US20050191925A1 - Layered polymer fiber insulation and method of making thereof - Google Patents

Layered polymer fiber insulation and method of making thereof Download PDF

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Publication number
US20050191925A1
US20050191925A1 US10/789,143 US78914304A US2005191925A1 US 20050191925 A1 US20050191925 A1 US 20050191925A1 US 78914304 A US78914304 A US 78914304A US 2005191925 A1 US2005191925 A1 US 2005191925A1
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Prior art keywords
liner
layer
insulator
fibers
layers
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US10/789,143
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English (en)
Inventor
Jeffrey Tilton
Jerry Parks
Larry Targett
Gregory Helwig
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Owens Corning Intellectual Capital LLC
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Individual
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Priority to US10/789,143 priority Critical patent/US20050191925A1/en
Assigned to OWENS-CORNING FIBERGLASS TECHNOLOGY reassignment OWENS-CORNING FIBERGLASS TECHNOLOGY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HELWIG, GREGORY S., PARKS, JERRY M., TARGETT, LARRY E., TILTON, JEFFREY A.
Priority to PCT/US2005/006213 priority patent/WO2005084934A1/fr
Publication of US20050191925A1 publication Critical patent/US20050191925A1/en
Assigned to OWENS CORNING INTELLECTUAL CAPITAL, LLC reassignment OWENS CORNING INTELLECTUAL CAPITAL, LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: OWENS-CORNING FIBERGLAS TECHNOLOGY, INC.
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/08—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • 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
    • D04H1/54—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 by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/559—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 by welding together the fibres, e.g. by partially melting or dissolving the fibres being within layered webs
    • 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
    • D04H1/72—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 randomly arranged
    • D04H1/732—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 randomly arranged by fluid current, e.g. air-lay
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/728—Hydrophilic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/73—Hydrophobic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00—Buildings or parts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/637—Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/637—Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
    • Y10T442/638—Side-by-side multicomponent strand or fiber material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/637—Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
    • Y10T442/64—Islands-in-sea multicomponent strand or fiber material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/637—Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
    • Y10T442/641—Sheath-core multicomponent strand or fiber material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/659—Including an additional nonwoven fabric
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/659—Including an additional nonwoven fabric
    • Y10T442/66—Additional nonwoven fabric is a spun-bonded fabric
    • Y10T442/663—Hydroentangled
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/659—Including an additional nonwoven fabric
    • Y10T442/671—Multiple nonwoven fabric layers composed of the same polymeric strand or fiber material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/689—Hydroentangled nonwoven fabric
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/69—Autogenously bonded nonwoven fabric
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/696—Including strand or fiber material which is stated to have specific attributes [e.g., heat or fire resistance, chemical or solvent resistance, high absorption for aqueous compositions, water solubility, heat shrinkability, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T442/697—Containing at least two chemically different strand or fiber materials

Definitions

  • the present invention relates generally to a multilayer, wet processed, polymer-based mats having bicomponent and polymer staple fibers, where the layers are bonded together using heat and pressure.
  • This acoustical and thermal liner/insulator may be utilized to insulate an environment such as a passenger compartment of a vehicle from the heat and sound generated by mechanical components of that vehicle during its operation.
  • Other uses include application in insulating appliances such as dishwashers and clothes dryers and providing sound and thermal insulation for furnaces, air conditioning units and ductwork in buildings including homes, offices and industrial structures.
  • Acoustical insulation is well known in the art. Acoustical insulation typically relies upon both sound absorption, i.e. the ability to absorb incident sound waves, and transmission loss, i.e. the ability to reflect incident sound waves, in order to provide sound attenuation.
  • Sound absorption i.e. the ability to absorb incident sound waves
  • transmission loss i.e. the ability to reflect incident sound waves
  • One of the more prevalent uses of such insulation is in the motorized vehicle field where engine compartments, fire walls, fender wells, doors, floor pans and other components of the passenger compartment shell are commonly acoustically insulated to reduce engine and road noise for the benefit and comfort of passengers. Acoustical insulation is also prevalent in appliances such as dishwashers and heating and air conditioning units.
  • U.S. Pat. No. 6,008,149 discloses a moldable nonwoven fibrous composite article including at least two functional layers, which are made of the same nonwoven thermoformable polymeric chemical substance or material.
  • the composite articles are molded from separate rolls or sheets of variable compression and formable fabric layers.
  • Each of U.S. Pat. Nos. 6,156,682 and 6,364,976 discloses a laminated structure having a core of polymeric fibers, a thermosetting resin impregnated into the core, and individual chopped fibers randomly applied to opposite sides of the core layer.
  • the preferred method of bonding the fibers together is by a bicomponent fiber, in which an outer layer of fibers is constituted by a low melt temperature polymer, and an inner core layer of fibers which constitutes a polymer with a relatively higher melt temperature.
  • U.S. Pat. No. 4,780,359 discloses a nonwoven textile panel constructed of three layers of nonwoven textile fibers of polyphenylene sulfide fibers and Nomex® brand aramid fibers that have been carded, cross-lapped, needled-punched and thermally bonded by heating the panel to the temperature softening point of the polyphenylene sulfide fibers.
  • U.S. Pat. No. 5,501,898 discloses a support part for automobile roof linings.
  • the part may have from one to three layers consisting exclusively of polyester fibers.
  • the part contains no binder resin, connective fibers or glass fibers. All of the layers are pressed and compacted into the intended shaped by the action of pressure and heat.
  • U.S. Pat. No. 5,709,925 discloses a multi-layered laminated body used as an interior trim panel for an automobile.
  • the panel includes a three-layer substrate which includes a layer of natural fiber filler material embedded in a thermoplastic matrix and two cover layers comprising natural fibers, glass fibers or polyester fibers in a thermoplastic matrix material.
  • the panel further includes a foam intermediate layer and a decorative surface layer. The panels are produced by hot-laminating the individual layers of the substrate together and then laminating and molding the decorative surface layer onto the substrate.
  • an improved acoustical, compressible, polymer fiber liner/insulator is provided.
  • the blanket is made of multiples layers of wet process polymer based mats formed of bicomponent fiber and polymer staple fibers bonded together using heat and pressure.
  • the liner/insulator is typically used in automotive applications such as automobile doors or automobile passenger compartments to insulate the compartments from the heat and sound.
  • the thermal/acoustical liner may also be used in appliances such as dishwashers, heating and air conditioning units, marine applications and commercial interiors.
  • FIG. 1 is a cross-sectional view of the liner/insulator of the present invention.
  • FIG. 2 illustrates a wet-processing line for forming the liner/insulator of FIG. 1 .
  • FIG. 1 illustrates the liner/insulator designated by reference numeral 1 .
  • the polymer fiber blanket 1 is constructed of a plurality of layers 2 , 4 , and 6 .
  • Layers 2 , 4 and 6 are individual layers of wet processed mat.
  • FIG. 3 illustrates a typical processing line 50 .
  • a combination of polymer staple fibers 22 and the bicomponent fibers 24 are added to a whitewater chemical dispersion 52 within a mixing tank 56 to form thick whitewater slurry 54 at consistency levels of approximately 0.2 to 1 percent.
  • the thick slurry 54 formed is maintained under agitation in a single tank 56 or series of tanks.
  • the whitewater chemical dispersion 52 is used to obtain reasonable filamentation of the polymer staple fibers 22 and the bicomponent fibers 24 through steric, thermodynamic, and charge colloidal interactions.
  • the preferred whitewater dispersion 52 includes a viscosity modifier, a defoamer and a surfactant.
  • the viscosity modifiers used in the whitewater dispersion 52 are commonly used in nonwoven-type applications.
  • One preferred class of viscosity modifiers is a polyacrylamide viscosity modifier such as Nalco 7768, Magnifloc 1886A, and HyChem AE 874.
  • Another preferred viscosity modifier is a hydroxyethylcellulose, such as Natrosol 250HHBR.
  • other possible viscosity modifiers or flocculants that may be used include high molecular weight, water-soluble polymers that are well known to those of ordinary skill in the art.
  • the surfactants, or cationic dispersants, used in the whitewater dispersion aid in the wetting of the polymer staple fibers and the bicomponent fiber so that bundles of the fibers will disperse into individual filaments.
  • One class of surfactants utilized are ethoxylated alkylamine dispersants such as Schercopol DS-140, Nalco 8493, or Rhodameen VP532.
  • other dispersants may be used as well, including fatty acid amine oxides and polyethoxylated derivatives of amide condensation of fatty acid products.
  • preferred defoamers utilized in the whitewater dispersion 52 include Nalco PP04-3840 and GEO FM LTX.
  • the thick slurry 54 is then delivered through a control valve 58 and combined with a whitewater stream 76 from a silo 78 to form a lower consistency slurry 80 in the former 82 .
  • the ratio of thick slurry 54 to the silo stream 78 in the lower consistency slurry 80 will typically be in the range of 1:10 and 1:40.
  • the former 82 functions to equally distribute and randomly align the fibers 22 , 24 onto a moving woven fabric, or forming wire 96 , therein forming the filament network 14 .
  • Formers 82 that can accommodate the initial fiber formation include Fourdrinier machines, Stevens Former, Roto Former, Inver Former, cylinder, and VertiFormer machines. These formers offer several control mechanisms to control fiber orientation within the network 14 such as drop leg and various pond regulator/wall adjustments.
  • Deposited fibers forming the network 14 are partially dried over one or more suction boxes 94 .
  • the dewatered network 14 is then run through a drying oven 97 at a temperature sufficient to remove any excess water and sufficient to melt the sheath of the bicomponent fibers 24 , typically about 130 to 180 degrees Celsius.
  • the sheath material cools and adheres to polymer staple fibers 22 , therein forming one of the insulating layers.
  • the wet process is preferred over various dry-laid processes because the wet process provides an insulating layer with a more consistent weight per unit area.
  • the wet process also provides more intimate mixing of the fiber blends and more random fiber orientation. Compared with dry-laid processes, the wet process is capable of high production rates, thus providing a less costly insulating layer.
  • the layers 2 , 4 and 6 are preferably made of thermoplastic polymer fibers including thermoplastic polymer bicomponent fibers and thermoplastic polymer staple fibers.
  • the thermoplastic staple fibers and bicomponent fibers may be selected from a group of materials including but not limited to polyester, polyethylene, polypropylene, nylon, rayon, acetate, natural fibers (i.e., kenaf or hemp), polyethylene terephthalate and any mixtures and/or copolymers thereof. Further examples of fibers used can be found in commonly assigned U.S. patent application Ser. No. 10/636,078, filed Aug. 7, 2003.
  • the mat is made of 100% polymer fibers (polymer bicomponent fibers and polymer staple fibers).
  • the bicomponent fibers bond the fibers together within each individual layer of the mat. Heat and pressure is then applied to the mat and the multiple layers 2 , 4 and 6 are bonded together. Conventional flow-through ovens used in the art are used to heat and apply pressure to the layers 2 , 4 and 6 .
  • a surface-treating device may be used to bond the layers together such as that described in commonly assigned U.S. patent application Ser. No. 10/609,947, filed Jun. 30, 2003 herein incorporated by reference in its entirety.
  • the preferred temperature used to bond the layers 2 , 4 , 6 is between about 250° to about 400° F.
  • the amount and type of bicomponent fibers selected for the fiber formulation determines the strength of the bond formed between the multiple layers.
  • the layers 2 , 4 and 6 are typically between about 0.05 to about 0.30 inches thick.
  • the thickness of the final product is between about 0.125 and about 1.5 inches thick.
  • the layers 2 , 4 , 6 can have the same thickness, weight, fiber formulation or the layers can have two or more different combinations of fiber formulations, thickness and weight.
  • base layer 6 may be formulated to have a high heat resistance and/or have hydrophilic properties.
  • fibers such as high-melting bicomponent fibers, semi-crystalline fibers, thermoset polymer fibers or fibers coated with a heat resistant resin may be used.
  • hollow or shaped polymer fibers may be utilized. Further, the fibers may be coated with a water-swellable coating.
  • Another layer such a layer 4 may be composed of a fiber formulation that provides a barrier to moisture (hydrophobic fibers).
  • fibers in layer 4 include, but are not limited to, polyolefins, polyacetate and fibers having small pores or micro-denier fibers may be utilized.
  • Layer 2 may be composed of a fiber formulation that absorbs sound. Examples of sound absorbing fibers include, but are not limited to, natural fibers such as hemp and kenaf.
  • the liner/insulator may include a facing, on one or both sides, to improve strength and/or surface appearance.
  • a facing on one or both sides, to improve strength and/or surface appearance.
  • Other embodiments including facings and fiber combinations that may be used with the present invention are discussed in U.S. Pat. No. 6,669,265, which is incorporated herein by reference in its entirety.
  • a facing may be applied to the liner/insulator by heating one side of the liner/insulator, while the other side remains relatively cool.
  • a pressure is then applied for sufficient time to allow the polymer binding fiber to soften near the hot surface but not near the cold surface. When this occurs under compression, the hot side is reshaped into a higher density surface layer.
  • the cool side of the polymer binding fiber does not soften and, therefore, when the pressure is removed, the base zone retains most of its original thickness and density characteristics.
  • the intermediate zone undergoes only moderate densification.
  • This technique may be performed in a standard molding press where one platen runs hot and the other runs cool. This is followed by the printing of a selected face of the facing layer with desired graphics, patterns, designs or indicia. This process is described in detail in U.S.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Nonwoven Fabrics (AREA)
US10/789,143 2004-02-27 2004-02-27 Layered polymer fiber insulation and method of making thereof Abandoned US20050191925A1 (en)

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PCT/US2005/006213 WO2005084934A1 (fr) 2004-02-27 2005-02-25 Isolant de fibres polymères en couches et son procédé de fabrication

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Cited By (8)

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DE102005048603A1 (de) * 2005-10-06 2007-04-26 J.H. Ziegler Gmbh & Co. Kg Mit Kunststoff infiltrierbares Vlieslaminat für die Herstellung von faserverstärkten Kunststoffteilen
US20070270071A1 (en) * 2006-05-18 2007-11-22 Greer J Travis Nonwoven fabric towel
US20080003907A1 (en) * 2006-06-28 2008-01-03 Samuel Keith Black Facing Product for Vehicular Trim
US20080083279A1 (en) * 2005-12-28 2008-04-10 Lear Corporation Random incident absorber approximation
DE102007033635A1 (de) * 2007-03-20 2008-12-11 Johann Borgers Gmbh & Co Kg Vliesstoff-Formteil für Fahrzeuge
US20100287860A1 (en) * 2006-02-28 2010-11-18 Fernandez-Cano Pedro Luis Insulated Facade System
DE102009059975A1 (de) 2009-12-22 2011-06-30 Sitech Sitztechnik GmbH, 38442 Sitzstruktur
DE102017123283A1 (de) * 2017-10-06 2019-04-11 J.H. Ziegler Gmbh Vorrichtung, insbesondere Faserverbundproduktionsvorrichtung

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102005048603A1 (de) * 2005-10-06 2007-04-26 J.H. Ziegler Gmbh & Co. Kg Mit Kunststoff infiltrierbares Vlieslaminat für die Herstellung von faserverstärkten Kunststoffteilen
US20080083279A1 (en) * 2005-12-28 2008-04-10 Lear Corporation Random incident absorber approximation
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US20100287860A1 (en) * 2006-02-28 2010-11-18 Fernandez-Cano Pedro Luis Insulated Facade System
US20070270071A1 (en) * 2006-05-18 2007-11-22 Greer J Travis Nonwoven fabric towel
US20080003907A1 (en) * 2006-06-28 2008-01-03 Samuel Keith Black Facing Product for Vehicular Trim
DE102007033635A1 (de) * 2007-03-20 2008-12-11 Johann Borgers Gmbh & Co Kg Vliesstoff-Formteil für Fahrzeuge
DE102009059975A1 (de) 2009-12-22 2011-06-30 Sitech Sitztechnik GmbH, 38442 Sitzstruktur
DE102017123283A1 (de) * 2017-10-06 2019-04-11 J.H. Ziegler Gmbh Vorrichtung, insbesondere Faserverbundproduktionsvorrichtung

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