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US 9,315,930 B2Granted
Nonwoven textile made from short fibers
AssigneeZephyros, Inc.
InventorsMichael William Coates, Marek Henryk Kierzkowski, Philip John Gibbons, Alfred Johannas Eiden
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Abstract
A method of forming a nonwoven material, the method comprising: receiving fibrous material comprising thermo-plastic fibers; processing the fibrous material to produce short fibers; adding the short fibers to a preformed web; and heating and optionally compressing the preformed web to form a nonwoven material.
Claims21
A method of forming a nonwoven material, the method comprising:
- receiving fibrous material comprising thermoplastic fibers;
- processing the fibrous material to produce short fibers having an average length of about 2 mm or less;
- adding the short fibers to a preformed web;
- and
- heating and optionally compressing the short fibers and preformed web to form a nonwoven material;
- wherein the nonwoven material has a density of from about 200 kg/m3 to about 2000 kg/m3 and a selected air flow resistivity between about 275,000 Rayls/m and about 3,000,000 Rayls/m.
3 more elements
A method of forming a nonwoven material, the method comprising:
- receiving fibrous material comprising thermoplastic fibers;
- processing the fibrous material to produce short fibers having an average length of about 2 mm or less;
- distributing the short fibers approximately evenly on a conveyor to provide a short fiber layer;
- and
- heating the short fiber layer to form a nonwoven material;
- wherein the nonwoven material has a selected air flow resistivity between about 275,000 Rayls/m and about 3,000,000 Rayls/m and a density of from about 200 kg/m3 to about 2000 kg/m3.
3 more elements
A method of forming a nonwoven material, the method comprising:
- receiving fibrous material comprising fibrous waste material including bi-component fiber for facilitating bonding of the fibrous materials;
- processing the fibrous material to produce short fibers having an average length of about 2 mm or less, wherein the processing includes comminuting the fibrous waste material;
- distributing the short fibers across an area to form a precursor web;
- and
- bonding together at least some of the short fibers of the precursor web to form a nonwoven material by heating the short fibers to a temperature between about 100° C. and about 220° C.;
- wherein the nonwoven material has a selected air flow resistivity between about 275,000 Rayls/m and about 3,000,000 Rayls/m and a density of from about 200 kg/m3 to about 2000 kg/m3.
3 more elements
Dependencies are inferred from the claim text.