WO1999064656A1 - Nattes de fibres liees a l'aide de liants de fibres thermodurcissables contenant certaines resines epoxy - Google Patents

Nattes de fibres liees a l'aide de liants de fibres thermodurcissables contenant certaines resines epoxy Download PDF

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Publication number
WO1999064656A1
WO1999064656A1 PCT/US1998/022818 US9822818W WO9964656A1 WO 1999064656 A1 WO1999064656 A1 WO 1999064656A1 US 9822818 W US9822818 W US 9822818W WO 9964656 A1 WO9964656 A1 WO 9964656A1
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Prior art keywords
fiber
batt
binder
fibers
cross
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PCT/US1998/022818
Other languages
English (en)
Inventor
George S. Buck
Original Assignee
Buck George S
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Publication date
Application filed by Buck George S filed Critical Buck George S
Priority to AU12827/99A priority Critical patent/AU1282799A/en
Publication of WO1999064656A1 publication Critical patent/WO1999064656A1/fr

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Classifications

    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M23/00—Treatment of fibres, threads, yarns, fabrics or fibrous goods made from such materials, characterised by the process
    • D06M23/08—Processes in which the treating agent is applied in powder or granular form
    • 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
    • D04H1/58—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 applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/587—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 applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives characterised by the bonding agents used
    • 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
    • D04H1/58—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 applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/60—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 applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in dry state, e.g. thermo-activatable agents in solid or molten state, and heat being applied subsequently
    • 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
    • D04H1/58—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 applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/64—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 applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/507—Polyesters

Definitions

  • This invention relates to non-woven fibrous batts and pads bonded with certain polyester resin fiber-binders and to processes for their production.
  • the noted processes can utilize inexpensive recycled fibers. Such fibers are recovered from garment clippings, textile mill waste, and other waste fibrous products. These materials are sometimes referred to as "shoddy.”
  • the patented processes are anhydrous, that is, completely dry, employing neither water nor solvent.
  • the fiber-binder employed is in its solid powdered form. Batts produced by these prior processes find a wide variety of uses. They are useful as pads in mattresses, furniture, chairs and automobile seats. They are also useful as carpet underlay. In fact, these batts can be employed anywhere it is desired to provide resilience, thermal insulation, sound insulation and/or cushioning. These batts can be covered with other fabric or they may be visible to the naked eye.
  • these batts can be used almost everywhere that rubber or polyurethane foam have been used in the past. Such batts are, however, superior to foam for many reasons, particularly because they have a greater life under use. Because of their great utility these prior batts have achieved great commercial success. They are currently produced all over the world in quantities greater than about 25 million kilograms, about 25,000 tons, per year.
  • One disadvantage is the relatively high melting point of the thermoplastic resins used as fiber-binders.
  • a batt bonded with a dibutyl -maleate copolymer must be heated to about 195°C (383°F). Such a high melting point is expensive to maintain because of energy costs. Such a high melting point increases the possibility of adverse heat effects on components of the batt. The higher the melting point of the thermoplastic resin in the fiber-binder, the greater the danger that it or other components of the batt will catch fire.
  • the hydrochloric acid must be neutralized, usually with caustic (NaOH) or lime (CaO), producing as neutralization products respectively impure salt (NaCl), and impure calcium chloride (CaCl ). These neutralization products must be disposed of in a manner consistent with a proper regard for the environment. Such disposal is expensive, but vital. Some environmentalists have suggested that a relationship exists between chlorine and the presence in the environment of dioxin.
  • the effluent by-products produced during batt curing may produce effluent opacities above acceptable limits.
  • Expensive emission control devices are required for monitoring and control. After formation of these prior batts with white fibers and chlorine containing resins, yellowing of the fibers may occur. Where the fibers are visible, consumer demand is diminished.
  • thermoplastic binders must be utilized in the form of small particles.
  • One method is to polymerize monomers producing directly a resin of the desired particle size. The high cost of this method makes it commercially impractical. A less expensive method is to form the resin without regard to particle size and then grind it to the desired size.
  • some of these prior thermoplastic binders are relatively soft and require very long grinding times to achieve the desired particle size. Because of their softness the particles tend to deform rather than fracture. Grinding at cryogenic temperatures is of limited success, but is expensive.
  • the cost of all the noted prior thermoplastic fiber-binders has increased dramatically. This increase has resulted in increased costs for products employing such prior batts, leading to the substitution of other, inferior, less expensive products.
  • thermoplastic fiber-binder More recently some success has been achieved when the prior thermoplastic fiber-binder is contacted with the fibers of the batt by blowing it through a fully formed batt.
  • the thickness of such a batt is limited to about 5 cm (2 inches) because of the tendency of the thermoplastic fiber-binder to fail to penetrate the batt fully.
  • Increasing the air speed through the batt has been only partially successful. As a result, such process is limited to those employing preformed batts of less than 7 cm (3 inches).
  • a completely unrelated, non-analogous field of electrostatic coating also has a number of problems related to the disposal of waste coating powders.
  • the substrate to be coated which may be an automobile body, is given an electrical potential different from a powder spray gun.
  • Coating powder is projected through said gun in a gas stream toward the substrate.
  • Some of the coating powder does not adhere to the substrate and is collected as scrap.
  • a portion of the powder, which is entrained in the air, is then recovered in filters as scrap.
  • Much of this scrap cannot be reused without adversely affecting the resultant coatings.
  • the scrap must be disposed of in an environmentally responsible manner.
  • the disposal of this scrap is a burden on the coating factory.
  • Some factories burn the scrap, whereas others pay to have it transported to an acceptable land fill.
  • Today, millions of pounds of scrap material are injected into the environment annually. If the scrap is burned a danger exists of contributing to air pollution. If the scrap is placed in a land fill a danger exists of contaminating drinking water sources.
  • Another object of the present invention is to provide fibrous batts substantially free from one or more of the disadvantages of batts and pads made by prior processes. Another object of the present invention is to provide an improved fibrous batt substantially free from one or more of the problems of prior batts.
  • Still another object is to provide batts and pads utilizing a fiber-binder which is free from chlorine.
  • Yet another object is to provide improved batts and pads which do not contain or release hydrochloric acid.
  • Still another object is to provide improved batts and pads which are bonded with a recycled, readily available materials.
  • An additional object is to provide improved, adequately bonded batts and pads in thickness greater than about 5 cm (2 inches) by contact with a fiber-binder. Still another object is to provide improved pads wherein the bending resistance of the batt or pad can be achieved by simply controlling the time and temperature at which the batt is cured.
  • Yet another object is to provide improved batts and pads wherein the particles of fiber-binder have a greater affinity for the fibers than heretofore.
  • An additional object is to provide improved batts and pads manufactured at lower temperatures than previously possible, with a resultant energy savings.
  • Still another object is to provide improved batts and pads equivalent in properties to prior batts, but employing less fiber-binder.
  • An additional object is to provide improved bonded fibrous batts and pads which utilize a fiber-binder that can readily and inexpensively be ground to the desired particle size.
  • Yet another object is to provide improved batts and pads from binders which do not deposit a gummy residue during the heating step required during batt formation
  • a further object is to provide a hot moldable batt without requiring the use of phenolic resins which produce toxic fumes, undesirable odor, and unacceptable odor from the curing ovens.
  • Figure 1 is an elevational view of an apparatus suitable for manufacturing the batts and pads of the present invention.
  • Figure 2 is a plan view of the apparatus of Figure 1.
  • Figure 3 is a sectional view taken along line 3-3 of Figure 2.
  • Figure 4 shows a portion of another apparatus suitable for manufacturing the batts and pads of the present invention.
  • Figure 5 is a schematic representation on a greatly enlarged scale showing the raw batt of the present invention with the particles of fiber-binder adhering to the batt prior to curing.
  • Figure 6 is a view similar to that of Figure 5 but showing the cured batt with the fibers bonded at their intersections with the fiber-binder of the present invention.
  • Figure 7 is a schematic representation of a hot molding process employing a batt of the present invention at that stage of the process when the mold is open.
  • Figure 8 is a schematic representation of a hot molding process employing a batt of the present invention at that stage of the process when the mold is closed.
  • Figure 9 is a molded batt or pad produced by the process of Figures 7 and 8.
  • Figure 10 is a graph showing the unexpectedly greater bending resistance of pads of the present invention compared with those of the prior art when bending resistance is measured in the transverse direction.
  • Figure 11 is a graph showing the unexpectedly greater bending resistance of pads of the present invention compared with those of the prior art when bending resistance is measured in the running or machine direction.
  • Figure 12 is a side view of an apparatus used for measuring batt or pad bending resistance as that term is used herein.
  • Figure 13 is a view of the apparatus of Figure 12 taken along line 13-13 of Figure 12 before measuring.
  • Figure 14 is a view of the apparatus of Figure 12 taken along line 13-13 of Figure
  • a non-woven batt comprising fibers bonded with a fiber-binder, the binder comprising: (i) a solid polyester resin having polyester groups, and
  • the fibers do not melt or decompose at temperatures below 100°C
  • the fiber-binder has a glass plate flow length of from about 15mm to about 150mm before being bonded to the fibers, and wherein the fiber-binder has an average particle size from about 1 to about 200 microns.
  • the improved bonded, non-woven, batts and pads of fibers result from the following steps;
  • A. a solid polyester resin having: (a) polyester groups; (b) a molecular weight above about 2000; (c) a glass transition temperature above about 40°C; (d) a melting point above about 70°C; and
  • the hot cured batt is frequently referred to as a cross- linked batt or semi-cross linked batt to further distinguish the mechanism of the inventive process from the prior art.
  • the batt itself is only physically cross-linked with the melted particles of resin which have themselves been cross-linked or partially cross-linked by the chemical reactions described herein.
  • the time and temperature of the heating step, Step III can be limited such that the cross-linking agent reacts with fewer than all the polyester end groups and preferably from about 5 to about 40 percent of the end groups of the polyester resin thereby converting the raw batt into a hot, semi- cross-linked batt which is subsequently cooled.
  • This semi-cross-linked batt is then placed between open male and female molds.
  • the molds are closed, causing the semi- cured batt to take the form of these molds.
  • the male mold, the female mold, and the semi-cured batt are heated to a crosslinking temperature above the melting point of the fiber-binder but below the scorching or melting point of the fibers thereby softening the fiber-binder and reacting the cross-linking agent with the remaining end groups of the polyester resin. This converts the semi-cured batt into a fully cured batt in the form of shaped article.
  • polyester resins of the present invention are a product which results from the esterification reaction of a polycarboxylic acid and a polyol.
  • the constituents of these resins are almost always a dicarboxylic acid and a diol oil.
  • terephthalic acid or isophthalic acid are reacted with glycols such as ethylene glycol, propylene glycol, di-ethylene glycol, 1 ,4 butane diol, 1 ,6 hexane diol, neo-pentane diol etc.
  • terephthalic acid and ethylene glycol are the most commonly used acids and glycols and will be used herein, without limitation to other options, to illustrate the polyester resins useful in making the improved batts and pads which are the subject of the present invention.
  • Polyester resins of the types described above are most commonly used as thermoplastics to make such products as fibers and films, including films to make beverage bottles.
  • the molecular weight of these resins ranges from 40,000 to 50,000, and the typical melting range of polyethylene terephthalate is around 490°F, (254°C). This melting range is too high to make these resins useful as fiber binders.
  • Lower melting point polyesters can be made by utilizing various proportions of isophthalic acid, and diols such as 1,4 butane diol or 1,6 hexane diol, neopentyl glycol, etc.
  • these polyesters are considerably more expensive and depending on the molecular weight are very difficult to pulverize to fine powders even under cryogenic conditions.
  • polyester resins useful in the present invention have either the formula illustrated in la. or lb. shown below. Structures as shown
  • n is about 9 to about 45.
  • polyester resin will seldom be all la or lb, the ratio depending on the method of preparation.
  • the presence of a hydroxy terminal group acts as a chain length stopper in high acid number polyesters and similarly the carboxy n groups act as chain stoppers in low acid number polyesters.
  • These unbalanced terminals also act to stop the cross-linking reactions described below which are the subject of this invention.
  • other glycols and di-ols than ethylene glycol may be used, and part or all isophthalic acid may also be employed without affecting the principle of this invention or its function.
  • the preferred polyester resins are based on the reaction between terephthalic acid and ethylene glycol.
  • polyester with a high acid number an excess of the acid above the stoichiometric ratios yields acid terminated resin, and similarly an excess of glycol or a diol yields hydroxy terminated polyester.
  • the acid number can be determined by titration. Where the polyester is an acid terminated resin, the acid number ranges from about 25 to about 300, preferably about 25 to about 100, most preferably from about 30- 90. Where the polyester is an hydroxy terminated polyester, the hydroxy number ranges from about 20 to 300, more preferably about 25 to 200, most preferably about 25 to about 100.
  • the polyester resins useful in the present invention generally have a number average molecular weight of from about 1,000 to about 12,500 and preferably from about 1,500 to about 6,500. In a preferred embodiment, the number average molecular weight is above about 2000.
  • the polyester resin generally has a glass transition temperature, frequently called "Tg", above about 40°C, and preferably above about 50°C, and a melting point above about 70°C and preferably from about 80°C to about 150°C.
  • Tg glass transition temperature
  • the polyester resin can have a widely varying molecular weight as long as it is solid.
  • polymers are a mixture of individual molecules each having a different distinct molecular weight.
  • the average molecular weight of the preferred polyester resins is between about 1,000 and about 10,000 and is preferably between about 3 ,000 and 13 ,000.
  • hydroxyl functional and acid functional polyester resins are useful in the practice of this invention.
  • Suitable hydroxyl functional resins are described in US Patents 4,124,570, 4,264,751 and 4,275,189, the teachings of which are herein incorporated.
  • Suitable acid functional resins can be prepared using either a one stage process, wherein an excess of acid functional monomers are initially charged to the reactor as disclosed in US 4,740,580 or a two stage process such as disclosed in US 4,085,159 and 4,147,737, the teaching of which are herein incorporated.
  • the polyester resins useful in the practice of this invention can have functionality of from about 2 to as high as 8 or 10, preferably between 2-6 and most preferably between 2.4-4.
  • Semi crystalline resins can also be used as all or part of the polyester resin forming the fiber binder of this invention. As with their amorphous counterparts, they can be primarily hydroxyl terminated or primarily acid terminated with the functionality described above. Semi crystalline resins are characterized by showing a crystalline melting point, Tm, as measured by a differential scanning calorimeter (DSC). Suitable crystalline polyester resins are described in US 4,442,270, US 4,859,760 and US 4,352,924.
  • polyester resins useful in the fiber-binders of the present invention may be obtained from scrap powder paint which is available from, for example, paint manufacturers and ultimate users of powder paints. Synonyms of scrap powder paints include fines, oversized materials, distressed materials, obsolete materials, off-grade materials and off-spec materials, by which is meant materials which do not meet independent specifications and/or are out-dated.
  • cross-linking agents useful with the selected polyester resin are well-known. They may be prepared according to published procedures or obtained from commercial sources. Examples include beta-hydroxyalkylamides such as Primid, oxazolines, resins comprised of residues of glycidyl methacrylate (GMA), and/or glycidyl acrylate, TGIC, epoxy and novalac resins, blocked polyisocyanates and uretidone resins, polyester resins, TMGU (tetramethoxymethylglycouril) and tetraalkyltitanates.
  • beta-hydroxyalkylamides such as Primid, oxazolines
  • polyester resins TMGU (tetramethoxymethylglycouril) and
  • the fiber-binder can be formulated by a wide variety of well-known methods, one method is simply to mix the finely divided polyester resin and the finely divided cross- linking agent and any other ingredients. All ingredients are then briefly heated until they melt. The ingredients are then rapidly cooled before any substantial cross-linking reaction takes place between the polyester resin and the cross-linking agent. The exact degree to which cross-linking has taken place is difficult to determine but it is estimated that fewer than ten percent of the terminal groups are reacted with the cross-linking agent when the mixture is melted and mixed in an extruder, where the residence time is less than about 60 seconds. The cooled ingredients, which are frequently in the form of a solid sheet, are broken into small chips and then comminuted to the desired particle size.
  • the crosslinking reaction begins slowly to take place. Lower temperatures inhibit the reaction, whereas higher temperatures favor it.
  • the reaction progresses, those skilled in the art have identified three distinct stages, namely, the "A-stage", where the mixture is soluble in organic solvents, and is fusible, by which is meant it melts and flows; the "B-stage,” wherein the mixture is fusible but insoluble; and the “C-stage”, wherein the mixture is both insoluble and infusible.
  • the fiber-binders of the present invention go through these same stages. When first contacted with the fibers the fiber-binder is in the A-stage.
  • the fiber-binder When partially cross- linked the fiber-binder is in the B-stage. Batts having the fiber-binder in this stage can be hot or cold molded. When fully cross-linked the fiber-binder is in the C-stage.
  • the polyester resin and the cross-linking agent may be mixed in.
  • the particles of the fiber-binder have an average size from about one to about 200 microns, preferably from about 5 to 50 microns. When the particles have a size smaller than 10 microns they can advantageously be mixed with particles having a larger size. If the average particle size is greater than about 40 microns there may be a reduced efficiency in the production of firm resilient batts.
  • the fiber-binder can be applied to the fibers in widely varying ratios but the fiber- binder generally comprises from 2 to 40 and preferably from 5 to 30 weight percent based on the combined weight of the fibers and the fiber-binder.
  • the fiber-binders of the present invention are solid; they are neither aqueous solutions, nor solutions employing other solvents. They are free from solvents and water.
  • Glass plate flow length is a significant characteristic of fiber-binders useful in the present invention. Glass plate flow length is determined by pressing the fiber-binder into a mold to form a pill or cylinder 12 mm in diameter and 6 mm high. This cylinder is is placed on a hot plate at a temperature of 190°C (375°F) at an angle of 35° to the horizontal.
  • the length of the streak made by the cylinder, in one minute is termed the "hot plate flow".
  • a fiber-binder in the C-stage that does not flow at all will have a glass plate flow of 12 mm, i.e., the diameter of the cylinder. Fiber-binders in the early A-stage can have glass plate flows that exceed 160 mm. Glass plate flow provides a simple and convenient method to determine the degree of cross-linking between the polyester resins and the cross-linking agent.
  • the described test also demonstrates one fiber-binder characteristic making the fiber-binder optimally useful in this invention.
  • the fiber- binders of the present invention generally have glass plate flow lengths of from about 15 to about 150 mm and preferably from about 35 to about 125 mm. Others skilled in the art sometimes refer to "hot plate flow” as "glass plate melt flow” or "melt flow”.
  • Fillers and colorants may be added to resins. Fillers are usually less expensive than resins. This permits a filled resin to be made at a cost lower than a fiber-binder which is free from filler. Although fillers are not required to be present in the fiber- binders of the present invention, when present, they provide new and unexpected results. It is possible to use filled fiber-binders and achieve the same batt properties as with unfilled fiber-binders. While this effect is not fully understood, it is believed that after the comminution of the filled resin, particles of filler protrude from the surface of the fiber- binder particle. However, upon such particles being heated, a new and novel structure is produced. Apparently the mixture of polyester resin and cross-linking agent melt and flow, completely surrounding the filler particle.
  • This structure may be thought of as a concentric sphere with the melted, sticky, fiber-binder, then in the A-stage or early B- stage, forming a covering on the outside. This covering is completely adequate to bond with fibers.
  • the particles of the filler have an average size from about one to about 200 microns, preferably from about 5 to 15 microns. Smaller particle sizes are functional in the present invention, but may cause environmental problems because they tend to be respirable.
  • the fillers are inorganic and insoluble in water. Salts of strong acids and weak bases are suitable, as well as salts of weak acids and weak bases. Silica, aluminum-silicates and alumina are all suitable classes. Examples of preferred fillers include, among others, calcium carbonate, barium sulfate, iron oxides, carbon black, and titanium dioxide.
  • the fiber-binder can include a wide variety of other additives.
  • additives include among others: catalysts, dyes, pigments, flow control agents, fire retardants, self extinguishing agents, desiccants and all manner of additives which are used herein for their known purposes.
  • Any catalyst known to accelerate or retard the rate of reaction of the hydroxy or carboxy groups and the active group of the cross-linking agent can be employed.
  • catalysts include among others: tertiary amines, imidaxoles amic acids and quaternary ammonium and onium compounds, phosphonium compounds, phenolic compounds, organic and inorganic acids.
  • fire retardants include: boric acid, monoammonium phosphate, diamonium phosphate and aluminum trihydrate. These additives can be in the form of liquids or particles so long as the fiber-binder remains solid, has the desired particle size and suffers no adverse affects.
  • the fibers can be contacted with the fiber-binder in a wide variety of ways.
  • the fibers can be loose, in the form of a thin web, or in the form of a batt.
  • the fiber-binder can be sprinkled on the fibers under the influence of gravity or can be entrained in a stream of gas or vapor, advantageously air. Any method which leaves the desired quantity of fiber-binder desirably distributed throughout the batt is acceptable.
  • Natural fibers include cotton, wool, jute, and hemp.
  • Synthetic fibers include those of polyester, nylon, acrylic, rayon, glass and polypropylene.
  • any fibers or mixture of fibers are acceptable, including those in which the fibers may be new and unused, known as virgin fibers, or those that are waste, reclaimed from garment cuttings, fiber manufacture or textile processing and which do not melt or decompose at temperature below 100°C (212°F).
  • the preferred fibers are those having a denier of 1 to 22 although finer and coarser fibers are also sometimes useful.
  • the heating of raw batt containing the fibers and the uncured fiber-binder can be accomplished by any convenient means such as infrared, or microwave but is most conveniently accomplished by hot air which is passed through the batt. This hot air is heated to a temperature above the melting point of the fiber-binder but below that temperature at which the fibers are adversely affected. Adverse effects include scorching or burning of cellulosic or wool fibers or melting or shrinking of synthetic resin fibers.
  • the heating is generally done at a temperature of from about 100°C (212°F) to about 240°C (465°F) for a time sufficient to permit the fiber-binder to flow to the intersections of the fibers and to cross-link there. This is generally accomplished in from about twenty seconds to about ten minutes, and usually from one to five minutes. Such heating converts the raw batt into a hot cured batt.
  • the hot cured batt is cooled, preferably to room temperature, by any of a wide variety of means.
  • the batt can be passed through chilled rolls, air can be passed through the batt, the batt can be placed in a cooling chamber or some other means can be used for cooling the batt.
  • the apparatus 10 comprises an opener or garnet 11, a fiber-binder dispenser 12, a cross laying mechanism 13 and, as shown in Figure 2, an oven 14.
  • the garnet 11 comprises an inlet chute 18 adapted to feed bulk fibers to the rotating drum 19 of the garnet 11.
  • the garnet 11 is also provided with a plurality of tooth rolls 21, 22, 23, 24, 25 which together with the teeth (not shown) on the drum 19, take bulk fibers 20 and convert them to a web 31 which adheres to the drum 19.
  • the web 31 adhering to the drum 19 is transferred to the drum 28 where it is removed by comb 29.
  • the structure and function of the dispenser 12 is described in detail in Buck '680 and in Buck '428.
  • a wide variety of other methods can be employed to contact the fiber-binder with the fibers -
  • Another method performs the contacting of the fibers with the fiber-binder after the fibers have been opened and loosened from a compressed bale and at the stage when they are entrained in an air stream and prior to being deposited on a screen or in the slot of an air lay system for producing non-woven batts.
  • the non-woven batt can be converted into its final form and the particulate fiber-binder blown through the entire batt. It has been unexpectedly found that the fiber-binders of the present invention penetrate these batts better than do the prior fiber-binders. Furthermore a greater percentage of the fiber-binder is retained in the batt 25 than when prior fiber-binders are used. All such contacting methods are useful in the present invention so long as the contacting is effective.
  • the web 39 then goes to the conveyor 41 and thence to the conveyor 42.
  • the lower end of the conveyor 42 is attached to a traveller 43 which moves back and forth on the track 44.
  • the conveyor 42 is positioned above and at right angles to the other conveyor 45.
  • the apparatus 10 is adjusted such that the speed of the conveyor 42 is several times faster than the speed of the conveyor 45. By virtue of this speed difference, the web 39 is cross laid back and forth on the conveyor 45 thus forming a raw batt 47.
  • the raw batt 47 passes between an upper foraminous belt 49 and a lower foraminous belt 50 (See Figure 3) . While held 5 between the belts 49, 50, the raw bat 47 passes into the oven 14.
  • the oven 14 is provided with heating means 52 in which the temperature can be controlled by a thermostat 53.
  • the oven 14 is also provided with air circulating means such as a fan (not shown) that causes the hot air to circulate in the direction shown by the arrows 55 and 56.
  • air circulating means such as a fan (not shown) that causes the hot air to circulate in the direction shown by the arrows 55 and 56.
  • This hot air heats and melts the particles 33, 34 of the fiber-binder causing them to flow to the intersections of the fibers is and further causes them to cross-link, thereby hardening the fiber-binder.
  • the resultant product is the finally fully cross-linked or partially cross-linked batt 58 depending on the temperature of the oven 14 and the length of time that the batt remained in the oven 14.
  • Figure 4 there is shown an alternative particle dispenser 12' which takes the place of the particle dispenser 12 of Figures 1, 2, and 3.
  • a raw batt 47 exists between two foraminous belts 60, 62.
  • Streams of air represented by the arrows 64, 66, are passed through the batt 47. These streams of air are laden with particles of fiber-binder. The particles loosely adhere to the fibers of the batt 47'. It has been found that fiber-binders of the present invention have a greater adherence to the fibers of the raw batt 47' than do the prior art thermoplastic fiber-binders.
  • particles such as the particles 33, 34 of uncured fiber- binder
  • the particles are adhering to fibers 20, 20', 20" of the raw batt 47, 47'.
  • the particles after heating, the particles, such as the particles 33, 34, have melted and have migrated to the intersections of the fibers 20, 20', 20".
  • This heating has also caused the polyester resin of the fiber-binder to react with the cross-linking agent of the fiber-binder thus cross-linking this thermosetting composition.
  • the bending resistance and resilience of the batt are directly proportional to the extent of cross-linking. A small amount of cross-linking gives a soft resilient batt.
  • the batt will have maximum firmness and strength. All other things being equal the extent of cross-linking can be controlled by the temperature and time of heating for cross-linking. Lower temperatures , and shorter times yield less cross-linking, while higher temperatures and longer times yield more cross-linking.
  • Figure 7 illustrates the hot molding of batts of the present invention. Such batts can be hot-molded if the time and temperature of the heating step, Step III, is limited such that the cross-linking agent reacts with less than all the terminal groups of the polyester resin. In this case the resultant product will be a semi-cross-linked batt 47'".
  • the semi-cross-linked batt 47" is placed between an open male mold 70 and an open female mold 72.
  • the male mold 70 is provided with passages 74, 76, adapted to receive a heated fluid such as steam or hot oil.
  • the female mold 72 has a fluid receiving passage. Either or both of the molds can be heated by any other convenient means such as electrical resistance heating.
  • the molds 70, 72 are closed causing the semi-cross-linked batt 47" to take the form of the molds 70, 72.
  • Hot oil or steam under pressure is passed through the passages 74, 76, 78, heating the molds 70, 72, and thus heating the semi- cross-linked batt 47" to cross-linking temperature.
  • This cross-linking temperature is above the melting point of the fiber-binder but below the scorching or melting point of the fibers thereby further reacting the cross-linking agent with the remaining terminal groups of the polyester resin.
  • This converts the semi-cross-linked batt 47" into a fully cross-linked bat 47 in the form of shaped article 47 shown in Figure 9.
  • Figures 12, 13, and 14 show the manner in which bending resistance is measured.
  • FIGs 12 and 13 show an apparatus 88 comprising a scale 90, with a clamp 92 carried by a rotatable shaft 94 mounted parallel to the scale 90 about 20 cm (8 inches) above it.
  • the batt 58 is positioned in the clamp 92 and held above and out of contact with the scale 90 as shown in Figures 12 and 13.
  • the shaft 94 is rotated one full turn as shown in Figure 14 and the highest reading on the scale 90 noted.
  • the batt 58 has a width of 30 cm (12 inches) and a length of 30 cm (12 inches).
  • Example 2 This example is a polyester cross-linked with caprolactam blocked IPDI polymer
  • Example 3 is a pad cross-linked with Primid®XL552, which is bis- N 1 - dihydroxyethyl adipamide.
  • Example 4 compares the prior art pad with one made from scrap powder paint consisting of a mixture of polyester cross-linked with TGIC, polyester cross-linked with IPDI (a urethane) and a polyester cross-linked with an epoxy resin.
  • the mixture in this case is roughly 40% of IPDI cross-linked material, 20% of TGIC cross-linked material, and 40% of polyester cross-linked with epoxy resin.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Dispersion Chemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

L'invention concerne des nattes et des matelas de fibres non tissées liés à l'aide de liants de fibres contenant certaines résines polyester et leurs procédés de fabrication.
PCT/US1998/022818 1998-06-10 1998-10-28 Nattes de fibres liees a l'aide de liants de fibres thermodurcissables contenant certaines resines epoxy WO1999064656A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU12827/99A AU1282799A (en) 1998-06-10 1998-10-28 Fibrous batts bonded with thermosetting fiber-binders of certain polyester resins

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US9445098A 1998-06-10 1998-06-10
US09/094,450 1998-06-10

Publications (1)

Publication Number Publication Date
WO1999064656A1 true WO1999064656A1 (fr) 1999-12-16

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AU (1) AU1282799A (fr)
WO (1) WO1999064656A1 (fr)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6296795B1 (en) 2000-05-19 2001-10-02 George S. Buck Non-woven fibrous batts, shaped articles, fiber binders and related processes
WO2008049980A1 (fr) * 2006-10-27 2008-05-02 Fibroline France Renfort composite pour impregnation ou enduction
EP2135913A1 (fr) 2008-06-20 2009-12-23 Schlumberger Holdings Limited Fibres revêtues actives de manière électrique et/ou magnétique pour opérations de forage
EP2206761A1 (fr) 2009-01-09 2010-07-14 Services Pétroliers Schlumberger Fibres revêtues actives de manière électrique et/ou magnétique pour opérations de forage
US8372787B2 (en) 2008-06-20 2013-02-12 Schlumberger Technology Corporation Electrically and/or magnetically active coated fibres for wellbore operations
US8424262B2 (en) 2006-04-27 2013-04-23 Dow Global Technologies Llc Polymeric fiber insulation batts for residential and commercial construction applications

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0308074A2 (fr) * 1987-08-20 1989-03-22 Sekisui Kagaku Kogyo Kabushiki Kaisha Articles composites moulés, et procédé pour les fabriquer
US5183708A (en) * 1990-05-28 1993-02-02 Teijin Limited Cushion structure and process for producing the same
WO1993011292A1 (fr) * 1991-11-27 1993-06-10 E.I. Du Pont De Nemours And Company Nouveaux rouleaux de nappe de fibres de remplissage
JPH0892877A (ja) * 1994-09-22 1996-04-09 Nippon Ratetsukusu Kako Kk リサイクル性に優れた繊維製品
DE4441765A1 (de) * 1994-11-24 1996-05-30 Teodur Nv Bindemittelzusammensetzung zur Herstellung von Faservliesen und Verfahren zur Herstellung von Faservlies-Formteilen
WO1997042367A1 (fr) * 1996-05-09 1997-11-13 Buck George S Liaison de nattes de fibres a l'aide de liants de fibres thermodurcissables, contenant certaines resines epoxy

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0308074A2 (fr) * 1987-08-20 1989-03-22 Sekisui Kagaku Kogyo Kabushiki Kaisha Articles composites moulés, et procédé pour les fabriquer
US5183708A (en) * 1990-05-28 1993-02-02 Teijin Limited Cushion structure and process for producing the same
WO1993011292A1 (fr) * 1991-11-27 1993-06-10 E.I. Du Pont De Nemours And Company Nouveaux rouleaux de nappe de fibres de remplissage
JPH0892877A (ja) * 1994-09-22 1996-04-09 Nippon Ratetsukusu Kako Kk リサイクル性に優れた繊維製品
DE4441765A1 (de) * 1994-11-24 1996-05-30 Teodur Nv Bindemittelzusammensetzung zur Herstellung von Faservliesen und Verfahren zur Herstellung von Faservlies-Formteilen
WO1997042367A1 (fr) * 1996-05-09 1997-11-13 Buck George S Liaison de nattes de fibres a l'aide de liants de fibres thermodurcissables, contenant certaines resines epoxy

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
DATABASE WPI Section Ch Week 9624, Derwent World Patents Index; Class A13, AN 96-236619, XP002092822 *

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6296795B1 (en) 2000-05-19 2001-10-02 George S. Buck Non-woven fibrous batts, shaped articles, fiber binders and related processes
EP1162297A1 (fr) * 2000-05-19 2001-12-12 BUCK, George S. Nappes fibreuses non tissées, articles moulés, liant pour fibres et procédés en rapport
US8424262B2 (en) 2006-04-27 2013-04-23 Dow Global Technologies Llc Polymeric fiber insulation batts for residential and commercial construction applications
WO2008049980A1 (fr) * 2006-10-27 2008-05-02 Fibroline France Renfort composite pour impregnation ou enduction
EP2135913A1 (fr) 2008-06-20 2009-12-23 Schlumberger Holdings Limited Fibres revêtues actives de manière électrique et/ou magnétique pour opérations de forage
US8372787B2 (en) 2008-06-20 2013-02-12 Schlumberger Technology Corporation Electrically and/or magnetically active coated fibres for wellbore operations
EP2206761A1 (fr) 2009-01-09 2010-07-14 Services Pétroliers Schlumberger Fibres revêtues actives de manière électrique et/ou magnétique pour opérations de forage

Also Published As

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