Method of forming a nonwoven molded article
AssigneeZephyros, Inc.
InventorsMichael William Coates, Philip John Gibbons, John Cain
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Abstract
A method of forming a nonwoven article comprising receiving fibrous material comprising thermoplastic fibers; processing the fibrous material to produce short fibers, wherein the processing step comprises granulation using at least one granulator with a screen; distributing the short fibers approximately evenly across an area to form a short fiber web, wherein the distributing step comprises a use of a recyclate spreader; heating the short fiber web to fuse the short fibers to form a nonwoven material; and forming a sheet of the nonwoven material.
Claims16
A method of forming a nonwoven article, the method comprising:
- a) receiving fibrous material comprising thermoplastic fibers;
- b) processing the fibrous material to produce short fibers having a length of about 3 mm or smaller, wherein the processing step comprises granulation utilizing at least one granulator with a screen;
- c) distributing the short fibers approximately evenly across an area to form a short fiber web, wherein the distributing step comprises a recyclate spreader;
- d) heating the short fiber web to fuse the short fibers to form a nonwoven material;
- e) forming a sheet of the nonwoven material;
- and
- f) molding the sheet into a molded article having a three-dimensional shape.
Dependencies are inferred from the claim text.