WO2009089579A2 - Formation de tapis non tissés - Google Patents

Formation de tapis non tissés Download PDF

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Publication number
WO2009089579A2
WO2009089579A2 PCT/AU2009/000034 AU2009000034W WO2009089579A2 WO 2009089579 A2 WO2009089579 A2 WO 2009089579A2 AU 2009000034 W AU2009000034 W AU 2009000034W WO 2009089579 A2 WO2009089579 A2 WO 2009089579A2
Authority
WO
WIPO (PCT)
Prior art keywords
fibres
mat
opener
fibre
opened
Prior art date
Application number
PCT/AU2009/000034
Other languages
English (en)
Other versions
WO2009089579A3 (fr
Inventor
Hugh William Eric Higgins
Original Assignee
Boral Australian Gypsum Limited
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.)
Filing date
Publication date
Priority claimed from AU2008900189A external-priority patent/AU2008900189A0/en
Application filed by Boral Australian Gypsum Limited filed Critical Boral Australian Gypsum Limited
Priority to NZ587184A priority Critical patent/NZ587184A/xx
Priority to AU2009204678A priority patent/AU2009204678A1/en
Publication of WO2009089579A2 publication Critical patent/WO2009089579A2/fr
Publication of WO2009089579A3 publication Critical patent/WO2009089579A3/fr

Links

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
    • D04H1/54—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
    • D04H1/42—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
    • D04H1/4209—Inorganic fibres
    • D04H1/4218—Glass fibres
    • D04H1/4226—Glass fibres characterised by the apparatus for manufacturing the glass fleece

Definitions

  • This invention relates to methods and apparatus for forming thermal insulation from glass fibres, particularly methods which may be used to manufacture products having a high loft and thermal rating.
  • Glass fibre insulation is an important building material for thermal and acoustic insulation of dwellings as well as commercial and industrial buildings. With increasing awareness of the environment and the need to reduce green house gas emissions, building insulation is becoming and evermore important material in helping reduce the heating and cooling energy loads placed upon electricity generators.
  • a suitable building insulation could be manufactured by using chop strand glass fibre, binder fibre and non-woven machinery such as a card and cross lapper or an airlay coupled with a curing oven and the required ancillary equipment.
  • Conventional airlay equipment would not normally be expected to produce a mat with sufficiently high loft and thermal rating.
  • the invention resides in a method of forming a non-woven mat of fibres, including: forming a bed of fibres containing inorganic fibres blended from one or more fibre sources, feeding the bed into a first opener to form a mat having coarsely opened fibres, feeding the coarsely opened mat into a second opener to form a mat having finely opened fibres, and curing the finely opened mat; wherein the second opener includes a squeeze roller, nose bar, and a lickerin.
  • the first opener includes a squeeze roller, a nose bar, and a lickerin.
  • the first opener includes two opposed squeeze rollers and a lickerin.
  • the coarsely opened mat primarily contains randomised fibres without a regular visible structure.
  • the finely opened mat primarily contains individualised fibres with a partly or wholly layered structure.
  • the invention resides in a method of forming a non- woven mat of fibres, including: forming a bed of fibres containing inorganic fibres blended from one or more fibre sources, feeding the bed into a first opener to form a mat of largely opened fibres, feeding the opened mat into a second opener to form a mat having multiple fibre layers, and curing the multiple layered mat.
  • first and/or second opener includes a respective squeeze roller, nose bar, and lickerin.
  • both first and second openers include a squeeze roller having a rubberised surface and a carding surface respectively.
  • the invention resides in apparatus for forming a non woven mat, including: a blender which forms a bed from one ore more fibre sources, a first fibre opener which forms a coarsely opened mat from the bed, a second fibre opener which forms a finely opened mat from the coarsely opened mat, and an oven which cures the finely opened mat; wherein the second fibre opener includes a squeeze roller, nose bar, and a lickerin.
  • the first fibre opener includes a squeeze roller, nose bar, and a lickerin.
  • the first fibre opener includes two opposed squeeze rollers and a lickerin.
  • the squeeze roller of the first opener has a rubberised surface and the squeeze roller of the second opener has a carding surface.
  • an anti static device is included between the first and second fibre openers.
  • the anti static device is typically a water sprayer.
  • the invention resides in a method of manufacturing a non woven insulation product, including: combining glass fibres with polymer melt fibres, opening the combined fibres in a two stage opening process, forming the combined glass fibres into a high loft matt, bonding the fibres in the matt by heating to melt the melt fibres, and forming the bonded matt into a product of required dimensions.
  • the invention resides in a method of manufacturing a non woven insulation product, including: opening glass fibres in a two stage opening process, forming the opened glass fibres into a high loft mat, adding a resin powder to the mat, bonding the fibres in the mat by heating to melt the resin, and forming the bonded mat into a product of required dimensions.
  • the first opening stage includes a rotating drum with relatively coarse carding wire and the second opening stage includes a rotating drum with relatively fine carding wire.
  • the glass fibres are Eglass with an average diameter in the range 9 to 14 microns.
  • the glass fibres are blended at 50 to 90% by weight with the polymer melt fibres.
  • the insulation product has a thermal rating R between 1.5 and 6.
  • the product has a loft between 90 and 220 mm, and a weight between 900 g/m 2 and 3 kg/m 2 .
  • Figure 1 schematically shows a two stage airlay process which forms a non woven mat
  • Figure 2 provides detail of a first fibre opener in the airlay process
  • Figure 3 provides detail of a second fibre opener in the airlay process
  • Figure 4 shows an alternative fibre opener
  • Figure 5 gives thermal performance data relating to fibreglass batts
  • FIG. 6 schematically shows alternative fibre openers
  • Figure 7 shows a two stage process which combines glass fibres and polymer melt fibres
  • Figure 8 shows a process in which resin powder is added to a mat formed from glass fibres
  • Figure 9 shows a first opener for either process in Figure 7 or Figure 8.
  • Figure 10 shows a second opener for either process.
  • Figure 1 shows the main components of an airlay process in which fibres are blended, opened and formed into a mat, which can then be cured and cut into a product such as insulation batts for example.
  • the fibres are generally obtained from two or more sources (not shown), and preferably include an inorganic fibre such as fibreglass, and a melt fibre such as a bicomponent polymer. Other fibres or substances may also be added depending on the required product.
  • the fibre sources for Figure 1 include stock materials which are separated and roughly blended in a condenser 10 which forms a bed 11 on a conveyor.
  • the bed generally contains clumps of fibres which must be opened and mixed.
  • a first fibre opener 12 carries out a coarse opening stage and is followed by a second fibre opener 13 which carries out a fine opening stage.
  • the bed 11 is thereby converted into a mat 14.
  • Static electricity created by the inorganic fibres must usually be reduced after the first opening stage, and an antistatic system such as a water sprayer 15 may be required between the two stages.
  • the mat is cured in a suitable fashion, typically in an oven 16 which binds the inorganic fibres and the melt fibres.
  • FIG 2 provides more detail of a preferred first opening stage in Figure 1.
  • the fibre opener includes a squeeze roller 20, nose bar 21 and lickerin drum 22.
  • the nose bar is a feed plate which is shaped for close operation with the feed roller and the lickerin drum, and has a work point or edge 23 which is located between these components.
  • the lickerin is a carding roller which combs and separates the fibres from the incorning bed of material and pulls the fibres over the edge of the nose bar.
  • An air current 24 then carries the fibres downwards towards an outgoing conveyor 25.
  • a vacuum may be applied beneath the conveyor to assist the airflow.
  • the first opening stage shown in Figure 2 results in largely randomised fibres, possibly still with some partial alignments, that are placed on the conveyor to form a relatively low loft web.
  • the squeeze roller in Figure 2 is a rubber coated cylinder about 200mm in diameter, set about 5mm from the edge of the nose bar.
  • the rotational speed of the roller is set such that its tip speed is equal the speed of the incoming conveyor, and these are controlled together to a speed of about 1-2Om per minute.
  • the lickerin drum is cylinder about 600mm in diameter also set about 5mm from the nose bar, and wound with saw tooth carding wire of about 10-12 gauge.
  • the lickerin rotates at about 800-lOOOr ⁇ m and is located about 600mm above the outgoing conveyor.
  • FIG 3 provides more detail of a preferred second opening stage in Figure 1.
  • the fibre opener includes a squeeze roller 30, nose bar 31 and lickerin drum 32. These components are similar to the first opener in Figure 2 but are operated differently.
  • the nose bar 31 is a feed plate shaped for close operation with the feed roller and the lickerin drum.
  • the nose bar has a work point or edge 33 which is located between these components.
  • the lickerin is a carding roller which combs and separates the fibres from the incoming bed of material and pulls the fibres over the edge of the nose bar.
  • An air current 34 then carries the fibres downwards towards an outgoing conveyor 35 through which a vacuum may be applied.
  • the second opening stage shown in Figure 3 results in a mat 14 having layers of primarily finely opened and individualised fibres. The mat may be partly or wholly layered and forms a relatively high loft web.
  • the squeeze roller in Figure 3 is about 200mm in diameter and wound with carding wire of about 16 gauge.
  • the roller is set about 2mm or less from the edge of the nose bar and has a speed matching the incoming conveyor.
  • the lickerin drum is a cylinder about 600mm in diameter also set about 2mm or less from the nosebar and wound with 16 gauge carding wire.
  • the lickerin rotates at about 1800-2000rpm and is located at about 800mm about the outgoing conveyor.
  • Figure 4 shows an alternative opening stage having a squeeze roller 4O 5 nose bar 41, lickerin drum 42, guide roller 43 and a moving plate 46.
  • the moving plate is an optional feature which assists the layering process.
  • the nosebar functions generally as described above and an airflow 44 carries fibres onto a conveyor 45.
  • the system shown here may be used as the second opening stage to create a mat 14.
  • the plate extends across the width of the mat and the rollers and oscillates as indicated at about 35 to 60 cycles per minute.
  • the plate is typically up to about 200mm wide and pivots about a fixed edge which is located upstream in the flow of fibres.
  • the plate has a free edge located downstream in the flow of fibres, which moves up to about 200mm during each cycle.
  • the lickerin has been rotated at speeds of about 3000rpm.
  • Figure 5 contains three tables which enable a rough comparison between the properties of fibreglass insulation formed using a conventional airlay process and insulation formed using a modified process such as described in relation to figures 1-3.
  • Conventional airlay processes generally use opening stages which involve squeeze rollers rather than a nosebar, as shown in Figure 6 for example, and also use relatively fine fibres.
  • the inorganic fibres used in the modified process were StarStran LCF 991, 51 mm chopped strand supplied by Johns Manville specifically for carding and airlaying, and had a mean diameter of about 13 ⁇ m.
  • the binder fibres were bi-component fibre from the Far Eastern Textile Company: 4 denier 51 mm core-sheath low melt. It can be seen that a mat formed by the modified process had an R rating comparable to a mat formed by the conventional phenolic formaldehyde resin glass wool process.
  • Mats formed according to the process of Figures 1-3 typically have a loft in the range 90 to 220mm, a weight in the range 850 to 2200 gsm, and a thermal resistance in the range 1.5 to 6,0 m 2 K/W. However, a range of characteristics are possible.
  • Figure 6 shows a range of opening stages which are typically used in conventional airlay equipment. These involve various combinations of squeeze rollers and lickerin drums which need not be described in detail. None involve a nosebar.
  • the opening stages shown in Figure 6a., 6b, 6c and 6d respectively involve a single squeeze roller, a double squeeze roller, a pair of double squeeze rollers, and a double squeeze roller plus a transfer roller.
  • a conventional opener such as shown in Figure 6 might be used in the first opening stage shown in Figure 1, rather than a nosebar system such as shown in Figure 2, although the results are expected to be inferior to the examples given above.
  • the second opening stage preferably always involves a nose bar and associated rollers as shown in Figures 3 or 4.
  • Figures 7 and 8 show the main components of an overall manufacturing process for inorganic insulation products such as fibreglass batts. Each includes two initial fibre opening stages followed by a mat forming process such as described above. The initial opening stages have been required in some cases to ensure that clumps of fibres are thoroughly worked and opened prior to the relatively fine stages described above.
  • the inorganic fibres which are used in these processes are bonded in two different ways to form a suitably robust structure.
  • the fibres are preferably Eglass and other fibres or substances may be added depending on the required product.
  • glass fibres from bins 70 are initially combined with polymer melt fibres from bin 71, typically bi-component polymer fibres which partially melt when the mat is cured.
  • the mixture then passes through two coarse opening stages 72 and 73, before a bed of fibres is passed into a mat forming process 74 such as described above.
  • the resulting mat is then cured in an oven 75.
  • glass fibres from bins 80 are blended alone, with a resin powder being added by an applicator 81, before the mat enters the oven 85.
  • the initial blend passes through two coarse opening stages 82, 83, before a bed of fibres is passed into a mat forming process such as described in relation to Figure 1.
  • An airlay process or carding and crosslapping process may be used for example.
  • the fibre sources in Figures 7 and 8 include stock materials which are provided in a series of bins from which they are roughly separated and formed into a bed on a conveyor.
  • the bed generally contains clumps of fibres which must be opened and mixed,
  • a first fibre opener carries out a coarse opening stage and is followed by a second fibre opener which carries out a relatively fine opening stage and forms the mat.
  • Static electricity created by the inorganic fibres must usually be reduced after either or both opening stages, and antistatic systems such as water mist sprayers may be required.
  • FIG 9 provides more detail of the first opening stage 72 or 82 in Figure 7 or 8.
  • the opener includes an upright housing 90 containing a passage which feeds fibres to a combination of squeeze rollers 91 and a shredder drum 92.
  • a coarsely formed mixture from the fibre sources is delivered to the top of the housing and falls under gravity towards the squeeze rollers.
  • the rollers counter rotate and urge the fibres onto the drum, after which the fibres flow from an exit at the foot of the housing, past a water mist sprayer 93.
  • the surface of the drum has a relatively coarse structure which breaks down clumps of fibres.
  • the surface of this drum is lined with V6 shredder wire and rotates at about 600 ⁇ m.
  • FIG 10 provides more detail of the second opening stage 73 or 83 in Figure 7 or 8.
  • the opener includes an upright housing 100 similar or the same as the opener in Figure 9.
  • a passage within the housing feeds partially opened fibres from the first opener down to a combination of squeeze rollers 101 and a shredder drum 102.
  • the rollers urge the fibres onto the drum as before, after which they flow from the foot of the housing past a water mist sprayer 103.
  • the surface of the drum in this case has a relatively fine structure which further breaks down any clumps of fibres.
  • the surface of this drum is lined with Vl 2 shredder wire and rotates at about 800rpm.
  • the resulting products typically had a thermal rating R between 1.5 and 6.
  • the products preferably have a loft between 90 and 220 mm, and a weight between 900 g/m 2 and 3 kg/m 2 .

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Inorganic Chemistry (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

L'invention porte sur des procédés pour fabriquer des tapis non tissés contenant des fibres minérales, et ayant un gonflant et un indice d'isolation thermique relativement élevés. Le procédé comprend deux étapes d'ouverture de fibre, typiquement une première étape d'ouverture grossière suivie par une deuxième étape d'ouverture plus fine, comprenant de préférence un rouleau de pincement, une barre de pression et un tambour briseur. La deuxième étape peut produire en résultat un tapis en couches. Les fibres minérales peuvent être mélangées à des fibres fondues polymères avant la première étape d'ouverture, ou à un liant en un point approprié après les étapes d'ouverture. Les tapis peuvent être utilisés pour des produits d'isolation thermique.
PCT/AU2009/000034 2008-01-15 2009-01-15 Formation de tapis non tissés WO2009089579A2 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
NZ587184A NZ587184A (en) 2008-01-15 2009-01-15 Forming non woven mats with two fibre opening stages
AU2009204678A AU2009204678A1 (en) 2008-01-15 2009-01-15 Forming non woven mats

Applications Claiming Priority (8)

Application Number Priority Date Filing Date Title
AU2008900189 2008-01-15
AU2008900189A AU2008900189A0 (en) 2008-01-15 Method of forming a non woven mat
AU2008901253A AU2008901253A0 (en) 2008-03-14 Methods of forming non-woven insulation
AU2008901253 2008-03-14
US7106508P 2008-04-10 2008-04-10
US7106808P 2008-04-10 2008-04-10
US60/071,065 2008-04-10
US61/071,068 2008-04-10

Publications (2)

Publication Number Publication Date
WO2009089579A2 true WO2009089579A2 (fr) 2009-07-23
WO2009089579A3 WO2009089579A3 (fr) 2009-09-03

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/AU2009/000034 WO2009089579A2 (fr) 2008-01-15 2009-01-15 Formation de tapis non tissés

Country Status (3)

Country Link
AU (1) AU2009204678A1 (fr)
NZ (1) NZ587184A (fr)
WO (1) WO2009089579A2 (fr)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103956503A (zh) * 2014-05-08 2014-07-30 大连理工高邮研究院有限公司 一种降低纤维静电的液流电池电极制备方法
WO2020033617A1 (fr) * 2018-08-10 2020-02-13 3M Innovative Properties Company Machines, systèmes et procédés de fabrication de toiles de fibres aléatoires
WO2020033616A1 (fr) * 2018-08-10 2020-02-13 3M Innovative Properties Company Machines, systèmes et procédés de fabrication de bandes de fibres aléatoires

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3642554A (en) * 1970-02-16 1972-02-15 Certain Teed Prod Corp Closed mat forming system
US4904439A (en) * 1988-07-18 1990-02-27 Johnson & Johnson Method of making a non-woven fiber web using a multi-headed ductless webber
US4971742A (en) * 1989-05-12 1990-11-20 General Motors Corporation Method and apparatus for forming a highly isotropic web structure
US6263545B1 (en) * 2000-02-17 2001-07-24 Akiva Pinto Batt forming apparatus
US20040161993A1 (en) * 2001-09-06 2004-08-19 Gary Tripp Inorganic fiber insulation made from glass fibers and polymer bonding fibers
US20040176003A1 (en) * 2001-09-06 2004-09-09 Alain Yang Insulation product from rotary and textile inorganic fibers and thermoplastic fibers
US20040242107A1 (en) * 2003-05-30 2004-12-02 Collins Loren M. Non-woven flame blocking fabric and method

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3642554A (en) * 1970-02-16 1972-02-15 Certain Teed Prod Corp Closed mat forming system
US4904439A (en) * 1988-07-18 1990-02-27 Johnson & Johnson Method of making a non-woven fiber web using a multi-headed ductless webber
US4971742A (en) * 1989-05-12 1990-11-20 General Motors Corporation Method and apparatus for forming a highly isotropic web structure
US6263545B1 (en) * 2000-02-17 2001-07-24 Akiva Pinto Batt forming apparatus
US20040161993A1 (en) * 2001-09-06 2004-08-19 Gary Tripp Inorganic fiber insulation made from glass fibers and polymer bonding fibers
US20040176003A1 (en) * 2001-09-06 2004-09-09 Alain Yang Insulation product from rotary and textile inorganic fibers and thermoplastic fibers
US20040242107A1 (en) * 2003-05-30 2004-12-02 Collins Loren M. Non-woven flame blocking fabric and method

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103956503A (zh) * 2014-05-08 2014-07-30 大连理工高邮研究院有限公司 一种降低纤维静电的液流电池电极制备方法
WO2020033617A1 (fr) * 2018-08-10 2020-02-13 3M Innovative Properties Company Machines, systèmes et procédés de fabrication de toiles de fibres aléatoires
WO2020033616A1 (fr) * 2018-08-10 2020-02-13 3M Innovative Properties Company Machines, systèmes et procédés de fabrication de bandes de fibres aléatoires
US11814754B2 (en) 2018-08-10 2023-11-14 3M Innovative Properties Company Machines systems and methods for making random fiber webs
US11814763B2 (en) 2018-08-10 2023-11-14 3M Innovative Properties Company Machines systems and methods for making random fiber webs

Also Published As

Publication number Publication date
AU2009204678A1 (en) 2009-07-23
WO2009089579A3 (fr) 2009-09-03
NZ587184A (en) 2013-03-28

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