Apparatus and method for making a polymer fill
AssigneeArden Companies
InventorTom C. Current
Life of this patent
Estimating the term…
Abstract
A process for manufacturing a polymer fill, the method comprising the steps of blending polymer fibers to form a polymer fill, depositing the polymer fill onto a surface, orientating the polymer fibers in a desired orientation, heating the polymer fill, compressing the polymer fill and cooling the polymer fill. The surface carries the polymer fill from the blending step through the heating step, and wherein the polymer fill enters the compression step independent of the surface.
Claims27
A process for manufacturing a non-woven product, comprising the steps of:
- depositing a layer of polymer fill including fibers onto at least one movable surface, wherein the movable surface transports the deposited layer of polymer fill including the fibers to one or more stations for
- orientating the fibers in a non-random orientation,
- heating the layer of polymer fill including the orientated fibers,
- compressing the layer of polymer fill including the orientated, heated fibers, and
- cooling the layer of polymer fill including the orientated, heated, compressed fibers;
- and
- forming the transported layer of polymer fill including the orientated, heated, compressed and cooled fibers into a non-woven fabric, wherein the orientating step includes aligning the fibers in a first non-random orientation, wherein the first non-random orientation includes a horizontal orientation, and aligning the fibers in a second non-random orientation, wherein the second non-random orientation includes a vertical orientation.
An assembly for manufacturing a non-woven product, comprising:
- a conveyor that provides
- means for carrying a layer of polymer fill including a plurality of fibers through one or more stations including
- a first carding machine that provides
- means for aligning the plurality of fibers in a first, non-random, horizontal orientation,
- a second carding machine that provides
- means for aligning the plurality of fibers in a second, non-random, vertical orientation, and
- an oven that provides
- means for heating the layer of polymer fill including the plurality of orientated fibers;
- a pair of rollers that provides
- means for compressing the layer of polymer fill including the plurality of orientated, heated fibers;
- and
- a cooling system that provides
- means for cooling the layer of polymer fill including the plurality of orientated, heated, compressed fibers.
An assembly for manufacturing a non-woven product, comprising:
- a conveyor including a first, upstream end and a second, downstream end, wherein the conveyor interfaces with
- at least two carding machines, and
- an oven
- a pair of compression rollers including an input side and an output side, wherein the input side is located proximate the second, downstream end of the conveyor;
- and
- a cooling system located proximate the output side of the pair of rollers.
Dependencies are inferred from the claim text.