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
  • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
  • D04H1/74—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being orientated, e.g. in parallel (anisotropic fleeces)
• • 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

Definitions

• the present invention related to improvements in insulation, and in particular to the use of bonded monoacrylic, acrylic or polyamide, polyester and like synthetic or cellulose fibres either alone or in combination with animal fibres and either in batt form or as 'blow in' insulation.
• a further object of the present invention is to provide an insulation which is not hazardous to the health, but yet has all the properties of existing insulation.
• the present invention provides a method of forming a batt of bonded fibres for use as insulation, said fibres comprising monoacrylic, acrylic or other synthetic or cellulose fibres with from 0 to 95% wool fibres, said batt being formed by ragging, teasing and otherwise doffering the fibres of waste textile and other materials to form a randomly dispersed fibre sliver, passing said sliver through a lapper and, while maintaining a resin emulsion spray means a predetermined distance from said sliver, spraying said sliver with a resin emulsion which preferably includes one or more of a fire-proofing resin, a smoke retardant and pesticide, to thereby form a mat of predetermined thickness of the resin emulsion impregnated sliver, evaporating or otherwise removing up to about 80%, and preferably 50%, of the water from the mat without substantial heating of the mat, subsequently setting the resins by curing, and cutting the mat to form batts of desired length.
• the bonded fibres have a plurality of air pockets which assists in the insulation effect. If desired for a 'blow in' installation, the batts may be broken down into small balls of bonded fibre in loose form.
• wool fibres in amounts between 25% and 60% of total fibres is preferred having regard to the known fire-retardant properties of wool. In addition, it is rot proof and vermin proof. As the insulation is not visible in the finished installation, it is possible to make use of wool 'seconds', especially black fleeces, cuttings from the shearing sheds and recycled woollen jumpers and other garments.
• Other fibres which are combined with the wool fibres and which are particularly useful in the invention include monoacrylic, acrylic, polyamide and polyester synthetic fibres as well as other natural fibres such as cotton. These types of fibres, when matted and bonded together in a batt, preferably with additional wool fibres, results in an insulation material which is extremely economical to produce, which can be formed of waste clothing and other waste materials and which has excellent insulating properties without the hazards of other known insulating products.
• Wool and other fibres are affected by heat and become soft and less resilient. Because of the water content of the resin emulsion, up to 75% by weight, and the heat required to cure the resins, the impregnated mat may collapse and shrink when subjected to the external heating source required to cure the resins.
• the mat is therefore treated prior to the curing step to remove up to 80% of the water in a manner which obviates or reduces the heating effect on the fibres and resin.
• the water removal treatment is carried out by dielectric heating. However, other substantially non-heating treatments may also be used.
• Resins suitable for use in the present invention include flame depressants such as modified acrylic self­crosslinking polymers such as Rhoplex HA-20, available from Rohn & Haas.
• flame depressants such as modified acrylic self­crosslinking polymers such as Rhoplex HA-20, available from Rohn & Haas.
• Other additives to the spray include Aluminium Trihydrate and Ken Gard (Trade Mark) (I.C.I. smoke suppressant) and Perigen (Trade Mark) (a pesticide) especially suitable against clothes moths and carpet beetle and available from Burroughs Wellcome.
• the insulation so formed may be used in any location i.e. in home, office, factory or other building, for either heat or acoustic insulation.
• a mixture of ragged acrylic and cotton garments and new wool is fed to a doffer, or carding machine, which separates the fibres and teases them to form a sliver or relatively thin web of randomly dispersed fibres, comprising 50% acrylic and cotton fibres and 50% wool fibres.
• the sliver has a thickness of about 1/8 inch.
• the sliver is fed from the doffer, or carding machine, onto a horizontal lapper which oscillates at a predetermined rate to deliver the sliver to a conveyor where the sliver is lapped onto itself to build up a mat of a predetermined thickness.
• the lapper Before the sliver leaving the lapper engages on the conveyor, or on to previously lapped material on the conveyor, it is sprayed with an emulsion of resins comprising Rhoplex Resin, Aluminium Trihydrate and Perigen pesticide.
• the water content of the emulsion is approximately 54% by weight.
• a spary boom having a plurality of spray nozzles for spraying the resin emulsion is mounted adjacent the lapper and is connected thereto by a linkage system which maintains the boom a predetermined distance from the material sliver moving from the lapper towards the conveyor.
• the linkage system causes the boom to move with the lapper but through a distance related to the actual sliver movement which, because of the oscillating lapper movement and the distance between the lower end of the lapper and the conveyor, is different than the actual lapper movement.
• a second boom positioned on the opposite side of the sliver to the spray boom is fed with air to produce an air cushion to thereby balance the forces produced by the resin emulsion spray and maintain the sliver in its correct alignment with the conveyor.
• the mat formed of the lapped sliver which is thoroughly impregnated with the resin emulsion sprayed onto the sliver, is conveyed to a dielectric drying station and passes between spaced plate electrodes which are electrically charged by high frequency A.C. potential.
• the frequency and voltage applied to the plate electrodes are chosen to optimize drying of the mat with minimum heating of the fibres. Approximately 50% of the water content is removed at the drying station.
• the mat is then conveyed to a curing oven heated to about 150°C to complete the drying and to cure the resins to form a relatively rigid but resilient insulating mat material.
• a curing oven heated to about 150°C to complete the drying and to cure the resins to form a relatively rigid but resilient insulating mat material.
• Insulation batts composition Wool - nominal - 50% W/W Acrylic and Cotton - nominal 50% W/W Rhoplex Resin - nominal 25 - 42 g/m2 (ex Rohn & Haas - Rhoplex HA/20) Flame retardant: Aluminium Trihydrate (ex Alcoa) Thickness: Nominal 68 mm
• each specimen had a backing of 4.5 mm thick Fire Resistant board and was restrained by a layer of approx. 0.8 mm diameter square wire mesh having a spacing of approx. 12 mm in each direction.
• wool, synthetic and other natural fibres are bonded together to form an insulation batt which may then be installed in a desired location.
• the batt may be broken down into small balls which are blown or otherwise spread over the desired location, again to provide insulation.
• the batt thickness is considerably less than the thickness of the fibreglass batt of comparable heat insulation.
• the present invention provides a means of insulation that avoids the health hazards of the existing insulation, which is able to use discarded or second­grade wool fleeces, thereby improving the farmers' ecomonic return on his flock, and yet the insulation so produced is equal to that which it is to replace.
• discarded wool, synthetic and other natural fibres, or wool, synthetic and other natural fibre garments may be ragged and used in the present invention, again reducing the cost of raw materials.
• the resins used should preferably be selected to ensure the batt retains its bulk and structural integrity.
• a stiffening agent such as starch, resin stiffeners or similar agents, can be added to the batt either by incorporating the stiffening agent into the resin emulsion or by separately spraying the sliver or the mat.

Landscapes

• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Nonwoven Fabrics (AREA)
• Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)

Applications Claiming Priority (1)

Publications (1)

Family

ID=24496748

Family Applications (1)

Country Status (1)

Cited By (3)

Citations (4)

• 1987
  • 1987-07-03 EP EP87305892A patent/EP0297187A1/fr not_active Withdrawn

Patent Citations (4)

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