EP0706588B1 - Verfahren und vorrichtung zur herstellung von faserigen vliesstoffen - Google Patents

Verfahren und vorrichtung zur herstellung von faserigen vliesstoffen Download PDF

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Publication number
EP0706588B1
EP0706588B1 EP94919022A EP94919022A EP0706588B1 EP 0706588 B1 EP0706588 B1 EP 0706588B1 EP 94919022 A EP94919022 A EP 94919022A EP 94919022 A EP94919022 A EP 94919022A EP 0706588 B1 EP0706588 B1 EP 0706588B1
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EP
European Patent Office
Prior art keywords
sliver
mat
bonding agent
fibrous material
batts
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP94919022A
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English (en)
French (fr)
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EP0706588A1 (de
Inventor
Lindsay John Newton
Brent Douglas Mantell
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
NEW WOOL PRODUCTS Ltd
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NEW WOOL PRODUCTS Ltd
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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
    • D04H1/58Non-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
    • D04H1/64Non-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
    • 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
    • D04H1/4266Natural fibres not provided for in group D04H1/425
    • 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

Definitions

  • This invention relates to the manufacture of fibrous material mats or batts, in particular but not solely to low density batts for thermal insulation or padding.
  • the invention also relates to other properties of these batts, such as fire resistance and resilience to crushing.
  • a method of forming resin impregnated fibre batts is disclosed in US Patent No. 4,678,822, on which the two-part form of claim 1 is based.
  • the resin is an acrylic self crosslinking polymer containing fire and smoke retardants and a pesticide.
  • the fibres may be natural and/or synthetic in origin and are often waste materials.
  • the materials are randomly dispersed in a sliver which is sprayed with the resin during a continuous folding process known as lapping.
  • the sliver is lapped up to a required thickness on a moving conveyer, and the resulting mat is cured at around 150°C and cut into batts having a density of around 25 kg/m 3 .
  • the textile industry incorporates various natural and/or 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 contain these salts or other chemicals such as metal oxides or halogenated organic compounds.
  • inorganic salts such as borates and phosphates
  • resin compositions which contain these salts or other chemicals such as metal oxides or halogenated organic compounds.
  • 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 by a pair of spray booms which oscillate with the sliver during lapping to produce an even distribution of the bonding agent in the mat.
  • apparatus for manufacturing fibrous material batts comprising: lapping means which form a sliver of fibrous material into a moving multilayer mat, spraying means which oscillate with the sliver and deliver a fibre bonding agent onto 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, characterised in that alternate sides of the sliver are sprayed during lapping to produce an even distribution of the bonding agent in the mat.
  • a fragile sliver of fibrous material is continuously formed from a mass of natural and/or synthetic fibres such as found in waste wool.
  • the sliver is lapped into a lightweight mat which is carried on a moving conveyor.
  • a bonding agent and optionally other substances are sprayed onto the sliver in a fine mist as lapping takes place back and forth across the conveyor.
  • control may be excerted over the thickness of the mat by varying the lapping and conveying speeds, a further step of compression is normally required before the structure of the mat is fixed by curing.
  • the batts have a density of less than 15 kg/m 3 , and preferably 8 to 12 kg/m 3 .
  • the bonding agent which is sprayed onto the sliver is typically a resin emulsion containing the optional substances in an aqueous solution.
  • Batts being manufactured for thermal insulation must be fire resistant and one of the optical substances should be octaborate salt having a concentration of up to around 30% by weight.
  • the invention can be employed when making mats and batts from a range of natural and synthetic materials, including animal or plant fibres and acrylics, polyesters or polyamide. Natural wool is preferred due to its ready availability and lofting characteristics. It will also be appreciated that the fibrous material products can be put to a wide range of uses including thermal insulation and stuffing for various objects.
  • Figure 1 shows sliver 10 of fibrous material passing downwards through a lapping device 11.
  • the sliver is formed continuously from wool or a wool/synthetic mix, preferably at least 50% by weight of wool, which may be scoured or cleaned by a commercial process and possibly pretreated for fire resistance. Processes for treating the bulk material and forming the sliver are well known and will be not be described further.
  • the sliver itself has a fragile structure up to around 1 cm thick and perhaps 2 m in width.
  • the lapping device includes sliver control elements 30 and spray booms 31 which will be described later.
  • the device oscillates back and forth across a moving conveyor 12 onto which the sliver is folded, to create a continuous mat 13 of fibrous material.
  • the fibre bonding agent sprayed onto the sliver from booms 31 thoroughly impregnates the mat, which is typically 10 to 20 cm thick.
  • the conveyor passes through a bath 14 which removes any oversprayed bonding agent.
  • Figure 2 shows mat 13 from above, with an exaggerated zigzag structure caused by the relative motion of the lapping device 11 and conveyor 12.
  • the zigzag is very 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 exaggerated in Figure 1.
  • 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 compressed to a greater or lesser degree in obtaining a required thickness.
  • the conveyors contact the mat, still wet from the spraying operation, through a non-sticking mesh surface.
  • 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 heater/fan 21 blows hot air up through conveyor 17 and out of the oven through an exhaust 22. Heat is exchanged to incoming air which passes down through conveyor 16 from inlet 23.
  • the upwards moving air is typically at a temperature of up to 120°C and preferably heats the mat to a temperature of between 70 and 100°C.
  • the downwards moving air has a temperature of between 50 to 60°C.
  • the mat 13 is finally cut at a guillotine device 25 after curing and drying.
  • Figures 3a and 3b show 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 both sides of the sliver 10 are sprayed with a resin to hold the structure of the mat, and other substances to provide certain properties of resilience and retardance.
  • the spray booms are alternately switched off for brief periods when the sliver is closest, to obtain economic and even distribution of resin.
  • Spraying takes place preferably with the resin at a temperature up to about 50°C and generally between about 25 and 40°C. This assists evaporation of moisture prior to curing and avoids need of elaborate radiative or other drying means which have been proposed previously.
  • Curing takes place in the oven preferably at a temperature less than about 120°C and generally between about 70 and 100°C. Higher curing temperatures are usually of no advantage and may be detrimental to some fibres and resins.
  • the resin emulsion normally includes various fire and smoke retardants, pesticides, fungicides and the like in the form of an aqueous solution.
  • a surfactant such as sold by Eastman Chemicals Ltd of the United States, under the trade mark TEXANOL, may also be added.
  • Resins suitable for the low temperature curing are preferably acrylic polymer emulsion types with low film forming properties during spraying and high self crosslinking properties during curing.
  • a suitable resin is marketed by A C Hatrick (NZ) Limited under the trade mark ACROCRYL. It has not been used successfully with boric acid or borax in the past and compositions of this kind have been disregarded due to the unfavourable chemical reactions which occur. Other salts and resins may also be suitable but those mentioned are the most cheaply and widely available at present.
  • a composition of TIMBOR dissolved in water and ACROCRYL forms an emulsion which gives surprisingly good fire resistance and resilience to treated materials.
  • the resin is an acrylic cross-linked variety which is cured at around 70 to 100°C once applied.
  • Preferred mixtures for spraying onto a fibrous material sliver during lapping have been found to comprise a resin emulsion with up to 30% by weight of resin solids and up to 30% by weight of an octaborate salt. Most preferably 15 to 25% by weight of resin solids and 10 to 25% of sodium octaborate tetrahydrate.

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)
  • Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
  • Chemical Or Physical Treatment Of Fibers (AREA)

Claims (15)

  1. Verfahren zum Herstellen von Faserstoff-Vliesen, umfassend die Schritte:
    Ausbilden eines Bandes (10) aus verteiltem Fasermaterial,
    Zusammenlegen der Bahn zu einer sich bewegenden mehrlagigen Matte (13),
    Besprühen der Bahn (10) mit einem Faserbindemittel während des Zusammenlegens,
    Aushärten des Bindemittels an der sich bewegenden Matte (13), und
    Abschneiden der Matte zur Herstellung von Vliesen in den erforderlichen Abmessungen mit der gewünschten Dichte,
       dadurch gekennzeichnet, daß abwechselnde Seiten der Bahn (10) durch ein Paar von Sprühleisten besprüht werden, die mit der Bahn (10) bei dem Zusammenlegen schwingen, um eine gleichmäßige Verteilung des Bindemittels in der Matte zu erreichen.
  2. Verfahren nach Anspruch 1, bei dem die sich bewegende Matte während des Aushärtens auf die gewünschte Dicke komprimiert wird.
  3. Verfahren nach Anspruch 1 oder 2, bei dem die Sprühleisten (31) in im wesentlichen entgegengesetzte Richtungen auf die Bahn (10) hin sprühen.
  4. Verfahren nach einem der vorhergehenden Ansprüche, bei dem durch die Matte zum Fördern der Aushärtung erhitzte Luft nach oben geblasen wird.
  5. Verfahren nach einem der vorhergehenden Ansprüche, bei dem das Fasermaterial mindestens 50 Gew.-% Wolle enthält.
  6. Verfahren nach einem der vorhergehenden Ansprüche, bei dem die Vliese eine Dichte von weniger als 15 kg/m3 besitzen.
  7. Verfahren nach Anspruch 6, bei dem die Vliese eine Dichte zwischen 8 und 12 kg/m3 besitzen.
  8. Verfahren nach einem der vorhergehenden Ansprüche, bei dem das Faserbindemittel ein Oktaboratsalz enthaltendes Harz aufweist.
  9. Verfahren nach einem der vorhergehenden Ansprüche, bei dem das Faserbindemittel ein Harz mit 10 bis 25 Gew.-% Natriumoktaborat-Tetrahydrat aufweist.
  10. Fasermaterialmatte oder -vlies, hergestellt nach dem Verfahren gemäß einem der vorhergehenden Ansprüche, mit einer Dichte von weniger als 15 kg/m3.
  11. Fasermaterialmatte oder -vlies, hergestellt nach dem Verfahren gemäß einem der Ansprüche 1 bis 9, mit einem ein Oktaboratsalz beinhaltenden Bindemittel.
  12. Vorrichtung zum Herstellen von Fasermaterialvliesen, umfassend:
    eine Zusammenlegeeinrichtung (11), die eine Bahn (10) aus Fasermaterial zu einer sich bewegenden mehrlagigen Matte (13) zusammenlegt,
    eine Sprüheinrichtung (31), die mit der Bahn (10) schwingt und auf die Bahn (10) während des Zusammenlegens ein Faserbindemittel aufbringt,
    eine Aushärteeinrichtung (20), die das Bindemittel an der sich bewegenden Matte (13) nach dem Zusammenlegen der Bahn (10) erhitzt, und
    eine Schneideinrichtung (25), welche die Matte (13) zu Vliesen mit den gewünschten Abmessungen und der gewünschten Dichte schneidet,
       dadurch gekennzeichnet, daß abwechselnde Seiten der Bahn (10) während des Zusammenlegens besprüht werden, um eine gleichmäßige Verteilung des Bindemittels in der Matte (13) zu erreichen.
  13. Vorrichtung nach Anspruch 12, umfassend eine Komprimiereinrichtung (16, 17), die im Verein mit der Aushärteeinrichtung (20) die sich bewegende Matte (13) auf die gewünschte Dicke reduziert.
  14. Vorrichtung nach Anspruch 12 oder 13, bei der die Sprüheinrichtung (30) Sprühleisten auf jeder Seite der Bahn aufweist, die das Bindemittel etwa in Richtung auf die Bahn (10) lenken, bevor die Bahn zu der Matte (13) zusammengelegt wird.
  15. Vorrichtung nach einem der Ansprüche 12 bis 14, bei der die Aushärteeinrichtung (20) heiße Luft nach oben durch die sich bewegende Matte (13) bläst.
EP94919022A 1993-06-28 1994-06-28 Verfahren und vorrichtung zur herstellung von faserigen vliesstoffen Expired - Lifetime EP0706588B1 (de)

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
NZ24800493 1993-06-28
NZ24800493 1993-06-28
NZ24845693 1993-08-20
NZ24845693 1993-08-20
PCT/NZ1994/000067 WO1995000691A1 (en) 1993-06-28 1994-06-28 Fibrous material batts

Publications (2)

Publication Number Publication Date
EP0706588A1 EP0706588A1 (de) 1996-04-17
EP0706588B1 true EP0706588B1 (de) 1999-11-03

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
EP94919022A Expired - Lifetime EP0706588B1 (de) 1993-06-28 1994-06-28 Verfahren und vorrichtung zur herstellung von faserigen vliesstoffen

Country Status (8)

Country Link
EP (1) EP0706588B1 (de)
JP (1) JPH09501741A (de)
AT (1) ATE186342T1 (de)
AU (1) AU683898B2 (de)
CA (1) CA2166185A1 (de)
DE (1) DE69421532T2 (de)
DK (1) DK0706588T3 (de)
WO (1) WO1995000691A1 (de)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE19513815C2 (de) * 1995-04-12 1998-02-19 Schiller & Partner Gmbh Ingeni Vorrichtung zum Herstellen ausgerüsteter Vliese

Family Cites Families (4)

* Cited by examiner, † Cited by third party
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 (ja) * 1987-12-04 1989-06-09 Asahi Glass Co Ltd 敷物
US5240766A (en) * 1992-04-01 1993-08-31 Hollingsworth & Vose Company Gasket material

Also Published As

Publication number Publication date
WO1995000691A1 (en) 1995-01-05
DE69421532D1 (de) 1999-12-09
ATE186342T1 (de) 1999-11-15
JPH09501741A (ja) 1997-02-18
EP0706588A1 (de) 1996-04-17
AU7010394A (en) 1995-01-17
AU683898B2 (en) 1997-11-27
DK0706588T3 (da) 2000-05-08
CA2166185A1 (en) 1995-01-05
DE69421532T2 (de) 2000-05-25

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