JPH03501142A - bonded fiber insulation batts - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

[Detailed description of the invention] On the verge of a note Bonded fiber insulation batt Giabin field This invention relates to improvements in insulation materials, particularly in the form of batts or blown-in insulation materials. (brow in) bonded synthetic fibers, e.g. monoacrylic , acrylic or polyamide, polyester or other synthetic fibers or Concerning the use of cetate fiber alone or in combination with animal hair.

Conservation of heat is highly desirable in view of current energy costs. living ring One way to conserve heat in the environment is to insulate housing. In this field, glass Fiberglass insulation is widely available, but fiberglass is hazardous to health. It provides flame retardancy to blown glass fibers, which are difficult to process into batts. The use of chemicals to protect people's health is also harmful to health.

! Drum Spring Australian patents 527,843 and 540.132 include fiber Disclosed is a method for bonding materials to form insulating batts, in which up to 95% wool fiber is used. The method also includes waste wool, second-grade wool, etc. The fibers are tattered and combed to create a mat of randomly dispersed fibers. This includes manufacturing batts of desired thickness. Next to bat is resin, Insecticides, flame retardants, etc. are sprayed, and the resin is cured and fixed.

However, the resin is not evenly distributed throughout the material, which prevents the mat from forming effectively. the loft or thickness and associated loss of insulation. It was found that there is a tendency for

Other fibers are scattered on the cloth and soften or melt due to heat. Methods have been proposed for bonding bars to form nonwoven or woven fabrics. Oath Tralia Patent No. 459,539 describes a non-woven fabric made of wool and pre-degradable fibers. Fabric formation is disclosed. Wool fibers are mixed with previously fallen fibers. The fibers are first impregnated with water and mixed into a cloth structure using a heated drum. It can be combined with its own internally bonded cross fibers for uniformity. Oh Stralia Patent No. 460.528 describes a method for manufacturing fiber structures using conjugation. A method is disclosed in which some of the surfaces of the fiber structure are potentially adhesive. , made of a heat-activated polymer.

The patent specification only describes the use of conjugated fibers to produce textiles. and there is no disclosure of insulating batts.

Australian Patent No. 500,317 describes a bonded non-woven fiber bag. A method of manufacturing a sheet is disclosed. In the same specification, the bat is crimped or crimped. The softening temperature of the softening component on the lower side of the conjugated fiber It is heat treated by passing a fluid at a temperature higher than 30°F upward through the vat. This way Such heat causes interfiber bonding of the conjugated fibers. Combine like this Cooling fluid is passed through the bat from above to prevent the bat from collapsing. The fibers are cooled down. The method of the patent relies on upward passage of fluid through the material. It exists. However, insulation batts are designed for insulation. , fluid flow is practically prevented. Therefore, this method is suitable for manufacturing insulation batts. is not suitable.

Australian Patent Application No. 59302773, which has already been invalidated, has a previous invalidity. The formation of nonwoven fabrics from webs of fibers containing fibers is disclosed; When the web is heated, the surrounding fibers melt, creating a web that does not undergo thermal changes. forming a series of fluid beads at the intersections with the fibers. This method is effective In order to achieve this, the melted pre-pressure bead is placed at the intersection with the fiber, which does not undergo thermal change. Must be able to locate.

The rough surface of the wool fibers retards the movement of these pre-agglomerated beads. Therefore, in order to effectively perform this method using wool fiber, a large amount of pre-treatment is required. Requires relapsing fiber.

The methods listed above are suitable for producing non-woven webs or textiles or for producing loose fibers. Wool fibers, which have excellent insulation properties, are useful in the manufacture of bats. There is no way to effectively manufacture insulation batts using fibers from waste wool products. It is impossible in both cases. We heat the inside of the vat and other fibers. The fibers can be softened to the extent that they bond with each other, and the fibers randomly separate into the batt when cooled. The batting material is made of synthetic plastic bonded fibers that can remain dispersed. Effective insulation batts from waste wool products and other waste wrappers by adding to They discovered that it is possible to produce

SUMMARY OF THE INVENTION It is therefore an object of the present invention to provide an improved thermal insulation bag formed from waste textiles and other materials. The purpose of the present invention is to provide a method for manufacturing insulation materials.

In addition, it is not harmful to health, has all the required properties of current insulation materials, and is economical. It would also be desirable to provide an insulating material that can be manufactured.

Summary of the invention The present invention uses monoacrylic or acrylic fibers or other synthetic fibers. is a fiber made of acetate fiber and 0-95% wool fiber. The present invention provides a method for manufacturing an insulating batt formed by bonding, the batt having a relatively low softening point. Or a coupling fiber made of synthetic plastic, resin or other material with a melting point. for example by adding fibers from waste textiles or other waste to the fibers. The fibers are run by any suitable means such as raging, combing, or otherwise stripping. Form a sliver dispersed in a dam and pass this sliver through a wrapper to the desired A thick mat is formed, and flame retardants, pesticides, and smoke suppressants are optionally added to this mat. The mat is heated to a temperature at which the bonding fibers at least soften and exhibit tackiness. to combine with other fibers in the mat and cool the mat. and cutting to form a batt of desired length.

By bonding the wool fibers in this way, the roses) have a real height and are multiplied. Since it has several air pockets, the heat insulation effect is promoted. bat as desired The fibers can be cut into small spheres with loosely bonded fibers for blowing.

The amount of wool fiber used may be between 25% and 80% of the total fibers, but In view of the known flame retardant properties of wool, amounts between 70% and 80% are preferred. This is in addition It also acts as a preservative and insect repellent. The insulation will not be visible from the outside when it is finally installed. and second-grade wool, especially darkened wool, shorn shoulders from shearing sheds and regenerated sheep. Preferably, woolen clothing is used.

The bonding fibers are made of relatively low melting point resins or pre-snapping materials, such as copolymer. Midofiber, saponified ethylene vinyl acetate polymer fiber , polyester fiber, nylon, polio fants), vinyl chloride, etc. Some, e.g. inner core compared fibers that have a relatively high melting point and other parts, such as the outer layer, that have a relatively low melting point. -In other words, Funschkeit fiber can also be used. Matrix instead Filaments may also be dispersed within. Bonded fibers are present in amounts between 1% and 60%. I can exist.

Other fibers useful in the present invention in combination with wool fibers include wool fibers. synthetic fibers such as no-acrylic, acrylic, polyamide and polyester; There are also other natural fibers such as cotton.

This type of fiber is preferably further added with wool fibers to form a matte The insulation material can be manufactured extremely economically by bonding them together to form a batt. It can also be made from discarded clothing or other waste materials, and even be made from well-known insulating products. It can exhibit excellent heat insulation properties without causing any harmful effects. Map the coupled fibers When added to fibers dispersed in fibers, it softens or melts the bonded fibers. It can be completely combined with other fibers and maintain the bulk and elasticity of the bat.

The rigidity of the insulating batt formed according to the present invention is determined by adding resin or sizing agent to the batt. In one embodiment of the present invention, the odor can be enhanced by adding or spraying. The resinous material is added to the batting material in the form of resin fibers or resin powder. available. The resin is activated and hardened during the heating step, covering the fibers inside the batt. to strengthen the bat structure.

Alternatively, a resinous material may be applied to one or both sides of the mat forming the insulation batt. Spraying to form a resin skin on the bat, thereby giving it rigidity You can also do it. This kind of resin spraying should be done before heating to remove the previously degraded fibers. Preferably, the resin is simultaneously cured by heating to soften the resin. Also the bar It is also possible to heat the resin before spraying, but in this case the resin will harden. A second heating stage is required.

Mats can also be formed by slivers of fibers, which It is passed through a manufacturing wrapper and formed into a mat of desired heat. Furthermore, ma The fibers of waste textiles and other waste are tattered, carded, or otherwise Stripped, blown or randomly dispersed fibers on mat forming conveyor The fibers may be transported there to the desired thickness and trimmed.

Fibers such as wool tend to soften and lose their elasticity under the influence of heat and moisture. natural Since the moisture content of the fibers and preferred optional materials can be up to 75% by weight , the heat required to soften the pre-degradable fibers and melt the resin. The mat may collapse or shrink; therefore, the mat must be drained of moisture prior to the heating step. Eliminate the effects of heat on fibers and resin by removing up to 80% of heat. Preferably, it is removed or reduced. This kind of water removal is done by dielectric heating. is preferable. Other substantially non-thermal treatments may also be utilized.

To soften the pre-degradable fibers, melt and dry any resin present. Microwave heating can be used instead. Such microwave heating involves multiple stages It will be held in The first step is to prepare a buffer prior to mixing or adding the binding fibers. The drying of the fibers was carried out, and in the second step, the binding fibers were added. Following subsequent mat formation, the bonded fibers are softened and the other fibers in the mat - to be combined with

Microwave heating may occur if the fiber contains moisture or other microwave receptors. Another feature of the present invention is that metal or may add other microwave receptors to the fiber, such as polyacetylene, or The coupling fiber is coated with a suitable microwave receptor. The fiber is equipped with a microwave receptor. Aluminum to bond fiber By integrating other metal particles, the bonded fiber is processed when exposed to microwaves. Preferably, it is thermally softened or melted.

Separately, microwave receptors can also be added to the constituent fibers of the mat. When chroma wave energy is applied, the microwave receptor generates heat and the bat is internally heated. , whereby softening of the coupling fibers may take place.

The batt may also contain additives for flame retardation, smoke suppression, and insecticide. Matfa Preferred additives to the ivar include aluminum trihydrate, KenGa rd(TM) (1,C,1, smoke suppressant) and Perigen(TM) (insecticide) Perigen is a burr and beetle. Burroughs Wellcome Available from lcome). Alternatively, thermoplastic bonded fibers can be flame retardant. Fibers or powders such as agents, pigments, smoke suppressants, etc. may also be included.

The insulation material formed as described above can be used in houses, offices, factories, and other buildings. , it can be used anywhere and for either thermal or sound insulation.

i Ritate Yotansei Rui ■ Example 1 Bottles made of wool, cotton and/or acrylic, whether or not they contain new wool. A mixture of garments with low melting point polypropylene and dofa or carton. About 5% to 20% of acrylic and cotton fibers, about 70% to 80% wool fibers and about 15% bonded fibers A relatively thin wafer in which slivers or fibers are randomly distributed. form a block. The sliver has a thickness of approximately 1/8 inch. Sliver is dot A horizontal wrapper is fed from a fur or card machine. The wrapper has a predetermined degree The slivers are vibrated at the same time and sent to a conveyor, where they are stacked and placed in a predetermined position. Formed into a thick mat.

Before the sliver passes the wrapper and is on the conveyor.

or for pre-stacked material on the conveyor. emulsions of flame retardants, insecticides, etc. is sprayed. The water content of the emulsion is approximately 54% by weight.

Spray boom with multiple spray nozzles for spraying emulsions is mounted in close proximity to the wrapper and is connected to the wrapper via a coupling mechanism. Ru. The linkage connects the boom to the sliver moving from the wrapper to the conveyor. and separated by a predetermined distance. The linkage moves the boom with the wrapper, but the distance is related to the actual movement of the sliver.

The actual movement of the sliver is due to the vibration of the wrapper and the connection between the lower end of the wrapper and the conveyor. This is because the movements of the actual rapper differ due to the distance between them.

A second boom is located on the opposite side of the sliver to the spray pool; Air is supplied to the room to form an air cushion. This allows emulsion The blowing forces are balanced and the sliver is properly aligned with the conveyor. kept in position.

A mask made by layering slivers that are soaked in by spraying emulsion onto the sliver. The sheets are transported to a dielectric drying station where the electrode plates are exposed to a high frequency alternating potential. passed through the space between. The frequency and voltage applied to the electrode plates prevent mat drying. It is ideally selected to minimize the amount of heat applied to the fiber. This drying At least 50% of the water is removed at the station.

The mat is then softened until the bonded fibers become tacky and other fibers in contact in an oven heated to a temperature between 110°C and 180°C to bond to carried to. These fibers are relatively hard but elastic after cooling Form a heat insulating mat material. The heat insulating mat material formed in this way after cooling is That is, the bat can be cut to an appropriate length or rolled into a long length if desired.

In a preferred embodiment of the invention, about 5% to 30% of the fibers of the mat before heating % is made up of bonded fibers. lower or higher temperature softening point and melting point Although it functions effectively even if the bonded fiber has and a melting point of 200°C or less.

Example 2 A mat is formed on a conveyor in the same manner as in Example 1. However, this implementation For example, fibers obtained from climbing clothes and other natural fibers are combined separately. Rather than adding synthetic fibers, bonding fibers are synthetic yarns used in clothing. It is part of the waste material used to form bats. In this case, the heating temperature is It is controlled to a value effective for melting or softening the thread.

A hardening resin is incorporated into the mat material when the emulsion is sprayed. The resin material and other additives are both soaked into the mat by spraying. be done.

The resin introduced into the mat is cured as well by an oven that heats the bonded fibers. The insulation batt is formed by coating the matte fibers with resin. strength is given to

Example 3 of natural and synthetic fibers obtained from waste, especially the wool of rags and cotton clothing. Mix the mixture with other waste wool fibers to determine the total wool content in the mixture. The amount is about 90%, and the mixture is made of polyamide fiber and polyester fiber. Add a length of about 20mm of bonding fiber made of a mixture of fiber and nylon. Ta.

Randomly distribute bonded fibers by mixing them with other fibers The fibers were then transferred to a forming hopper. The forming hopper extends vertically. The fibers have substantially parallel sides that form the fibers into a mat structure. This map The fibers are conveyed from the bottom of the hopper to a conveyor, where they are rolled. A mat of the desired thickness is formed by using the lathe.

The mat thus formed is conveyed through the oven by a conveyor and The bonding fiber is heated here to a temperature between 160” and 180°C. The bar softens or melts, and the softened fibers become sticky and come into contact with each other. can be coupled to fibers of On the other hand, the molten thermoplastic resin material A bead is formed by reaching the intersection.

The formed mat is heated and then cooled, and the softened or melted pre-stretching resin is When recured, a heat insulating mat material having relatively hardness and elasticity is formed.

The cooled mat is cut into batts of desired length.

Example 4 A mat is formed in the same manner as in the third example. However, before passing through the oven A resin-based material is sprayed onto the top surface of the mat, and the fibers forming the top surface are sprayed onto the top surface of the mat. becomes wet and forms a resin-based skin there.

The mat can then be passed through the oven. The residence time in this oven is The resin skim is not sufficient to completely soften or melt the bonded fibers. The time should be set long enough to cure the material.

The mat is then turned over so that the bottom side that was in contact with the conveyor becomes the top side. , a resin-based material is sprayed onto this surface. Matt then returns to the oven, Alternatively, the bonded fibers of the pre-coated resin are softened and/or introduced into a second oven. Otherwise, it is continuously heated until it melts. In this second oven, The second resin surface is similarly cured.

The mat leaving the second oven has resin skins on both sides, and these skins This assists in supporting the insulating batt and at the same time aids in handling the batt.

Example 5 The coupling fiber is a special fiber containing aluminum powder as a microwave receptor. The mat is formed in a similar manner as described in Example 3, except that the bar . This bonded fiber is formed by extrusion and has a softening point of 160°C. Ru.

The mat thus formed is passed through a microwave oven and The aluminum powder is completely heated by the energy, and the bonded fibers are heated and softened and Binds to adjacent fibers. This heating is done internally and cannot be Residence time in the bun is relatively short.

Microwave energy also heats the moisture in the fibers that make up the mat. In other words, it exerts a drying effect and reduces the moisture content inside the insulation batt. Ru.

Resin spraying and curing by utilizing bonded fibers inside the mat according to the present invention The difficulties associated with this and the attendant problems of handling toxic materials are eliminated. Sara In particular, bats produced in this way can be made from waste wool material and other waste materials. By using this method, it becomes more economical.

As can be understood from the above explanation, wool, synthetic and other natural fibers are are combined to form an insulating batt, and this insulating batt is attached at the desired location. can. Also, such bats can be broken into small spheres and blown to the desired location. However, by otherwise dispersing it can also provide a thermal insulation function.

The inherent insulating properties of wool, synthetic and other natural fibers make them especially suitable for matte forms. The thickness of the batt should be equal to that of glass fibers with similar insulation properties. It can be made much thinner than the thickness of the bat.

In other words, the present invention eliminates the health hazards of existing insulation measures and can use second-grade wool, improving the economics of wool return for farmers, and Provides a means of insulation equivalent to that of the one to be replaced. . In addition, the present invention uses discarded wool, synthetic and other natural fibers, i.e. Garments made of wool, synthetic and other natural fibers are available in rags and raw material costs are low. The number of people is reduced to nothing.

Also, although the explanation was made assuming that the combined fibers are heated using an oven, Other means of heating can also be used, including irradiation with electron beams, heating fluids, and the like.

Similarly, although preferred chemicals and resins have been described above, they may also be used with fibers. Other chemicals and resins may be used as long as they are compatible.

Flexible or lightweight natural or synthetic fibers or non-elastic fibers The batt formed by If you don't give it strength, it will collapse from the inside over time, reducing its insulation properties. . Therefore, the bonding fibers used ensure the shape and structural integrity of the bat. It must be selected so that it can be maintained. Also, if desired, starch , resin reinforcing agents and other reinforcing agents, spraying is added to emulsions, and slivers are also added. or by spraying the mat separately or using suitable resin fibers dispersed in the mat. or by using resin powder dispersed in the mat, it can be added to the batt for insulation. Heating the bat is inherently difficult, so the mat that forms the bat is relatively thin. Once formed, two or more mats can be stacked together to achieve the desired thickness. is formed.

In addition, we added reinforcements to give the bat enough rigidity so that it can stand on its own when stood upright at the end. Even if the bat is formed on the strong web so that the reinforcing web is integrated with the bat. good. In other words, webs made of plastic mesh materials, aluminum foil, etc. The mat is formed directly on the reinforcing web, or the reinforcing web is formed between two mats. A batt of a desired thickness may be formed by stacking them in a sandwiched state.

Alternatively, reinforcing fibers may be added to the fibers that make up the mat. These reinforcing fibers are thick and strong enough to increase the stiffness of the bat. It is something that

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Claims (17)

[Claims] 1. Monoacrylic or acrylic fiber or other synthetic fiber or Combining fibers consisting of acetate fibers and 0-95% wool fibers A method for producing an insulating bat made of It has a softening point or melting point of between 50°C and has adhesive properties that allow it to adhere to the fibers. Synthetic plastics, resins or other materials that are softened or melted until Add a combined fiber of to form a mat of desired thickness in which the fibers are randomly dispersed, heating at least the bonded fibers in the mat to their softening or melting point; an insulating batt comprising the step of heating to bond the fibers forming said mat; manufacturing method. 2. Tattering waste textiles and other waste fibers, including wool fibers Prepare the fibers making up said mat by combing, otherwise stripping. The method for manufacturing a heat insulating batt according to claim 1, further comprising the step of: 3. The randomly dispersed fibers are coated with flame retardants, pesticides and/or smoke suppressants. The method for producing a heat insulating batt according to claim 1 or 2, further comprising the step of adding an agent. 4. The randomly dispersed fibers are activated and hardened by heat. Any one of claims 1 to 3, further comprising a step of adding a powder-like or powder-like resin material. The method for producing a heat insulating bat as described in the above. 5. A claim comprising the step of spraying a synthetic resin on at least one surface of the mat. Item 5. A method for manufacturing a heat insulating bat according to any one of Items 1 to 4. 6. The material of the bonding fiber is copolyamide, saponified ethylene vinyl acetate. Copolymer, polyester, nylon, polyoliphant The groove is selected from the group consisting of: 5. The method for manufacturing a heat insulating bat according to any one of 5. 7. A microwave receptor is added to at least a portion of the coupling fiber and includes a microwave receptor. The heat insulating bag according to any one of claims 1 to 6, which is coated or coated. Method of manufacturing. 8. The microwave receptor is aluminum powder or polyacetylene. Item 7. The method for manufacturing an insulating batt according to item 7. 9. Said heating is performed by microwave energy applied to said mat. The method for manufacturing a heat insulating bat according to any one of claims 1 to 8. 10. The bonding fibers may be present in the mat at a concentration of about 5% to about 25% by weight before heating. 7. The method of manufacturing an insulating batt according to claim 6, wherein the insulating batt is present in % by weight. 11. The wool fibers are present in the mat at a concentration of about 25% to about 8% by weight before heating. 11. The method of manufacturing an insulating batt according to claim 10, wherein the insulating batt is present at 0% by weight. 12. Prior to the heating step, the mat is reduced in moisture content of its fibers. The method for manufacturing a heat insulating bat according to any one of claims 1 to 11, further comprising drying the bat for drying. 13. An insulating bat made by bonding fibers containing 50% or more wool fibers. A process for producing a thermoplastic having a softening point between 120°C and 180°C. The resin fiber and at least the surface part are soft between 120°C and 180°C. A consequential fiber with a conversion point, a thermoplastic material, and a microwave receptor. Approximately 25% of the combined fibers are selected from a groove consisting of composite fibers. In addition to said fibers, said fibers and said coupling fibers A mat of a desired thickness in which the particles are randomly dispersed is formed, and the mat is heated and/or or by applying microwaves to the bonded fibers at least until they become tacky. softening the bonded fibers to adhere them to other fibers; or The fibers are bonded by adhering the other fibers to each other, and A method for manufacturing an insulating batt comprising the step of forming the mat into individual batts. . 14. drying the mat before bonding the fibers; The method for manufacturing a heat insulating bat according to claim 13. 15. The mat is sprayed with or impregnated with resin thread material, and then the resin is hardened. The heat insulating bag according to claim 13 or 14, further comprising a step of converting the heat insulating bag into Method of manufacturing. 16. Layering two or more mat sections to form a composite batt. The method for manufacturing a heat insulating batt according to claim 13, comprising: 17. 14. The method of claim 13, further comprising the step of integrally forming the bat with a reinforcing web. The method of manufacturing the heat insulating bat described.