WO1989004886A1 - Bonded fibrous insulation batt - Google Patents
Bonded fibrous insulation batt Download PDFInfo
- Publication number
- WO1989004886A1 WO1989004886A1 PCT/AU1988/000455 AU8800455W WO8904886A1 WO 1989004886 A1 WO1989004886 A1 WO 1989004886A1 AU 8800455 W AU8800455 W AU 8800455W WO 8904886 A1 WO8904886 A1 WO 8904886A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- fibres
- mat
- bonding
- batt
- heating
- Prior art date
Links
- 238000009413 insulation Methods 0.000 title description 18
- 238000000034 method Methods 0.000 claims abstract description 32
- 210000002268 wool Anatomy 0.000 claims abstract description 31
- 239000000463 material Substances 0.000 claims abstract description 30
- 239000002699 waste material Substances 0.000 claims abstract description 17
- 229920001169 thermoplastic Polymers 0.000 claims abstract description 14
- 239000004416 thermosoftening plastic Substances 0.000 claims abstract description 14
- 238000002844 melting Methods 0.000 claims abstract description 12
- 230000008018 melting Effects 0.000 claims abstract description 12
- 238000010438 heat treatment Methods 0.000 claims description 33
- 239000011347 resin Substances 0.000 claims description 32
- 229920005989 resin Polymers 0.000 claims description 32
- 239000000835 fiber Substances 0.000 claims description 16
- 230000000694 effects Effects 0.000 claims description 8
- 239000003063 flame retardant Substances 0.000 claims description 7
- 239000000575 pesticide Substances 0.000 claims description 7
- 229920002994 synthetic fiber Polymers 0.000 claims description 7
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 claims description 6
- 238000001035 drying Methods 0.000 claims description 6
- 239000004033 plastic Substances 0.000 claims description 6
- 229920003023 plastic Polymers 0.000 claims description 6
- 239000000843 powder Substances 0.000 claims description 6
- 230000003014 reinforcing effect Effects 0.000 claims description 6
- 229920000728 polyester Polymers 0.000 claims description 5
- 239000012260 resinous material Substances 0.000 claims description 5
- 239000000779 smoke Substances 0.000 claims description 5
- 238000005507 spraying Methods 0.000 claims description 5
- 239000004411 aluminium Substances 0.000 claims description 4
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical group [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 4
- 229910052782 aluminium Inorganic materials 0.000 claims description 4
- 239000004753 textile Substances 0.000 claims description 4
- 229920003043 Cellulose fiber Polymers 0.000 claims description 3
- 239000004677 Nylon Substances 0.000 claims description 3
- 229920001778 nylon Polymers 0.000 claims description 3
- 239000012815 thermoplastic material Substances 0.000 claims description 3
- HSFWRNGVRCDJHI-UHFFFAOYSA-N alpha-acetylene Natural products C#C HSFWRNGVRCDJHI-UHFFFAOYSA-N 0.000 claims description 2
- 239000005038 ethylene vinyl acetate Substances 0.000 claims description 2
- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 claims description 2
- 229920001197 polyacetylene Polymers 0.000 claims description 2
- 239000004800 polyvinyl chloride Substances 0.000 claims description 2
- 229920000915 polyvinyl chloride Polymers 0.000 claims description 2
- 239000002131 composite material Substances 0.000 claims 2
- 238000010030 laminating Methods 0.000 claims 1
- 239000000155 melt Substances 0.000 claims 1
- 229920003002 synthetic resin Polymers 0.000 claims 1
- 239000000057 synthetic resin Substances 0.000 claims 1
- 239000000839 emulsion Substances 0.000 description 7
- 239000007921 spray Substances 0.000 description 6
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 6
- 239000012530 fluid Substances 0.000 description 5
- 239000000203 mixture Substances 0.000 description 5
- 230000008569 process Effects 0.000 description 5
- 229920000742 Cotton Polymers 0.000 description 4
- 239000011324 bead Substances 0.000 description 4
- 239000004744 fabric Substances 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 4
- 239000000654 additive Substances 0.000 description 3
- 230000015572 biosynthetic process Effects 0.000 description 3
- 239000011152 fibreglass Substances 0.000 description 3
- 231100001261 hazardous Toxicity 0.000 description 3
- 230000036541 health Effects 0.000 description 3
- 239000003351 stiffener Substances 0.000 description 3
- RLLPVAHGXHCWKJ-IEBWSBKVSA-N (3-phenoxyphenyl)methyl (1s,3s)-3-(2,2-dichloroethenyl)-2,2-dimethylcyclopropane-1-carboxylate Chemical compound CC1(C)[C@H](C=C(Cl)Cl)[C@@H]1C(=O)OCC1=CC=CC(OC=2C=CC=CC=2)=C1 RLLPVAHGXHCWKJ-IEBWSBKVSA-N 0.000 description 2
- MXRIRQGCELJRSN-UHFFFAOYSA-N O.O.O.[Al] Chemical compound O.O.O.[Al] MXRIRQGCELJRSN-UHFFFAOYSA-N 0.000 description 2
- 241001651311 Perigenes Species 0.000 description 2
- 239000004952 Polyamide Substances 0.000 description 2
- 238000009960 carding Methods 0.000 description 2
- 239000003153 chemical reaction reagent Substances 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 2
- 238000009434 installation Methods 0.000 description 2
- 239000012774 insulation material Substances 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 239000004745 nonwoven fabric Substances 0.000 description 2
- 229920002647 polyamide Polymers 0.000 description 2
- 238000011282 treatment Methods 0.000 description 2
- 241000396431 Anthrenus scrophulariae Species 0.000 description 1
- 241001465754 Metazoa Species 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 229920002472 Starch Polymers 0.000 description 1
- 241000130767 Tineidae Species 0.000 description 1
- 239000002998 adhesive polymer Substances 0.000 description 1
- 239000005030 aluminium foil Substances 0.000 description 1
- 238000007664 blowing Methods 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 230000001609 comparable effect Effects 0.000 description 1
- 239000012809 cooling fluid Substances 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000002276 dielectric drying Methods 0.000 description 1
- 238000010894 electron beam technology Methods 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 244000144992 flock Species 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 239000000383 hazardous chemical Substances 0.000 description 1
- 231100000206 health hazard Toxicity 0.000 description 1
- 238000010348 incorporation Methods 0.000 description 1
- 239000011810 insulating material Substances 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002923 metal particle Substances 0.000 description 1
- 230000005012 migration Effects 0.000 description 1
- 238000013508 migration Methods 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
- -1 polypropylene Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 238000010008 shearing Methods 0.000 description 1
- 238000004513 sizing Methods 0.000 description 1
- 239000008107 starch Substances 0.000 description 1
- 235000019698 starch Nutrition 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 235000013616 tea Nutrition 0.000 description 1
- 231100000331 toxic Toxicity 0.000 description 1
- 230000002588 toxic effect Effects 0.000 description 1
- 230000032258 transport Effects 0.000 description 1
Classifications
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—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
- D04H1/4266—Natural fibres not provided for in group D04H1/425
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4274—Rags; Fabric scraps
-
- 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
-
- 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
- D04H1/542—Adhesive fibres
- D04H1/544—Olefin 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
- D04H1/54—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
- D04H1/542—Adhesive fibres
- D04H1/546—Polyvinyl acetate
-
- 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
- D04H1/542—Adhesive fibres
- D04H1/549—Polyamides
-
- 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
- D04H1/542—Adhesive fibres
- D04H1/55—Polyesters
-
- 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
- D04H1/542—Adhesive fibres
- D04H1/551—Resins thereof not provided for in groups D04H1/544 - D04H1/55
-
- 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
- E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
- E04B1/78—Heat insulating elements
-
- 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
- E04B2001/743—Animal products, e.g. wool, feathers
-
- 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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
- Y02A30/00—Adapting or protecting infrastructure or their operation
- Y02A30/24—Structural elements or technologies for improving thermal insulation
- Y02A30/244—Structural elements or technologies for improving thermal insulation using natural or recycled building materials, e.g. straw, wool, clay or used tires
Definitions
- the present invention relates to improvements in thermal insulation material, and in particular to the use of bonded synthetic fibres such as onoacrylic, acrylic or polyamide, polyester and like synthetic or cellulose fibres either alone or in combination with animal fibres and either in batt form or as 'blow in' insulation.
- bonded synthetic fibres such as onoacrylic, acrylic or polyamide, polyester and like synthetic or cellulose fibres either alone or in combination with animal fibres and either in batt form or as 'blow in' insulation.
- Australian Patent No. 500,317 discloses a method of producing a bonded, non-woven, fibrous batt.
- the batt is formed of crimped or crimpable conjugate fibres and is subjected to a heat treatment by upward passage through the batt of a fluid having a temperature in excess of the softening temperature of the lower softening component of the conjugate fibres. Such heating effects inter-fibre bonding between the conjugate fibres.
- a cooling fluid is then passed upwardly through the bonded batt whereby the fibres are quenched without any batt collapse.
- the method of this patent is dependent on the upward passage of fluid through the material.
- an insulating batt is designed to insulate, and thereby effectively prevent passage of fluid therethrough.
- Lapsed Australian Patent Application No. 59302/73 discloses the formation of non-woven fabrics from a web of fibres which include thermoplastic fibres, and subject ⁇ ing the web to heat thereby the thermoplastic fibres melt to a series of fluid beads which locate at cross-over points of non-thermal fibres.
- the melted thermoplastic beads must be able to locate at non-thermal fibre cross-over points.
- the rough surface of wool fibres mitigates against such migration of the thermoplastic beads and, therefore, a substantial quantity of the thermoplastic fibres is required for proper operation of this process with wool fibres.
- the present invention provides a method of forming a batt of bonded fibres for use as insulation, said fibres comprising monoacrylic, acrylic or other synthetic or cellulose fibres with from 0 to 95% wool fibres, comprising the steps of incorporating with said fibres, bonding fibres of a synthetic plastics material, resin, or other material having a relatively low melting or softening point, forming said batt by any suitable means, such as by ragging, teasing and otherwise doffering the fibres of waste textile and other materials to form a randomly dispersed fibre sliver and passing said sliver through a lapper to thereby form a mat of a desired thickness, optionally incorporating in said mat a fire retardant, pesticide and a smoke retardant, heating said mat to a temperature at which the bonding fibres at least soften to a tackiness whereby the softened 1 fibres bond with other fibres in the mat, and cooling said mat, and cutting the mat to form batts of a desired length.
- the bonded woollen fibres are bonded so the batt is lofty and has a plurality of air pockets which assists in the insulation effect. If desired for a 'blow in' installation, the batts may be broken down into small balls of bonded fibre in loose form. Use of wool fibres can amount to between 25% and
- the bonding fibres may be selected from any relatively low melting point resinous or thermoplastics material, such as copolyamide fibres, saponified ethylene- vinyl acetate copolymer fibres, polyester fibres, nylon polyolifants, polyvinyl chloride and the like.
- Bi- component fibres may also be used in which one part, e.g. an inner core, is a relatively high melting point fibre with a second part, e.g. an outer layer, of a relatively low melting point.
- filaments may be distributed in a matrix.
- the bonding fibres may be present in amounts of from 1% to 60%.
- Other fibres which are combined with the wool fibres and which are useful in the invention include mono- acrylic, acrylic, polyamide and polyester synthetic fibres as well as other natural fibres such as cotton. These types of fibres, when matted and bonded together in a batt, preferably with additional wool fibres, results in an insulation material which is extremely economical to produce, which can be formed of waste clothing and other waste materials and which has excellent insulating properties without the hazards of other known insulating products.
- bonding fibres By incorporating bonding fibres into dispersed fibres throughout the mat, the softening or melting of the bonding fibres completely bonds the other fibres and maintains the loft and resiliency of the batts.
- the stiffness of an insulating batt formed in accordance with the invention may be increased by the use of resins or sizing agents incorporated in or sprayed onto the batt.
- resinous material is incorporated in the batt by incorporating either resin fibres or resin powder in the material from which the batt is formed. The resin is activated and cured during the heating step so as to coat fibres within the batt and stiffen the batt structure.
- the mat used for the formation of the insulating batt may be sprayed on one or both sides with a resinous material to provide a resin skin on the batt which acts to stiffen the batt.
- the resin spray is preferably applied prior to heating so that the heating which softens the thermoplastic fibres also cures the resin.
- the batt may be sprayed after the initial heating in which case a second heating step is required to cure the resin.
- the mat may be formed from a fibre sliver which is passed through a lapper to produce the mat of a desired thickness
- the mat may also be produced by ragging, teasing or otherwise separating fibres of waste textile and other materials and blowing or otherwise conveying the fibres, randomly dispersed, to a mat forming conveyor on which the fibres are disposed at the desired thickness.
- Wool and other fibres tend to be affected by heat and moisture and become soft and less resilient. Because of the water content of the natural fibres and the preferred optional materials, up to 75% by weight, the heat required to soften the thermoplastic fibres and to melt the resins may cause the mat to collapse and shrink.
- the mat is therefore preferably treated prior to the heating step to remove up to 80% of the water in a manner which obviates or reduces the heating effect on the fibres and resin.
- the water removal treatment is carried out by dielectric heating.
- other substan ⁇ tially non-heating treatments may also be used.
- microwave heating may be used for softening the thermoplastic fibres, for melting any resins present and for drying.
- Such microwave heating may take place in two or more stages, a first heating stage taking place to dry the batt fibres prior to mixing or incorporat- ing the bonding fibres.
- a second heating stage follows the formation of the mat, after incorporation of the bonding fibres, to cause the bonding fibres to soften and bond with the other fibres in the mat.
- the bonding fibres are provided with microwave receptors either by incorporating a metal or other receptive material such as a polyacetylene in the fibre or by coating the bonding fibres with an appropriate microwave receptor.
- the bonding fibres are formed with aluminium or other metal particles which, when subjected to the microwaves, heat the bonding fibre to soften or melt the fibre.
- a microwave receptive material is incorporated into the fibres forming the mat so that, when subjected to microwave energy, the receptive material heats and heats the batt internally facilitating softening of the bonding fibres.
- the batt may incorporate appropriate additives for fire retardant, smoke retardant and pesticide purposes.
- the preferred additives to the mat fibres include Aluminium trihydrate and Ken Gard (Trade Mark) (I.C.I. smoke suppressant) and Perigen (Trade Mark) (a pesticide) especially suitable against clothes moths and carpet beetle and available from Burroughs Wellcome.
- the thermoplastic bonding fibres may include therewith fibres or powders of flame retardants, pigments, smoke suppressants, etc.
- the insulation so formed may be used in any location i.e. in home, office, factory or other building, for either heat or acoustic insulation.
- a mixture of ragged garments which include woollen, cotton and/or acrylic garments, with or without new wool, is fed together with bonding fibres of a low melting point polypropylene to a doffer, or carding mac ⁇ hine, which separates the fibres and teases them to form a sliver or relatively thin web of randomly dispersed fibres, comprising about 5% to 20% acrylic and cotton fibres, about 70% to 80% wool fibres and about 15% bonding fibres.
- the sliver has a thickness of about 1/8 inch.
- the sliver is fed from the doffer, or carding machine, onto a horizontal lapper which oscillates at a predeter ⁇ mined rate to deliver the sliver to a conveyor where the sliver is lapped onto itself to build up a mat of a pre- determined thickness.
- the lapper Before the sliver leaving the lapper engages on the conveyor, or on to previously lapped material on the conveyor, it is sprayed with an emulsion of fire retardant, pesticides, etc. such as Aluminium Trihydrate and Perigen pesticide.
- the water content of the emulsion is approx ⁇ imately 54% by weight.
- a spray boom having a plurality of spray nozzles for spraying the emulsion is mounted adjacent the lapper and is connected thereto by a linkage system which maintains the boom a predetermined distance from the sliver moving from the lapper towards the conveyor.
- the linkage system causes the boom to move with the lapper but through a distance related to the actual sliver movement which, because of the oscillating lapper movement and the distance between the lower end of the lapper and the conveyor, is different than the actual lapper movement.
- a second boom positioned on the opposite side of the sliver to the spray boom is fed with air to produce an air cushion to thereby balance the forces produced by the emulsion spray and maintain the sliver in its correct alignment with the conveyor.
- the mat formed of the lapped sliver, which is impregnated with the emulsion sprayed onto the sliver, is conveyed to a dielectric drying station and passes between spaced plate electrodes which are electrically charged by high frequency A.C. potential.
- the frequency and voltage applied to the plate electrodes are chosen to optimize drying of the mat with minimum heating of the fibres. At least 50% of the water content is removed at the drying station.
- the mat is then conveyed to an oven heated to between 110°C. and 180°C. to soften the bonding fibres to a tackiness so that they bond to other contacting fibres.
- the fibres form a relatively rigid but resilient insulating mat material.
- the cooled batt is cut into suitable lengths, or rolled in a long length, as required.
- the bonding fibres may comprise between 5% and 30% of the fibres in the mat before heating. It is preferred that the bonding fibres have a softening point greater than 120°C. and a melting point of less than 200°C, although it will be appreciated that lower or higher softening and melt temperatures will still be effective.
- Example 2
- a mat is formed on a conveyor in the same manner as described in Example 1.
- the bonding fibres are the synthetic yarns incorporated into clothing and which form part of the waste material from which the batts are made.
- the heating temperature is controlled to effect melting or sof-teni g of these yarns.
- a curable resin is incorporated into the material of the mat by incorporating it with the emulsion spray which impregnates the mat with both the resin material and the other additives.
- the oven which heats the bonding fibres also cures the resin incorporated in the mat, the resin being coated on fibres of the mat so as to add stiffness to the insulating batt so formed.
- a mixture of natural and artificial fibres obtained from waste, and particularly ragged woollen and cotton garments was mixed with other waste wool fibres so that the total woolen content of the mixture was approximately 90%.
- bonding fibres having a length of approximately 20 mm, the bonding fibres comprising a mixture of copolyamide fibres, polyester fibres and nylon.
- the bonding fibres and other fibres were mixed together so that the bonding fibres were randomly dis ⁇ persed, and the fibres conveyed to a forming hopper.
- the forming hopper has substantially parallel sides extending vertically and cause the fibres to form into a mat structure which is fed from the lower end of the hopper to a conveyor passed a roller which forms the mat on the conveyor to the desired thickness.
- the conveyor transports the formed mat through an oven in which the mat is heated to a temperature which is between 160° and 180°C. At this temperature, the bonding fibres soften or melt, the softened fibres developing a tackiness which enables them to bond to other, contacting fibres while the melted thermoplastic material migrates to junctions of intersecting fibres to form beads thereon.
- the formed mat After heating, the formed mat is cooled so that the softened or melted thermoplastic material re-solidifies to form a relatively rigid but resilient insulating mat material.
- the cooled mat is cut into batts of desired length.
- a mat is formed in the same manner as described in Example 3. However, prior to passing the mat through the oven, the upper surface of the mat is sprayed with a resinous material to thereby wet the fibres forming the upper surface and form a resinous skin thereon. The • mat is then passed through the oven, the oven dwell time being insufficient to fully soften or melt the thermo ⁇ plastic bonding fibres, but being sufficient to cure the resin skin.
- Example 5 A mat is formed in a similar manner to that described in Example 3 except that the bonding fibres are special fibres which incorporate aluminium powder as a microwave receptor. The fibres are formed by extrusion and have a softening point of 160°C.
- the formed mat is passed through a microwave oven in which the mat is subjected to microwave energy which causes the aluminium powder to heat thereby heating and softening the bonding fibres which bond with adjacent and contacting fibres. Because the heating effect occurs internally, the residence time in the oven is relatively short.
- the microwave energy also acts to heat moisture in the mat fibres thus having a drying effect on those fibres and thereby reduce the moisture content of the insulating batts.
- an integral bonding fibre in the mat in accordance with the invention avoids difficulties associated with spraying and curing resins and attendant problems of handling toxic materials.
- the insulation batt so produced is substantially more economical particularly when made using waste wool and other waste materials. From the foregoing it will be seen that wool, synthetic and other natural fibres are bonded together to form an insulation batt which may then be installed in a desired location. Alternatively, the batt may be broken down into small balls which are blown or otherwise spread over the desired location, again to provide insula ⁇ tion. By reason of the inherent insulating properties of the wool, synthetic and other natural fibres, partic ⁇ ularly when matted, the batt thickness is considerably less than the thickness of the fibreglass batt of compar- able heat insulation.
- the present invention provides a means of insulation that avoids the health hazards of the existing insulation, which is able to use discarded or second-grade wool fleeces, thereby improving the farmers' economic return on his flock, and yet the insulation so produced is equal to that which it is to replace.
- discarded wool, synthetic and other natural fibres, or wool, synthetic and other natural fibre garments may be ragged and used in the present invention, again reducing .the cost of raw materials.
- the bonding fibres used should preferably be selected to ensure the batt retains its bulk and structural integrity.
- a stiffening agent such as starch, resin stiffeners or similar agents, can beadded to the batt either by incorporating the stiffening agent into the sprayed emulsion or by separately spraying the sliver or the mat, or by use of a suitable resin fibre dispersed through the mat or by use of resin powders dispersed through the mat.
- the mat from which the batts are made may be formed as a relatively thin mat and two or more mats subsequently laminated together to form a batt of the desired thickness. Further, in order to provide sufficient rigidity for a batt to be self-supporting when stood on its end, the batt may be made onto a reinforcing web which becomes an integral part of the batt. Thus, the mat may be formed directly onto a reinforcing web, such as a web of plastic mesh material or an aluminium foil or the like, or two mats may be laminated together with a reinforcing web therebetween to form a batt of the desired thickness.
- a reinforcing web such as a web of plastic mesh material or an aluminium foil or the like
- a reinforcing fibre may be incorpor ⁇ ated with the fibres forming the matt, such reinforcing fibre having a thickness and stiffness such that the rigidity of the batt is enhanced.
Abstract
Description
Claims
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
BR888807813A BR8807813A (en) | 1987-11-25 | 1988-11-25 | FIBROUS, CONNECTED, INSULATION BLOCK |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AUPI559587 | 1987-11-25 | ||
AUPI5595 | 1987-11-25 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO1989004886A1 true WO1989004886A1 (en) | 1989-06-01 |
Family
ID=3772599
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/AU1988/000455 WO1989004886A1 (en) | 1987-11-25 | 1988-11-25 | Bonded fibrous insulation batt |
Country Status (5)
Country | Link |
---|---|
EP (1) | EP0389524A4 (en) |
JP (1) | JPH03501142A (en) |
AU (1) | AU629806B2 (en) |
BR (1) | BR8807813A (en) |
WO (1) | WO1989004886A1 (en) |
Cited By (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5160406A (en) * | 1989-04-14 | 1992-11-03 | Matec Holding Ag | Method for producing a formed structural element |
WO1993001341A1 (en) * | 1991-07-10 | 1993-01-21 | Cotton Unlimited, Inc. | Method for making insulation |
EP0591658A1 (en) * | 1992-10-07 | 1994-04-13 | Benno Steiner | Thermal insulation element and process for its manufacture |
FR2722803A1 (en) * | 1994-07-19 | 1996-01-26 | Heraklith Holding Ag | INSULATING MATTRESS MADE OF FIBROUS MATERIAL IMPREGNATED WITH AN INSULATING PRODUCT |
GB2291622A (en) * | 1994-07-19 | 1996-01-31 | Heraklith Baustoffe Ag | Insulation board |
US5554238A (en) * | 1993-11-22 | 1996-09-10 | The United States Of America As Represented By The Secretary Of Agriculture | Method of making resilient batt |
WO2000065139A1 (en) * | 1999-04-27 | 2000-11-02 | Albany International Corp. | Blowable insulation clusters |
WO2000077287A1 (en) * | 1999-06-14 | 2000-12-21 | Albany International Corp. | Blowable insulation clusters |
WO2007078450A3 (en) * | 2005-12-23 | 2007-10-04 | Albany Int Corp | Blowable insulation clusters made of natural material |
WO2020101588A1 (en) * | 2018-11-12 | 2020-05-22 | Yünsa Yünlü Sanayi̇ Ve Ti̇caret Anoni̇m Şi̇rketi̇ | A nonwoven surface structure manufactured from wool wastes |
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- 1988-11-25 BR BR888807813A patent/BR8807813A/en unknown
- 1988-11-25 EP EP19880909956 patent/EP0389524A4/en not_active Withdrawn
- 1988-11-25 AU AU27814/89A patent/AU629806B2/en not_active Ceased
- 1988-11-25 WO PCT/AU1988/000455 patent/WO1989004886A1/en not_active Application Discontinuation
- 1988-11-25 JP JP63509198A patent/JPH03501142A/en active Pending
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Cited By (15)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5160406A (en) * | 1989-04-14 | 1992-11-03 | Matec Holding Ag | Method for producing a formed structural element |
WO1993001341A1 (en) * | 1991-07-10 | 1993-01-21 | Cotton Unlimited, Inc. | Method for making insulation |
EP0591658A1 (en) * | 1992-10-07 | 1994-04-13 | Benno Steiner | Thermal insulation element and process for its manufacture |
US5554238A (en) * | 1993-11-22 | 1996-09-10 | The United States Of America As Represented By The Secretary Of Agriculture | Method of making resilient batt |
DE4425472C2 (en) * | 1994-07-19 | 2000-07-13 | Oesterr Heraklith Gmbh | Insulating mat and method for producing an insulating mat |
GB2291622A (en) * | 1994-07-19 | 1996-01-31 | Heraklith Baustoffe Ag | Insulation board |
FR2722803A1 (en) * | 1994-07-19 | 1996-01-26 | Heraklith Holding Ag | INSULATING MATTRESS MADE OF FIBROUS MATERIAL IMPREGNATED WITH AN INSULATING PRODUCT |
WO2000065139A1 (en) * | 1999-04-27 | 2000-11-02 | Albany International Corp. | Blowable insulation clusters |
US6329051B1 (en) | 1999-04-27 | 2001-12-11 | Albany International Corp. | Blowable insulation clusters |
US6329052B1 (en) | 1999-04-27 | 2001-12-11 | Albany International Corp. | Blowable insulation |
WO2000077287A1 (en) * | 1999-06-14 | 2000-12-21 | Albany International Corp. | Blowable insulation clusters |
WO2007078450A3 (en) * | 2005-12-23 | 2007-10-04 | Albany Int Corp | Blowable insulation clusters made of natural material |
US7790639B2 (en) | 2005-12-23 | 2010-09-07 | Albany International Corp. | Blowable insulation clusters made of natural material |
NO338070B1 (en) * | 2005-12-23 | 2016-07-25 | Primaloft Inc | Blowable insulation clusters made of natural material |
WO2020101588A1 (en) * | 2018-11-12 | 2020-05-22 | Yünsa Yünlü Sanayi̇ Ve Ti̇caret Anoni̇m Şi̇rketi̇ | A nonwoven surface structure manufactured from wool wastes |
Also Published As
Publication number | Publication date |
---|---|
AU629806B2 (en) | 1992-10-15 |
EP0389524A1 (en) | 1990-10-03 |
EP0389524A4 (en) | 1990-11-28 |
BR8807813A (en) | 1990-10-23 |
AU2781489A (en) | 1989-06-14 |
JPH03501142A (en) | 1991-03-14 |
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