EP3110995B1 - Aus altbestandteilen geformte vliestafel und verfahren zur konstruktion davon - Google Patents

Aus altbestandteilen geformte vliestafel und verfahren zur konstruktion davon Download PDF

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Publication number
EP3110995B1
EP3110995B1 EP15709588.6A EP15709588A EP3110995B1 EP 3110995 B1 EP3110995 B1 EP 3110995B1 EP 15709588 A EP15709588 A EP 15709588A EP 3110995 B1 EP3110995 B1 EP 3110995B1
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EP
European Patent Office
Prior art keywords
fibers
web
bonded
mixture
further including
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EP15709588.6A
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English (en)
French (fr)
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EP3110995A1 (de
Inventor
Benoit Laurent
Ritesh Mehbubani
Elisa BONALDI
Eric K. Staudt
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Federal Mogul Powertrain LLC
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Federal Mogul Powertrain LLC
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Publication of EP3110995A1 publication Critical patent/EP3110995A1/de
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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/425—Cellulose series
    • 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
    • D04H1/4274—Rags; Fabric scraps
    • G—PHYSICS
    • G10—MUSICAL INSTRUMENTS; ACOUSTICS
    • G10K—SOUND-PRODUCING DEVICES; METHODS OR DEVICES FOR PROTECTING AGAINST, OR FOR DAMPING, NOISE OR OTHER ACOUSTIC WAVES IN GENERAL; ACOUSTICS NOT OTHERWISE PROVIDED FOR
    • G10K11/00—Methods or devices for transmitting, conducting or directing sound in general; Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
    • G10K11/16—Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
    • G10K11/162—Selection of materials
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B2001/742—Use of special materials; Materials having special structures or shape
    • E04B2001/746—Recycled materials, e.g. made of used tires, bumpers or newspapers

Definitions

  • This invention relates generally to nonwoven materials, and more particularly to nonwoven panels containing recycled ingredients.
  • landfills are being rapidly filled by these items, which in turn have a detrimental effect on the environment, both from a costly pollution standpoint and from the standpoint of losing any return value on the materials being disposed.
  • the nonwoven panel may include a nonwoven mat with a scrim layer laminated to an outer surface of the nonwoven mat.
  • the seatbelts and airbags from used vehicles and/or professional apparel are gathered and processed via a shredding or tearing operation.
  • the shredded or torn material referred to hereafter commonly as comminuted material, is sized to provide fibers ranging between about 30-75mm in length, as desired, and having a denier ranging between about 3-10.
  • the comminuted material is blended with low melt fibers, and then the mixture is processed via a nonwoven webbing process, such as in an air laid machine (e.g. Rando air laid machine or an air gravity machine).
  • the air laid machine mixes and forms a randomly oriented fiber web, wherein the web can be further processed in a needling operation and then optionally sent to a heating process (e,g., a heated conveyor oven or batch oven), or it can be sent directly from the air laid process to the heating process, depending on the finish panel structure desired.
  • a heating process e.g., a heated conveyor oven or batch oven
  • the end-of-life material used to form the web can be treated with a compounded mixture including an antimicrobial, a flame retardant, and a binder.
  • the mixture can be applied to the end-of-life material either prior to comminuting the material, after comminuting the material and prior to forming the air laid web, or as a coating on an exposed side of the web after forming web.
  • the compounded mixture of antimicrobial, flame retardant and binder can be provided having between about 1-4% dry pickup weight.
  • the nonwoven mat can include between about 50-70 wt% seatbelt fibers.
  • the nonwoven mat can include between about 30-50 wt% airbag fibers.
  • the nonwoven mat can include between about 0-50 wt% professional garment fibers.
  • the nonwoven mat can include between about 15-25 wt% low melt fibers.
  • the nonwoven web can have a weight ranging between about 200-1000gsm.
  • the scrim layer can have a weight ranging between about 25-200gsm.
  • the method can include forming the fibrous mixture containing at least 50 wt% of the first fibers from vehicle seatbelts and at least 30 wt% of the second fibers from vehicle air bags.
  • the method can include forming the fibrous mixture containing between 15-25 wt% of the low melt polymeric material.
  • the method can include forming the mixture containing between 50-70 wt% of the first fibers from vehicle seatbelts.
  • the method can include forming the mixture including between 0-50 wt% of the third fibers from professional garments.
  • the method can include applying a compounded mixture including an antimicrobial, a flame retardant, and a binder to the bonded web.
  • the method can include providing the compounded mixture applied to the web having a dry pickup between 1-4 wt%.
  • the method can include bonding a scrim layer to the bonded web.
  • the method can include providing the scrim layer having a weight between 25-200gsm.
  • the method can include first coating the bonded web with the compounded mixture and then bonding the scrim layer to a single side of the bonded web.
  • the method can include performing the bonding in a thermal treatment process.
  • Figure 1 illustrates a process flow used to construct an acoustic, nonwoven panel, referred to hereafter as panel 10 ( Figures 2 and 3 ), from end-of-life textile material 12 in accordance with the invention.
  • the process is generally a "closed-loop" process that reclaims and reprocesses parts from used, end-of-life parts of vehicles, such as trains and/or automotive vehicles, and in particular, from parts including high quality fibrous end-of-life textile materials, such as of nylon and polyester, including end-of life seatbelts and air bags, and/or from used, end-of-life professional apparel (e.g. imaging apparel).
  • vehicles such as trains and/or automotive vehicles
  • high quality fibrous end-of-life textile materials such as of nylon and polyester, including end-of life seatbelts and air bags
  • end-of-life professional apparel e.g. imaging apparel
  • the end-of-life textile material 12 used to construct the panel 10 includes at least one of first fibers 14 from end-of-life vehicle seatbelts, second fibers 16 from end-of-life vehicle airbags and third fibers 18 from end-of-life professional garments.
  • the ability to construct the panel 10, including the reclaimed end-of-life textile material 12, avoids having to send the reclaimed end-of-life material to a landfill or incinerator, thereby negating a negative impact on the environment, while further providing the ability to repurpose the high quality fibrous material from the reclaimed materials 12.
  • the end-of-life textile parts namely seatbelts and airbags from used vehicles, and/or professional apparel are gathered and can be bulked together, if desired, and then the gathered materials are processed via a shredding or tearing operation.
  • the separate types of end-of-life parts can be processed separately, and then mixed afterward, if desired, to allow optimal control of the percent-by-weight (wt%) of the different types of fibers in the resulting mixture.
  • the shredded or torn material referred to hereafter commonly as comminuted material, is sized as desired to provide fluffy textile fibers of a length ranging between about 30-75mm, and having a denier ranging between about 3-10, depending on the end type of acoustic panel being made.
  • the comminuted end-of-life material can be blended with other textile fibers, including low melt fibers 20, particularly if not already included in the end-of-life materials, along with additional materials, such as organic fibers including natural fibers of jute, kenaf, sisal and the like, and then the mixture is further processed via a nonwoven webbing process, such as in an air laid machine (e.g. Rando air laid machine or an air gravity machine).
  • the air laid machine mixes and randomly orients the fibers with one another to form the fibrous web 22 ( Figure 3 ).
  • the web 22 can then be processed in a needling operation, if desired, to bond or interlock the fibers with one another.
  • the bonded web 22 is sent through a chemical application station, such as a spraying, dipping, brushing, or any other type of coating process, by way of example and without limitation, wherein a chemical compounded mixture is applied to an outer surface of the bonded web 22 to form a coating 24 of the compounded mixture on the web 22.
  • a chemical application station such as a spraying, dipping, brushing, or any other type of coating process, by way of example and without limitation, wherein a chemical compounded mixture is applied to an outer surface of the bonded web 22 to form a coating 24 of the compounded mixture on the web 22.
  • the coating 24 can be formed about the entirety of the web 22, or the coating 24 can be formed on a selected portion of the web 22, such as to an outer surface of the web 22 that will remain generally exposed to the environment during use. Accordingly, with the web 22 having opposite sides 26, 28, the coating 24 can be applied over both sides 26, 28, or applied to cover a single side 26 of the web 22, thereby reducing the content and cost of the coating 24 on the finished panel.
  • the compounded mixture is applied to the web 22 having between about 4-10 wet pickup wt%, which results in a dry pickup between about 1-4 wt%.
  • the compounded mixture includes an antimicrobial agent, a flame retardant agent, and a binder agent.
  • the antimicrobial agent has dry pickup wt% between about 0.01-0.05
  • the flame retardant agent has a dry pickup wt% between about 0.5-2
  • the binder has a dry pickup wt% between about 0.5-2.
  • the antimicrobial agent can be provided as any suitable biocide, including dichloroctylisotliiazolinone-based agents, by way of example and without limitation.
  • the flame retardant agent can also be provided as any suitable flame retardant, including, by way of example and without limitation, ammonium sulphate, phosphorous-based, or bromine-based agents.
  • the binder can be provided as a styrene butadiene binder (SBR) or an acrylic binder.
  • SBR styrene butadiene binder
  • the compounded mixture can be applied to the end-of-life material either prior to comminuting the material, after comminuting the material and prior to forming the air laid web, or to the web prior to bonding the fibers of the web.
  • the process includes controlling the thickness, preferably between about 10-25min and density, preferably between about 200-1000gsm, of the finished web 22, such as via a belt or roller(s), by way of non-limiting example, within the heating oven used to melt the low melt fibers 20 added to, or pre-existing within the end-of-life material, Further, rather than using an oven to perform the heating, the nonwoven web 22 can be heated and sized (thickness and density) between heated rollers, if desired. In addition, sizing can further be controlled by passing the heated web 22 between cooled rollers after the web exits the heating/bonding process.
  • the panel 10 is shown as having a scrim layer 30 bonded to one side 28 of the web 22.
  • the scrim layer 30 is preferably provided as a microfiber scrim having lamination of spunbond/meltbond/spunbond (SMS) layers, and has a density ranging between about 25-200gsm.
  • SMS spunbond/meltbond/spunbond
  • the scrim layer 30 is preferably bonded to the side 28 of the web 22 via a hot melt adhesive.
  • the presence of the scrim layer 30 enhances the overall acoustic performance of the panel 10. It should be recognized that the side 28 having the scrim layer 30 bonded thereto can be void of the coating 24, thereby reducing the material and manufacture cost by saving on the expense of the coating chemical composition.
  • the content by wt% of the first fibers 14, second fibers 16, third fibers 18 and lower melt fibers 20 can be adjusted, within parameters specified herein, to provide the panel 10 with the performance characteristics sought.
  • the web 22 can be formed having between about 50-70 wt% of the first fibers 14 and between about 30-50 wt% of the second fibers and between about 15-25 wt% of the low melt fibers 20.
  • the panel 10 can be fabricated having at least 50 wt% of the first fibers 14 and at least 30 wt% of the second fibers 16,
  • the web 22 can be fabricated having between about 0-50 wt% of the third fibers 18 from professional garments.
  • the web 22 can be fabricated having between about 50-100 wt% of the first and/or second fibers 14, 16.
  • end-use panels 10 can be fabricated in accordance with the invention, wherein the panels 10 can be constructed having different constituent ingredients (types of end-of-life materials 12 with selected coatings 24 and scrim layers 30, as desired) and shapes/contours. While heating the web 22 and bonding the ingredients thereof to one another, the resulting contour and peripheral shape can be provided in a cutting and heat forming/compressing operation, wherein precise contour and peripheral shape and dimensions, including thickness over the entirety of the panel 10, whether constant or of varying thickness, can be readily formed.
  • constituent ingredients types of end-of-life materials 12 with selected coatings 24 and scrim layers 30, as desired
  • shapes/contours While heating the web 22 and bonding the ingredients thereof to one another, the resulting contour and peripheral shape can be provided in a cutting and heat forming/compressing operation, wherein precise contour and peripheral shape and dimensions, including thickness over the entirety of the panel 10, whether constant or of varying thickness, can be readily formed.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Acoustics & Sound (AREA)
  • Multimedia (AREA)
  • Nonwoven Fabrics (AREA)

Claims (15)

  1. Verfahren zur Konstruktion eines akustischen Vliesfeldes (10), wobei das Verfahren Folgendes umfasst:
    Formen eines Fasergemischs, enthaltend niedrigschmelzendes Polymermaterial (20) und mindestens 50 Gew.-% erster Fasern (14) aus Fahrzeugsicherheitsgurten und/oder mindestens 30 Gew.-% zweiter Fasern (16) aus Fahrzeugairbags;
    Formen eines Flächengebildes (22) aus dem Gemisch in einem Vliesbildungsprozesses; und Bindefasern (14, 16, 20) in dem Flächengebilde (22) miteinander.
  2. Verfahren nach Anspruch 1, ferner enthaltend das Formen des Fasergemischs, enthaltend mindestens 50 Gew.-% der ersten Fasern (14) und mindestens 30 Gew.-% der zweiten Fasern (16).
  3. Verfahren nach Anspruch 2, ferner enthaltend das Formen des Fasergemischs, enthaltend zwischen 15-25 Gew.-% des niederschmelzenden Polymermaterials (20).
  4. Verfahren nach Anspruch 1, ferner umfassend das Formen des Gemischs, enthaltend zwischen 50-70 Gew.-% der ersten Fasern (14).
  5. Verfahren nach Anspruch 1, ferner enthaltend das Auftragen eines zusammengesetzten Gemischs (24), enthaltend ein antimikrobielles, ein flammenhemmendes und ein Bindemittel auf das gebundene Flächengebilde (22).
  6. Verfahren nach Anspruch 5, ferner enthaltend das Binden einer Gitterschicht (30) an das gebundene Flächengebilde (22).
  7. Verfahren nach Anspruch 6, ferner enthaltend das Bereitstellen einer Gitterschicht (30) mit einem Gewicht von zwischen 25-100 g/qm.
  8. Verfahren nach Anspruch 1, ferner enthaltend das Ausführen des Bindens in mindestens einem eines Nadelvorgangs und eines Wärmebehandlungsprozesses.
  9. Akustisches Vliesfeld (10), das durch das Verfahren nach Anspruch 1 erhalten wurde, umfassend:
    ein gebundenes Fasergemisch, enthaltend niederschmelzendes Polymermaterial (20) und mindestens 50 Gew.-% erster Fasern (14) aus Fahrzeugsicherheitsgurten und/oder mindestens 30 Gew.-% zweiter Fasern (16) aus Fahrzeugairbags, wobei die Fasern (14, 16) in der Länge zwischen etwa 30-75 mm variieren und einen Denier im Bereich von etwa 3-10 aufweisen.
  10. Akustisches Vliesfeld nach Anspruch 9, wobei das gebundene Fasergemisch vernadelt wird.
  11. Akustisches Vliesfeld nach Anspruch 9, wobei das niederschmelzende Material (20) mindestens teilweise geschmolzen wird und optional wobei das niederschmelzende Material eine Bikomponentenfaser (20) ist.
  12. Akustisches Vliesfeld nach Anspruch 9, wobei das gebundene Fasergemisch zwischen 50-70 Gew.-% der ersten Fasern (14) enthält.
  13. Akustisches Vliesfeld nach Anspruch 12, wobei das gebundene Fasergemisch mindestens 30 Gew.-% der zweiten Fasern (16) enthält.
  14. Akustisches Vliesfeld nach Anspruch 9, ferner enthaltend ein zusammengesetztes Gemisch (24), das mit dem gebundenen Fasergemisch gebunden wird, wobei das zusammengesetzte Gemisch (24) ein antimikrobielles, ein flammenhemmendes und ein Bindemittel enthält.
  15. Akustisches Vliesfeld nach Anspruch 14, ferner enthaltend eine Gitterschicht (30), die mit dem gebundenen Fasergemisch gebunden ist.
EP15709588.6A 2014-02-26 2015-02-26 Aus altbestandteilen geformte vliestafel und verfahren zur konstruktion davon Active EP3110995B1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201461944851P 2014-02-26 2014-02-26
PCT/US2015/017701 WO2015130909A1 (en) 2014-02-26 2015-02-26 Nonwoven panel formed of end-of-life ingredients and method of construction thereof

Publications (2)

Publication Number Publication Date
EP3110995A1 EP3110995A1 (de) 2017-01-04
EP3110995B1 true EP3110995B1 (de) 2018-10-17

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN111074445A (zh) * 2020-01-03 2020-04-28 启东和安无纺材料有限公司 一种无纺布的制造方法及适用于该方法的装置

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Publication number Priority date Publication date Assignee Title
US7837009B2 (en) * 2005-04-01 2010-11-23 Buckeye Technologies Inc. Nonwoven material for acoustic insulation, and process for manufacture
US7744143B2 (en) * 2007-01-10 2010-06-29 Federal Mogul Powertrain Nonwoven panel and method of construction thereof
US20110305878A1 (en) * 2007-01-10 2011-12-15 Gladfelter Harry F Nonwoven panel and method of construction thereof
KR101658628B1 (ko) * 2008-12-04 2016-09-22 제피로스, 인크. 단섬유들로부터 만들어지는 부직포
JP5603936B2 (ja) * 2009-06-24 2014-10-08 フェデラル−モーグル パワートレイン インコーポレイテッド 不織シート材料、それから構築されたパネル、およびその構築方法

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EP3110995A1 (de) 2017-01-04
WO2015130909A1 (en) 2015-09-03

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