Fiber batts and the method of making
AssigneeAkzona Incorporated
InventorsCharles L. King, Nicholas J. Mussro, Jr., Dennis W. Roberts
Life of this patent
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Abstract
There is provided a fiber batt made from a plurality of entangled synthetic fibers arranged in a random fashion, forming a nonwoven structure. Each fiber contains a plurality of substantially spherically shaped void spaces. The batts may be made by an extrusion/blowing technique. It has been found that the batts are particularly useful as thermal insulators, as oil and water separators, and in controlled release applications.
Claims42
A fiberous batt comprising a plurality of synthetic fibers arranged in random fashion relative to one another, forming a crush resistant lofted non-woven structure, each of said fibers being formed of a polymeric structure containing a three dimensional matrix of substantially interconnected spherically shaped void spaces, said fibers being formed by
- heating a mixture of a base polymer in a compatible liquid for a sufficient time to form a homogeneous solution;
- forcing said solution through a narrow die;
- blowing a gas onto said solution as said solution passes out of said dies;
- cooling said solution to form a plurality of fibers;
- collecting said fibers onto a substrate in a batt form;
- and
- removing a substantial portion of said compatible liquid from said polymer.
A method of producing a batt having a plurality of fibers which are substantially continuous filaments forming a fibrous non-woven batt with the fibers each having a plurality of pores therein comprising the steps of:
- heating a mixture of a base polymer in a compatible liquid for a sufficient time to form a homogeneous solution;
- forcing said solution through a narrow die;
- blowing a gas onto said solution as said solution passes out of said die;
- cooling said solution to form a plurality of fibers;
- collecting said fibers onto a substrate in a batt form;
- and
- removing a substantial portion of said compatible liquid from said polymer, leaving pores in said fibers.
A method of using a fibrous batt as a thermal insulator, said batt including a plurality of synthetic fibers arranged in random fashion relative to one another, forming a lofted non-woven structure;
- said fibers formed of a polymeric structure containing a plurality of substantially spherically shaped void spaces, comprising the step of placing said batt between two sheets of textile material.
A method of using a fibrous batt as an oil and water separator, said batt including a plurality of synthetic fibers arranged in random fashion relative to one another, forming a lofted non-woven structure;
- said fibers formed of a polymeric structure containing a plurality of substantially spherically shaped void spaces, comprising the steps of applying said batt to a zone containing oil and water;
- permitting either the oil or the water but not both to be absorbed into said batt;
- removing said liquid ladened batt from said zone.
A method of using a fibrous batt as a controlled release member, said batt including a plurality of synthetic fibers arranged in random fashion relative to one another, forming a lofted non-woven structure;
- said fibers formed of a polymeric structure containing a plurality of substantially spherically shaped void spaces, comprising the steps of placing said batt in a zone containing a liquid;
- permitting said liquid to be absorbed into said batt;
- removing said batt from said zone;
- permitting said liquid to be released from said batt.
A method of using a fibrous batt as an oil and water separator, said batt including a plurality of synthetic fibers arranged in random fashion relative to one another, forming a lofted non-woven structure;
- said fibers formed of a polymeric structure containing a plurality of substantially spherically shaped void spaces, comprising the steps of pouring oil and water together onto said batt;
- permitting one substantial part of the oil or water, but not both, to be absorbed into said batt.
Dependencies are inferred from the claim text.