and be transported in the attachment station 20 through heat treated felt 29.In attachment station 20, felt is applied fire retardant, perhaps on felt, apply chemical preservative in case go mouldy or bitten by insect by the spraying or the mode of dusting.Other working procedure of being engaged in by work station 20 is the cutting felt.Can cut into short section, felt and other any desirable shape and size to felt.
The conventional method of production heat insulation felt is to use carding machine 9.And technology shown in Figure 2 need not be used carding machine, and its productivity ratio is high five times by the productivity ratio of conventional method heat production in the next life insulation felt that uses carding machine.The essential characteristic of method shown in Figure 2 is to use one or more openers to make the heat insulation felt and the heat insulation felt is directly sent into baking oven 18.As described herein, opener is that a kind of using gases eddy current and agitator, grid or other device mix and defibre, but also can comprise be used to collect and at least in part compacting mixed random towards fiber to form the device of loose felt.Opener 21 and opener 4 are examples of opener.
Specification, quantity and the ratio of the employed non-conductive fibre of method shown in Figure 1, viscose fibre and support fiber can be used for method shown in Figure 2 equally.The weight percentage ranges of the support fiber in the felt of producing according to the method for Fig. 2 preferably 5% to 20%.
According to 3.5 inches thick heat insulation felts that the method for Fig. 2 is produced, it is 11(R Value of 11 with the R value that its weight approximately is 2 to 2.5 ounces every square feet).
The thickness range of felt 29 is 1 to 8 inch.
Opener 21 comprises the Whecls by John d.Hollingsworth on, Inc.of Greenville, sc 29602-0516, the VIBRACHUTE CARD FEEDER. that U.S.A produces
The following example that provides is not in order to limit scope of the present invention, but for the preferred embodiment of the present invention various variations and difference with the prior art thereof in force is described to those skilled in the art.
Example 1
Selection has 7/8 inch long cotton fiber as non-conductive fibre.Have 1/8 inch to 1/4 inch long to roll cotton linters and cotton linter selected as supporting fiber.The D-262(E.I.du pont Dacron D-262 of Du Pont) polyester fiber is selected as viscose fibre.Non-conductive fibre and support fiber were 2.8 dawn.Polyester fiber is that 1.8 dawn, elongation are 200,1.5 inches of length, fusing point 142 ℃ (softening in the time of 78 ℃) are 155 ℃ (surfaces) with the sticking temperature of relative cotton, and promptly Dacron D-262 polyester is bonded on the cotton fiber when being heated to 155 ℃.The fusing point of non-conductive fibre is higher than 160 ℃.
Method with Fig. 1 is made felt.Place non-conductive fibre, support fiber and viscose fibre mixing opener 4 to mix, and be processed into the fiber guipure, through transport 15 the fiber guipures of making are delivered in the lapper 16 again by picker 6 and carding machine 9.Non-conductive fibre accounts for 60% of whole blended fiber weight; Cotton linters (support fiber) accounts for 20% of whole blended fiber weight; And the bonding particle accounts for 20% of whole blended fiber weight and is delivered in the baking oven 18 by transport 17 by lapper 16 finished felts.In baking oven 18, felt is heated to the temperature that is equal to or higher than 155 ℃ so that the polyester viscose fibre is softening and be bonded to non-conductive fibre and support on the fiber.After felt is removed from baking oven 18 and cooled off, with cutter sweep felt is cut into 6 feet long section again and package.Felt has the density of 2.9 inches thick, 1 foot wide and every cubic feet heavy 8 ounces like this.The thickness of felt, length and width can change as required.The insulation values of felt or title " R value " are R-11." R value " expression 1 BTU when existing the difference of 1 Fahrenheit temperature between two relative outer surfaces of insulator of insulating materials passes through 1 square feet of hourage that area is required.
Light and R value is greatly than the glass fibre felt of same size by the felt of 2.9 inches thick R-11 of this examples produce.
Example 2
Select 1 inch long cotton fiber, 7/8 inch long wool fibre and 1.5 inches long viscoses as non-conductive fibre.Select its length range in 1/8 inch to 1/4 inch scope cotton linters and polyacrylonitrile fibre as supporting fiber.The selection D-262(E.I.du pont D-262 of Du Pont) polyester fiber is as viscose fibre.Described non-conductive fibre and support fiber were 2.6 dawn.Described polyester fiber is that 2.2 dawn, percentage elongation are 200, its length is 1 inch, its fusing point is 142 ℃ (softening in the time of 78 ℃), this polyester fiber is 155 ℃ (surfaces) with respect to the sticking temperature of cotton fiber, is 120 ℃ with respect to the sticking temperature of viscose.The fusing point of non-conductive fibre is higher than 160 ℃.
Method with Fig. 1 is produced felt.Non-conductive fibre and viscose fibre are placed 4 mixing of mixing opener and be processed into the fiber guipure by picker 6 and carding machine 9, the fiber guipure is sent into lapper 16 by transport 15.Support fiber and viscose fibre are mixed separately form support-viscose fibre mixture.Non-conductive fibre accounts for 70% of whole weight in the fiber guipure of being made by carding machine 9, and viscose fibre accounts for 30% of the whole weight of fiber guipure made by carding machine 9.Support fiber account for support-viscose fibre mixture whole 60%, and viscose fibre accounts for 40% of support-whole weight of viscose fibre mixture.When the fiber guipure of being made by carding machine 9 is folded by lapper 16, one deck is had 1/8 inch to 1/4 inch thick support-viscose fibre mixture expand on the upper horizontal surface that is arranged in every layer of lapper 1.6 fiber guipure.Lapper 16 under one deck fiber web band one deck is supported before folding into that layer fiber guipure upper horizontal surface that has folded-the viscose fibre mixture expands on that layer fiber guipure upper horizontal surface that this layer folded.Like this, the felt after lapper 16 processing is a stratiform sandwich, all clips 1/8 inch to 1/4 inch thick support-viscose fibre layer of one deck between the fiber web belt of its every phase adjacency pair level trend.
The felt of being made by lapper 16 is put into baking oven 18 be heated to 120 ℃, so that viscose fibre is softening and adhere to cotton and the viscose glue non-conductive fibre gets on.After viscose fibre has adhered on the non-conductive fibre, felt is shifted out from baking oven and cool off.At work station 20 felt is cut into 50 inches long section, and be rolled into and involve in row packing.This felt have 2.9 inches thick, 1 foot wide, its R value approximately is 12.Can change thickness, width and the length of felt as required.In felt, support fiber and make the about 1/8 inch space of maintenance between adjacent fiber web belt.Support-viscose fibre the mixture that joins in the felt accounts for 15% of the good felt gross weight of manufacturing, and the insulation in the fiber guipure-viscose fibre mixture accounts for 85% of whole felt weight.The density of felt is every cubic feet heavy 7 ounces.
According to the insulation felt that the inventive method is made, support fiber wherein accounts for 1% to 50% of felt weight.Preferably support particle and account for 5% to 20% of felt weight.
When the cotton felt of example 2 is 5 inches when thick, the R value of this felt approximately is 19.And glass fibre felt must be 6 inches when thick, and its R value just can reach 19.When the cotton felt of example 2 is 7.9 inches when thick, its R value is 30.When the cotton felt of example 2 is 2.9 inches when thick, its R value is 11 as described.3.5 the thick glass fibre felt weight of inch is every square feet of non-conductive fibre 0.23 lbs.2.9 the cotton insulation felt weight of the example 2 that inch is thick is every square feet of insulating materials 0.12 lbs.
Example 3
Select 7/8 inch long cotton fiber as non-conductive fibre.Select the cotton linters of length range in 1/8 inch to 1/4 inch as supporting fiber.The selection D-262(E.I.du Pont Dacron D-262 of Du Pont) polyester fiber is as viscose fibre.Non-conductive fibre and support fiber were 2.8 dawn.Polyester fiber was 1.8 dawn, percentage elongation is 200, and length is 1.5 inches, and its fusing point is 142 ℃ (softening at 78 ℃), it is 155 ℃ (surfaces) with respect to the sticking temperature of cotton fiber, and promptly Dacron D-262 polyester fiber is bonded on the cotton fiber when being heated to 155 ℃.The fusing point of non-conductive fibre is higher than 160 ℃.
Utilize a kind of felt of device fabrication shown in Figure 2.If be ready and suitable, can use funneling baling press 2 shredding non-conductive fibres, support fiber or viscose fibre.In mixing opener 4, non-conductive fibre, support fiber and viscose fibre are mixed, and be processed into the fiber guipure, described fiber guipure is sent in the lapper 16 by transport 15 by picker 6 and carding machine 9.Non-conductive fibre accounts for 55% of whole blended fiber weight; Cotton linters accounts for 15% of whole blended fiber weight; And viscose fibre accounts for 30% of whole blended fiber weight.Deliver to the dispersion funnel 23 of opener 21 by transport 5 from the blended fiber of mixing output in the opener 4.The fiber 36 of falling into chamber 33 by funnel 23 is mixed stirring by the air-flow 22 of aforementioned the sort of mode.Air-flow 22 inlet chambers 33 backs are along the direction inlet chamber 34 of arrow 24 indications.The air-flow 24 of inlet chamber 34 is divided into two-way, and one road air-flow 26 is discharged by steam vent 25, and another road air-flow 28 is discharged by steam vent 38.Bringing the blended fiber 36 that stirred in the chamber 34 into by air-flow 24 is placed in or takes on the rectangle steel plate 31.Vibrating device 32 vibration steel plates 31 are so that compacting concentrates on the fiber 36 on the steel plate 31.Fiber on steel plate 31 has reached enough weight, and conveyer 30 will start outwards being exported by steam vent 38 along the direction of arrow 40 by the fibroplastic felt 29 of compacting.Felt 29 by conveyer 30 outputs is sent into baking oven 18 by transport 35 again.In baking oven 18, felt 29 is heated to and is equal to or higher than 155 ℃ temperature, so that polyester fiber is softening and be bonded to non-conductive fibre and support on the fiber.When the temperature in the baking oven 18 was higher than n155 °F, this temperature can not melt non-conductive fibre and support fiber.After shifting out, felt 29 is cooled to room temperature from baking oven 18.After this felt 29 is with device to be cut 20 cutting or the processing step that carries out other selection.
In the embodiments of the invention of explanation, the blended fiber of being exported by opener 4 is blown into maintenance case 42 by high pressure draught 5 from conduit 41 in Fig. 3 and 4.The pressure of employed high pressure draught is quite high, is generally 3000 to 7000 cubic feet of per minutes.So high stream pressure is very important, because high pressure draught can be the fiber tamping in keeping case 42.In Fig. 3,4, gas is discharged from keep case 42 along the arrow A direction by net wall 50.Pin discaling roll 43 is loosely hauled out the fiber 57 of compacting from keep case 42.The tooth bar 54 that outwards stretches on roller 44 outer circumference surfaces is being drawn the fiber of being sent here by pin discaling roll 43 57, and they are sent into chute feeding forming box 45.Gravity and roller 43,44,47 and 48 are moved down into fiber by chute feeding forming box 45.When fiber 57 moves through chute feeding forming box 45, bounce plate 46 and do reciprocal slamming along the arrow C direction, the extruding of the antetheca 56 of fiber 51 relative chute feeding forming boxes 45 is made real and form felt 51.Grovved roll 47 is hauled out felt 51 from chute feeding forming box 45.Grovved roll 48 continues the dilatory felt of being sent here by roller 47 51, and felt 51 is compressed between roller 48 and fixing arc support plate 55.The felt 51 of compression runs on the belt conveyor 30 and is delivered in the baking oven 18 along direction shown in the arrow 35 by belt conveyor 30 and (do not show among Fig. 3 and Fig. 4).Belt conveyor 30 is carried felt 51 with the speed of 20 feet to 60 feet of per minutes.On the contrary, be used for only moving with the speed of 10 feet to 15 feet of per minutes from the belt conveyor of carding machine output material.In Fig. 3, the groove line of extension has for the sake of clarity been handled with regard to simplifying on the outwardly directed pin tooth of roller 43, the outwardly directed tooth bar of roller 44 and roller 47 and 48.Roller 47 and each groove line of 48 all comprise the elongated slot of extension, these elongated slots are substantially perpendicular on the roller certain any tangent line, these elongated slots connect into the external peripheral surface of roller, and along with from the reducing of roller external peripheral surface distance, the sidewall slope of elongated slot stretch compile gradually tapered.Show the taper of each groove line among Fig. 4 significantly.The vibration velocity of plate 46 is per minute reciprocating motion 40 to 80 times.Roller 43,44,47 and 48 speed motion felts 51 with 20 feet to 60 feet of per minutes.
Amount by conduit 21 feeding fiber in keeping case 42 should be to produce the felt 51 with every cubic feet of required weight.For example, if the width D of chute feeding forming box 45 is 90 inches, the width of the felt 51 produced of chute feeding forming box 45 is exactly 90 inches so thus, and it is thick and with every cubic feet heavy 6 ounces felt 51 of the speed output of 20 feet of per minutes therefore need just to produce 90 inches wide, 4 inches with input quantity input fiber in keeping case 42 of 1124 pounds per hour by conduit 21.The felt that is gone out by the device fabrication of Figure 4 and 5 is necessary for every cubic feet of felt and weighs 6 ounces at least, preferably 6 to 15 ounces every cubic feet.When wanting to produce the lighter felt of every cubic feet of weight, the fiber that then is input to chute feeding forming box 45 need not be bounced plate 46 compactings.If the thickness of the felt shown in the arrow T equals 4 inches among Fig. 4, then every square feet of 4 inches felts weighs 2 ounces at least, that is, and and every cubic feet heavy 6 ounces at least on felt 51.
The thickness T of the felt of making by chute feeding forming box 45 51, its scope be about 1/4 inch to the width that keeps case.The width of the chute feeding forming box of being represented by arrow F among Fig. 3 45 is about 8 inches, and the height of the chute feeding forming box of being represented by arrow E 45 is about 18 inches.
The great advantage of the method and apparatus of Figure 4 and 5 is, it for example can produce 4 inches thick every cubic feet heavy 6 ounces the felt with 20 feet of per minutes or bigger speed output.And produce similar felt with carding machine, the output speed of its carding machine must be that 10 feet of per minutes and alternate folding four times are to produce 8 layers, 4 inches thick, every cubic feet of great about 3.6 to 4.5 ounces felts.
Along with the felt 51 processed speed that move through chute feeding forming box 45 increase, the possibility that occurs part " reduction " zone on the felt 51 also will increase, and the density in described " reduction " zone or the other parts of weight ratio felt are little.Above-mentioned phenomenon appears when the speed of high-speed production felt surpasses 50 feet of per minutes especially easily.When felt 51 moves through the machine shown in the Figure 4 and 5 with high like this speed, can use the machine shown in two or many Figure 4 and 5 simultaneously, the felt of exporting from a machine just can align and be stacked on the felt of exporting from other machine like this, makes the felt with two-layer or multilayer with this.So just need not be folded in a felt on the other parts felt but simply this felt is put into the lengthy motion picture that forms a unfolded on other felt.Every layer of this kind felt all is adjacent layer approximately uniform elongate in shape and size is equally arranged.When the multilayer felt is placed in when heating in the baking oven 18, bonding each stacked layer mutually of viscose fibre.In this structure, one deck zero defect layer wherein can cover and compensate other defective layer with the zone that is lower than required weight or density.Every layer can not have same " reduction " or low weight zone in same area with adjacent bed.If because certain reason, and adjacent layer is along having occurred same low weight defect area in its longitudinally same area, then should be wherein one being placed on another above layer the time, stagger in the low weight zone that makes the low weight zone of one deck wherein be adjacent that layer.The lamination felt of many productions of machinery shown in the Figure 4 and 5 has compensated the fault of construction of individual layer felt, and be easy to high-speed production thick or the high density felt.The high density felt can be by making thick felt and with roller thick felt compression being produced.
This paper has described invention and preferred embodiments thereof in detail, can understand foregoing description for a person skilled in the art and can implement the present invention.Be appreciated that according to essence of the present invention and can also carry out various changes that these all will belong to the present invention and attached claim institute restricted portion thereof to the present invention.

Claims (12)

1, a kind of method that is used for production heat insulation felt, its feature comprises the steps:
(a) in fibre-opening unit having, select temperature that viscose fibre and non-conductive fibre are mixed with first, wherein viscose fibre has a sticking temperature, viscose fibre softens and adheres on the non-conductive fibre under this temperature, described non-conductive fibre comprises synthetic fiber and the natural fabric from one group to be selected, this fiber has the fusion temperature higher than described sticking temperature, down to the fusing of small part non-conductive fibre, described sticking temperature is higher than the mixing temperature of described selection in this temperature.Wherein said fibre-opening unit having comprises:
(ⅰ) mixing chamber;
(ⅱ) be used for the device of described viscose fibre and non-conductive fibre feeding mixing chamber,
(ⅲ) a branch of air-flow of guiding enters described mixing chamber so that produce the device that eddy current is used to mix viscose fibre and non-conductive fibre therein;
(ⅳ) a branch of output gas flow is delivering described viscose fibre and the non-conductive fibre that has mixed;
(b) the described output gas flow of guiding enters felt and forms device and comprise the felt of non-conductive fibre and viscose fibre with formation, and described felt forms device and comprises:
(ⅰ) keep case, be used to receive described output gas flow and collect described non-conductive fibre and viscose fibre;
(ⅱ) be used for non-conductive fibre and viscose fibre are transported to the device of chute feeding forming box from keeping case;
(ⅲ) be used for moving the device of described fiber by chute feeding forming box;
(ⅳ) be used for described fiber being compressed into during by chute feeding forming box the device of felt at described fiber movement;
(ⅴ) be used for device that described felt is discharged from described chute feeding forming box,
The delivery of described output gas flow enters a certain amount of fiber that described felt forms device should be enough to produce and have every cubic feet of weight and surpass 6 ounces felt, and described discharger is discharged felt from described chute feeding forming box speed should be greater than 20 feet of per minutes;
(c) felt of described discharge is heated to is equal to or higher than described sticking temperature, is lower than described fusion temperature, so that described viscose fibre is softening and adhere on the described non-conductive fibre and inter-adhesive described non-conductive fibre; With
(d) the described felt of cooling is with the described viscose fibre that has softened that hardens.
2, according to the method for claim 1, it is characterized in that, in step (a), mix with described non-conductive fibre and viscose fibre supporting fiber, described support fiber has second fusion temperature, described viscose fibre is softening and adhere on the described non-conductive fibre at described selection softening temperature, and described softening temperature is less than first and second fusion temperatures.
According to the method for claim 2, it is characterized in that 3, described support fiber respectively has 1/8 to 3/8 inch long.
According to the method for claim 3, it is characterized in that 4, described non-conductive fibre is a cotton fiber.
According to the method for claim 1, it is characterized in that 5, described non-conductive fibre is a cotton fiber.
According to the method for claim 2, it is characterized in that 6, described non-conductive fibre is a cotton fiber.
According to the method for claim 4, it is characterized in that 7, the thickness of described felt is greater than 2 inches.
According to the method for claim 5, it is characterized in that 8, the thickness of described felt is greater than 2 inches.
According to the method for claim 6, it is characterized in that 9, the thickness of described felt is greater than 2 inches.
10, a kind of method that is used for production heat insulation felt, its feature comprises the steps:
(a) in fibre-opening unit having, select temperature that viscose fibre and non-conductive fibre are mixed viscose fibre and non-conductive fibre mixture to form random arrangement with first, described non-conductive fibre has one with the appearanceization temperature, has the described non-conductive fibre fusing of part at least in this fusion temperature, described fusion temperature is higher than described first and selects temperature, described viscose fibre has a sticking temperature, softening and be bonded on the described non-conductive fibre at the described viscose fibre of this temperature, described sticking temperature is higher than 130 °F, be higher than described selection mixing temperature and be lower than described fusion temperature;
(b) described blended fiber is fed into is processed into the fiber guipure in the processing unit (plant);
(c) select temperature that described fiber guipure is transported to second and be folded into felt in the lapper, described felt has:
(ⅰ) many overlapped fiber web belts and
(ⅱ) its thickness is thicker than the thickness of fiber guipure;
(d) select temperature to fold described fiber guipure to form one of described overlapping fiber web belt the 3rd with lapper;
(e) fiber being supported at the interval of one deck irregular alignment is put on one deck in the overlapping fiber web belt and abuts against on the end face of this layer;
(f) with the folding described fiber guipure of described lapper, another layer that forms described overlapping fiber web belt covers described support fibrage and engages;
(g) select temperature that the felt from lapper output is transported to the heater the 4th, felt is heated to sticking temperature, described felt junction temperature is;
(ⅰ) be lower than described support fiber fusion temperature and
(ⅱ) be higher than described second, third and select temperature with the 4th;
(h) with described heater felt is heated to sticking temperature and makes described viscose fibre softening and adhere on the described non-conductive fibre, described support fiber is
Non-conductive fibre to the described support fiber of small part one deck from described fiber web belt stretch out on the non-conductive fibre on another layer of linking in the described fiber web belt and
Described support fiber one deck in described fiber web belt and another interlayer keep certain space,
(ⅰ) viscose fibre that softened with sclerosis of the described felt of cooling.
According to the method for claim 10, it is characterized in that 11, described non-conductive fibre is a cotton fiber.
12, according to the method for claim 10, it is characterized in that, described cooled felt, its density is less than 1 pound every cubic feet.
CN92105495A 1991-07-10 1992-07-07 The manufacture method of heat insulator Pending CN1068375A (en)

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