US3765971A - Process for the dry production of a fiber web - Google Patents

Process for the dry production of a fiber web Download PDF

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US3765971A
US3765971A US00082241A US3765971DA US3765971A US 3765971 A US3765971 A US 3765971A US 00082241 A US00082241 A US 00082241A US 3765971D A US3765971D A US 3765971DA US 3765971 A US3765971 A US 3765971A
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web
bonding agent
fibers
bonding
layer
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H Fleissner
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    • 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
    • D04H1/58—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 applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/64—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 applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
    • D04H1/645—Impregnation followed by a solidification process
    • 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
    • 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
    • D04H1/44—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • 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
    • D04H1/58—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 applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/60—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 applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in dry state, e.g. thermo-activatable agents in solid or molten state, and heat being applied subsequently

Definitions

  • ABSTRACT [52] US. Cl. 156/62.2, 68/5 R, 156/624,
  • the present invention relates to a process and apparatus for producing a fiber web by a dry method, which web is bonded by means of bonding agents.
  • the dry method is advantageous in as far as there is no drying needed.
  • the fibers are oriented in one direction only so that at least in this direction the tensile strength of the web is rather low unless several layers of fibers are piled up, crossways.
  • the fiber web can also be coated with bonding agents. This coating can be done by means of a foam application, by a spreading-on application, application with a doctor blade or by spraying-on the bonding agent.
  • the web can be coated with the bonding agent on one side only or on both sides, but nevertheless, the final strength of such a coated web is very often insufficient.
  • Another method of producing a dry web consists of adding the so-called melting fibers to the blend of fibers. These melting fibers have a lower melting point than the other fibers and therefore cause all the fibers to stick together after having passed the heating aggregates, wherein only the melting fibers are rendered viscous. However, having solidified again, the melting fibers can re-assume a fiber structure.
  • this method could not be made use of in the present invention because the so-called melting fibers are genuine fibers which only feature a low melting point and have to be added before the web is formed so that after having melted, they can cause a sticking together of the web components. This is different with true bonding agents which are usually applied after the proper web formation. The bonding agents mingle with the fibers after the heating-up process, although this mingling is often insufficient.
  • the process according to the present invention can be characterized by saying that the bonding agent is applied in the web mixing unit or in the dosing unit in the form of a powdery, granular, fibrous or possibly liquid substance.
  • a web is formed in an essentially known way i.e. by means of at least one carding or blowing unit, followed by possibly a pre-bonding process utilizing needling units and/or hot calenders and a subsequent heat-bonding stage, the latter preferably being carried out in a perforated drum or belt steamer in which a vaporous and/or gaseous processing medium is guided, preferably drawn through the web.
  • the tensile strength of a web which has been produced by the dry method is satisfactory in one direction only, i.e. vertical to the web length. It is therefore known to pile the individual layers of the web up crossways in order to obtain a sufficient tensile strength in all directions of the final web. It is also known to zig-zag plait the web, which consists of high-quality fibers, onto a carrier fabric or inferior quality, e.g. a twilled cotton fabric or a sacking material length. For a textile material length produced in this way and having at least one cross-plaited surface layer, the present invention suggests applying the bonding agent before or during the plaiting process, between the individual layers. It is advantageous to apply a second bonding agent after the initial or pre-bonding process by means of needling units and/or hot calenders.
  • An apparatus for the dry production of a web comprises a mixing unit, a dosing unit, a web forming unit and a bonding unit.
  • the mixing unit and/or the dosing unit or the crossplaiter of a device for carrying through any of the described processes can be equipped with a spraying, pulverizing and/or straying assembly.
  • the bonding unit can be followed by an essentially known impregnating, slop padding or coating unit or by another bonding unit, preferably a perforated drum or belt dryer.
  • FIG. 1 shows a device for the dry production of a web with a subsequent thermic bonding unit
  • FIG. 2 shows a device for forming, needling, impregnating, bonding and drying of a carpet length, for example.
  • FIG. 1 shows a web fiber mixing machine marked 1.
  • the fibers are disorderly fed into the funnel-shaped mixing trough 2 by means of a conveyor belt 3.
  • the fibers are continuously mixed with a powdery, granular or fibrous bonding agent 4.
  • the fibers are guided onto a conveyor belt 5 which transports them to the pneumatic web layer 6.
  • the fibers can also pass a squeezing unit 7 which can be installed immediately in front of the web layer and in which a slight pre-bonding of the fiber blend can be obtained under the influence of heat.
  • the web layer 6 consists of a pneumatic assembly in which the fibers are separated by air pressure which is provided by a fan 8, and guided to a pair of perforated drums on which they are piled up and evenly transported to the conveyor 10.
  • the web which has already its final form is then bonded in a bonding unit marked 11 and, if necessary, dried.
  • the bonding unit comprises several perforated drums 12 which are arranged behind each other and on which the fiber web is uniformly heated and adheres because of a suction draft. The application of hot air to the fiber web causes the rapid bonding of the web which is then wound up on a batching device.
  • FIG. 2 shows a device for the production of carpets, for instance.
  • the web of high-quality fibers which is to serve as a surface layer, is produced in the above described way or in a machine assembly 13.
  • the fibers which are mixed with the bonding agent are guided onto a vibration chute 15 from which they are then transferred into a known web layer 16.
  • a conveyor 17 transports the completely formed but still unbonded web to the cross-plaiter 18 which comprises three conveyors and where the web is rendered thicker before being put crossways onto the carrier fabric which is supplied by the conveyor 19.
  • the double-layer material length is then fed into the needle looms 20 and 21 where the carrier layer and the still unbonded fiber web, in which the bonding agent is evenly distributed are mechanically united.
  • the final step of the carpet production is the thermic bonding process which can take place either immediately afterwards in the apparatus 22 or later, i.e., when the material has passed another impregnating or coating unit 23, in which further additives are applied to the material length in order to improve its tensile strength.
  • a continuous method for producing a fiber web by a dry method which comprises admixing at least a portion of a bonding agent uniformly with loose fibers, forming the resulting uniform admixture of the loose fibers and said bonding agent into a fiber web, the bonding agent being uniformly distributed throughout the formed web, and thereafter bonding the fiber web together by drawing a heated gaseous processing medium uniformly through said web.
  • a method for producing a fiber web by a dry method which comprises mixing a powdery, granular, or fibrous bonding agent uniformly with loose fibers, distributing the resulting uniform admixture of fibers and the bonding agent by air pressure to pile up the admixture of the fibers and the bonding agent between a pair of rotating perforated drums, forming the admixture of the fibers and the bonding agent into a fiber web on said perforated drums, and bonding the resulting fiber web by conveying the web on the surface of at least one sieve drum means subjected to a suction draft and by drawing a heated gaseous processing medium uniformly through said web on said sieve drum means.
  • a method for producing carpets by a dry method which comprises mixing a granular, powdery, or fibrous bonding agent uniformly with loose carpet fibers, forming the resulting uniform admixture of the fibers and the bonding agent into an unbonded web layer, rendering the web layer thicker by cross-plaiting the web layer, depositing the thick resulting web layer crossways onto a carrier fabric, mechanically uniting the ment medium through the web and through the carrier fabric on said sieve drum means.

Abstract

A method and apparatus for producing a fiber web by a dry method which comprises adding at least a portion of a bonding agent to the loose fibers and forming the loose fibers into a web, the bonding agent being uniformly distributed throughout the web.

Description

1 United States Patent 1191 1111 3,765,971 F leissner 1 Oct. 16, 1973 [5 PROCESS FOR THE DRY PRODUCTION OF 2,794,759 6/1957 Dildilian l56/62.2 X A FIBER WEB 3,147,165 9/1964 Slayter 156/622 3,220,900 11/1965 Ewerbring 156/622 InventorI Heinz Fleissner, wolfsgartenstr 3,529,447 9/1970 Eleissner et a1 68/5 Frankfurt am Main, Germany [22] Filed: Oct. 20, 1970 Primary Examiner-Edward G. Whitby [21] Appl' Attorney-Craig, Antonelli, Stewart & Hill [30] Foreign Application Priority Data Oct. 20, 1969 Germany P 19 52 741.4
[57] ABSTRACT [52] US. Cl. 156/62.2, 68/5 R, 156/624,
156/104, 425/81 [51 Int. Cl B24t 5/00 A method and apparatus for Producmg fiber Web by 58 Field of Search 156/622, 62.4, 104; a dry method which comprises adding at least 3 P 425/80 117/21, 100 5 R tion ofa bonding agent to the loose fibers and forming the loose fibers into a web, the bonding agent being [56] References Cited uniformly distributed throughout thewebn UNITED STATES PATENTS 3,246,064 4/1966 Moore et a1. 156/622 X 9 Claims, 2 Drawing Figures Patented Oct.16,1973 I 3,765,971
2 Sheets-Sheet 1 Inventor:
HEINZ FLEBSNER BY Cvaiy, Antoneui, skemarllvsHLll ATTORNEYS Patented Oct. 16, 1973 3,765,971
2 Sheets-Sheet 2 Inventor:
HUNL FLEBSNER B cvai Antoneui, 5Lemcrt4 ATTORNEYS PROCESS FOR THE DRY PRODUCTION OF A FIBER WEB BACKGROUND OF THE INVENTION The present invention relates to a process and apparatus for producing a fiber web by a dry method, which web is bonded by means of bonding agents.
Between the dry and the wet method of producing a fiber there is the following difference: With the wet method there is, just as in the production of paper, an emulsion produced which consists of a liquor and fibers which are disposed crossways, from which emulsion the liquor is removed by the force of gravity and by means of suction pumps with subsequent drying units. With the dry method, the fibers which are to form the web are laid in very thin layers by means of web-forming units such as carding machines, and then a certain number of these layers are piled up crossways. The wet web producing method features high production speeds and a great uniformity of the web, which consists of crossways lying fibers, but on the other hand it necessitates very power consuming subsequent drying processes and apparatus.
The dry method is advantageous in as far as there is no drying needed. On the other hand, the fibers are oriented in one direction only so that at least in this direction the tensile strength of the web is rather low unless several layers of fibers are piled up, crossways.
One problem with the dry production method is the application of the bonding agents which are to improve the strength of the webs. It is known to apply a bonding agent to the dry web by guiding the web through a padder which is filled with a bonding agent liquor. However, this results in a complete drying-out of the web which is to be avoided in order to save expense. The fiber web can also be coated with bonding agents. This coating can be done by means of a foam application, by a spreading-on application, application with a doctor blade or by spraying-on the bonding agent. The web can be coated with the bonding agent on one side only or on both sides, but nevertheless, the final strength of such a coated web is very often insufficient.
It is also known to apply a powdery or granular bonding agent or a melting film of binding agents to the web. These bonding agents are then melted in a heating unit and subsequently re-hardened so that the web fibers stick together. This method is advantageous because the drying process can be omitted, but it has been found that either the bonding powder or the like do not mingle thoroughly enough with the fibers or that the gelling process with a bonding agent film takes too long because the coated web are impermeable to air.
It has also been suggested to heat the material to be coated before applying the bonding agent, preferably nearly up to the processing temperature, which usually prevails in the gelling duct. If thermoplastic materials are used, it is advantageous to heat the web to be coated up to the melting temperature of the said thermoplastic substances. The same can be said for the use of gelling, curing or vulcanizing agents. Thorough experiments have shown that the last described method gives good results but also has the shortcomings that mingling of bonding agents with fibers is not always satisfactory, especially with thick fiber webs.
Another method of producing a dry web consists of adding the so-called melting fibers to the blend of fibers. These melting fibers have a lower melting point than the other fibers and therefore cause all the fibers to stick together after having passed the heating aggregates, wherein only the melting fibers are rendered viscous. However, having solidified again, the melting fibers can re-assume a fiber structure. However, this method could not be made use of in the present invention because the so-called melting fibers are genuine fibers which only feature a low melting point and have to be added before the web is formed so that after having melted, they can cause a sticking together of the web components. This is different with true bonding agents which are usually applied after the proper web formation. The bonding agents mingle with the fibers after the heating-up process, although this mingling is often insufficient.
SUMMARY OF THE INVENTION It is an object of the present invention to avoid the prior art disadvantages in the dry production of a fiber web.
It is another object of the present invention to provide a process and apparatus by which an absolutely uniform penetration of the bonding agent through even the thickest web can be obtained without any subsequent drying process, as is required when a liquid bonding agent has been applied.
Other objects and further scope of applicability of the present invention will become apparent from the detailed description given hereinafter; it should be understood, however, that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
According to the present invention it is suggested to add at least a portion of the bonding agent to the fibers before the actual web formation takes place.
The process according to the present invention can be characterized by saying that the bonding agent is applied in the web mixing unit or in the dosing unit in the form of a powdery, granular, fibrous or possibly liquid substance. Subsequently, a web is formed in an essentially known way i.e. by means of at least one carding or blowing unit, followed by possibly a pre-bonding process utilizing needling units and/or hot calenders and a subsequent heat-bonding stage, the latter preferably being carried out in a perforated drum or belt steamer in which a vaporous and/or gaseous processing medium is guided, preferably drawn through the web.
It has already been suggested that the tensile strength of a web which has been produced by the dry method is satisfactory in one direction only, i.e. vertical to the web length. It is therefore known to pile the individual layers of the web up crossways in order to obtain a sufficient tensile strength in all directions of the final web. It is also known to zig-zag plait the web, which consists of high-quality fibers, onto a carrier fabric or inferior quality, e.g. a twilled cotton fabric or a sacking material length. For a textile material length produced in this way and having at least one cross-plaited surface layer, the present invention suggests applying the bonding agent before or during the plaiting process, between the individual layers. It is advantageous to apply a second bonding agent after the initial or pre-bonding process by means of needling units and/or hot calenders.
An apparatus for the dry production of a web comprises a mixing unit, a dosing unit, a web forming unit and a bonding unit. According to the present invention the mixing unit and/or the dosing unit or the crossplaiter of a device for carrying through any of the described processes can be equipped with a spraying, pulverizing and/or straying assembly. In addition, the bonding unit can be followed by an essentially known impregnating, slop padding or coating unit or by another bonding unit, preferably a perforated drum or belt dryer.
DESCRIPTION OF THE DRAWINGS The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only and thus are not limitative of the present invention and wherein:
FIG. 1 shows a device for the dry production of a web with a subsequent thermic bonding unit; and
FIG. 2 shows a device for forming, needling, impregnating, bonding and drying of a carpet length, for example.
DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 shows a web fiber mixing machine marked 1. The fibers are disorderly fed into the funnel-shaped mixing trough 2 by means of a conveyor belt 3. In the funnel 2, the fibers are continuously mixed with a powdery, granular or fibrous bonding agent 4. After having been thoroughly mixed with the bonding agent 4, the fibers are guided onto a conveyor belt 5 which transports them to the pneumatic web layer 6. The fibers can also pass a squeezing unit 7 which can be installed immediately in front of the web layer and in which a slight pre-bonding of the fiber blend can be obtained under the influence of heat.
In this embodiment of the apparatus according to the present invention, the web layer 6 consists of a pneumatic assembly in which the fibers are separated by air pressure which is provided by a fan 8, and guided to a pair of perforated drums on which they are piled up and evenly transported to the conveyor 10. The web which has already its final form is then bonded in a bonding unit marked 11 and, if necessary, dried. The bonding unit comprises several perforated drums 12 which are arranged behind each other and on which the fiber web is uniformly heated and adheres because of a suction draft. The application of hot air to the fiber web causes the rapid bonding of the web which is then wound up on a batching device.
FIG. 2 shows a device for the production of carpets, for instance. The web of high-quality fibers, which is to serve as a surface layer, is produced in the above described way or in a machine assembly 13. In the hopper feeder 14, the fibers which are mixed with the bonding agent are guided onto a vibration chute 15 from which they are then transferred into a known web layer 16. A conveyor 17 transports the completely formed but still unbonded web to the cross-plaiter 18 which comprises three conveyors and where the web is rendered thicker before being put crossways onto the carrier fabric which is supplied by the conveyor 19.
It is possible to put a bonding agent between the individual layers. Without any pre-bonding having been effected, the double-layer material length is then fed into the needle looms 20 and 21 where the carrier layer and the still unbonded fiber web, in which the bonding agent is evenly distributed are mechanically united. The final step of the carpet production is the thermic bonding process which can take place either immediately afterwards in the apparatus 22 or later, i.e., when the material has passed another impregnating or coating unit 23, in which further additives are applied to the material length in order to improve its tensile strength.
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be apparent to one skilled in the art are intended to be included.
What is claimed is:
1. A continuous method for producing a fiber web by a dry method which comprises admixing at least a portion of a bonding agent uniformly with loose fibers, forming the resulting uniform admixture of the loose fibers and said bonding agent into a fiber web, the bonding agent being uniformly distributed throughout the formed web, and thereafter bonding the fiber web together by drawing a heated gaseous processing medium uniformly through said web.
2. The method of claim 1, wherein the bonding agent is mixed with the loose fibers in a powdery, granular, fibrous or liquid form.
3. The method of claim 1, wherein the loose fibers are cross-plaited on a carrier fabric forming a plurality of cross-plaited surface layer and additional portion of the bonding agent is applied between the individual layers before or during the cross-plaiting step.
4. The method of claim 1, wherein the web is prebonded by utilizing needles and/or hot calenders before being thermally bonded by drawing the heated gaseous processing medium through the web, said web being thermally bonded while being conveyed on the surface of at least one sieve drum means subjected to a suction draft.
5. The method of claim 4, wherein an additional bonding agent is applied after the pre-bonding step and before the step of drawing the heated gaseous medium through the web.
6. A method for producing a fiber web by a dry method which comprises mixing a powdery, granular, or fibrous bonding agent uniformly with loose fibers, distributing the resulting uniform admixture of fibers and the bonding agent by air pressure to pile up the admixture of the fibers and the bonding agent between a pair of rotating perforated drums, forming the admixture of the fibers and the bonding agent into a fiber web on said perforated drums, and bonding the resulting fiber web by conveying the web on the surface of at least one sieve drum means subjected to a suction draft and by drawing a heated gaseous processing medium uniformly through said web on said sieve drum means.
7. The method of claim 6, wherein the bonding of the web is effected by drawing hot air through the web.
8. A method for producing carpets by a dry method which comprises mixing a granular, powdery, or fibrous bonding agent uniformly with loose carpet fibers, forming the resulting uniform admixture of the fibers and the bonding agent into an unbonded web layer, rendering the web layer thicker by cross-plaiting the web layer, depositing the thick resulting web layer crossways onto a carrier fabric, mechanically uniting the ment medium through the web and through the carrier fabric on said sieve drum means.
9. The method of claim 8, wherein the composite is impregnated with an additive to improve its tensile strength prior to thermal bonding.
I F II 4'

Claims (8)

  1. 2. The method of claim 1, wherein the bonding agent is mixed with the loose fibers in a powdery, granular, fibrous or liquid form.
  2. 3. The method of claim 1, wherein the loose fibers are cross-plaited on a carrier fabric forming a plurality of cross-plaited surface layer and additional portion of the bonding agent is applied between the individual layers before or during the cross-plaiting step.
  3. 4. The method of claim 1, wherein the web is pre-bonded by utilizing needles and/or hot calenders before being thermally bonded by drawing the heated gaseous processing medium through the web, said web being thermally bonded while being conveyed on the surface of at least one sieve drum means subjected to a suction draft.
  4. 5. The method of claim 4, wherein an additional bonding agent is applied after the pre-bonding step and before the step of drawing the heated gaseous medium through the web.
  5. 6. A method for producing a fiber web by a dry method which comprises mixing a powdery, granular, or fibrous bonding agent uniformly with loose fibers, distributing the resulting uniform admixture of fibers and the bonding agent by air pressure to pile up the admixture of the fibers and the bonding agent between a pair of rotating perforated drums, forming the admixture of the fibers and the bonding agent into a fiber web on said perforated drums, and bonding the resulting fiber web by conveying the web on the surface of at least one sieve drum means subjected to a suction draft and by drawing a heated gaseous processing medium uniformly through said web on said sieve drum means.
  6. 7. The method of claim 6, wherein the bonding of the web is effected by drawing hot air through the web.
  7. 8. A method for producing carpets by a dry method which comprises mixing a granular, powdery, or fibrous bonding agent uniformly with loose carpet fibers, forming the resulting uniform admixture of the fibers and the bonding agent into an unbonded web layer, rendering the web layer thicker by cross-plaiting the web layer, depositing the thick resulting web layer crossways onto a carrier fabric, mechanically uniting the carrier fabric and the still unbonded fiber web layer, containing said bonding agent uniformly distributed throughout, and thereafter thermally bonding the web by conveying said web and said carrier fabric on the surface of at least one sieve drum means subjected to a suction draft and by drawing a heated gaseous treatment medium through the web and through the carrier fabric on said sieve drum means.
  8. 9. The method of claim 8, wherein the composite is impregnated with an additive to improve its tensile strength prior to thermal bonding.
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Cited By (23)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3862867A (en) * 1972-05-25 1975-01-28 Kendall & Co Process for producing reinforced nonwoven fabrics
US3947310A (en) * 1974-07-11 1976-03-30 Chevron Research Company Extra-wide nonwoven sheets
US3993518A (en) * 1974-09-19 1976-11-23 Buck Jr George Sumner Cotton batt and method for producing such
US4260265A (en) * 1978-07-07 1981-04-07 The Babcock & Wilcox Company Fiber-resin blending technique
US4319870A (en) * 1979-08-27 1982-03-16 American Can Company Apparatus for the manufacture of fibrous webs
US4753693A (en) * 1986-04-16 1988-06-28 Cumulus Fibres, Inc. Method for forming a vacuum bonded non-woven batt
US5057166A (en) * 1989-03-20 1991-10-15 Weyerhaeuser Corporation Method of treating discontinuous fibers
US5064689A (en) * 1989-03-20 1991-11-12 Weyerhaeuser Company Method of treating discontinuous fibers
US5071675A (en) * 1989-03-20 1991-12-10 Weyerhaeuser Company Method of applying liquid sizing of alkyl ketene dimer in ethanol to cellulose fibers entrained in a gas stream
US5079074A (en) * 1990-08-31 1992-01-07 Cumulus Fibres, Inc. Dual density non-woven batt
US5230959A (en) * 1989-03-20 1993-07-27 Weyerhaeuser Company Coated fiber product with adhered super absorbent particles
US5324391A (en) * 1990-10-31 1994-06-28 Weyerhaeuser Company Method for crosslinking cellulose fibers
US5432000A (en) * 1989-03-20 1995-07-11 Weyerhaeuser Company Binder coated discontinuous fibers with adhered particulate materials
US5437418A (en) * 1987-01-20 1995-08-01 Weyerhaeuser Company Apparatus for crosslinking individualized cellulose fibers
US5498478A (en) * 1989-03-20 1996-03-12 Weyerhaeuser Company Polyethylene glycol as a binder material for fibers
US5556976A (en) * 1987-01-20 1996-09-17 Jewell; Richard A. Reactive cyclic N-sulfatoimides and cellulose crosslinked with the imides
US5582644A (en) * 1991-12-17 1996-12-10 Weyerhaeuser Company Hopper blender system and method for coating fibers
US5804005A (en) * 1996-05-09 1998-09-08 Buck; George S. Bonding fibrous batts with thermosetting fiber-binders of certain expoxy resins
US6296795B1 (en) 2000-05-19 2001-10-02 George S. Buck Non-woven fibrous batts, shaped articles, fiber binders and related processes
US20060027944A1 (en) * 2004-08-09 2006-02-09 Rachelle Bentley Apparatus and method for in-line manufacturing of disposable hygienic absorbent products and product produced by the apparatus and methods
US20060143869A1 (en) * 2004-12-21 2006-07-06 Kronatec Ag Process for the production of a wood fiber insulating material board or mat and wood fiber insulating material boards or mats produced by this process
US20150252530A1 (en) * 2014-03-07 2015-09-10 Seiko Epson Corporation Sheet manufacturing apparatus
US9617103B2 (en) 2014-03-07 2017-04-11 Seiko Epson Corporation Sheet manufacturing apparatus

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DE2625177C3 (en) * 1976-06-04 1985-01-24 Vereinigte Papierwerke Schickedanz & Co, 8500 Nürnberg Absorbent bodies for hygienic purposes
DE3831496C2 (en) * 1988-09-16 2001-03-22 Fleissner Maschf Gmbh Co Process for the thermal consolidation of nonwovens with binding powder

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Cited By (31)

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Publication number Priority date Publication date Assignee Title
US3862867A (en) * 1972-05-25 1975-01-28 Kendall & Co Process for producing reinforced nonwoven fabrics
US3947310A (en) * 1974-07-11 1976-03-30 Chevron Research Company Extra-wide nonwoven sheets
US3993518A (en) * 1974-09-19 1976-11-23 Buck Jr George Sumner Cotton batt and method for producing such
US4260265A (en) * 1978-07-07 1981-04-07 The Babcock & Wilcox Company Fiber-resin blending technique
US4319870A (en) * 1979-08-27 1982-03-16 American Can Company Apparatus for the manufacture of fibrous webs
US4753693A (en) * 1986-04-16 1988-06-28 Cumulus Fibres, Inc. Method for forming a vacuum bonded non-woven batt
US5437418A (en) * 1987-01-20 1995-08-01 Weyerhaeuser Company Apparatus for crosslinking individualized cellulose fibers
US6436231B1 (en) 1987-01-20 2002-08-20 Weyerhaeuser Method and apparatus for crosslinking individualized cellulose fibers
US5556976A (en) * 1987-01-20 1996-09-17 Jewell; Richard A. Reactive cyclic N-sulfatoimides and cellulose crosslinked with the imides
US5498478A (en) * 1989-03-20 1996-03-12 Weyerhaeuser Company Polyethylene glycol as a binder material for fibers
US6270893B1 (en) 1989-03-20 2001-08-07 Weyerhaeuser Company Coated fiber product with adhered super absorbent particles
US5057166A (en) * 1989-03-20 1991-10-15 Weyerhaeuser Corporation Method of treating discontinuous fibers
US5432000A (en) * 1989-03-20 1995-07-11 Weyerhaeuser Company Binder coated discontinuous fibers with adhered particulate materials
US5230959A (en) * 1989-03-20 1993-07-27 Weyerhaeuser Company Coated fiber product with adhered super absorbent particles
US5071675A (en) * 1989-03-20 1991-12-10 Weyerhaeuser Company Method of applying liquid sizing of alkyl ketene dimer in ethanol to cellulose fibers entrained in a gas stream
US5516585A (en) * 1989-03-20 1996-05-14 Weyerhaeuser Company Coated fiber product with adhered super absorbent particles
US5064689A (en) * 1989-03-20 1991-11-12 Weyerhaeuser Company Method of treating discontinuous fibers
US5079074A (en) * 1990-08-31 1992-01-07 Cumulus Fibres, Inc. Dual density non-woven batt
US5324391A (en) * 1990-10-31 1994-06-28 Weyerhaeuser Company Method for crosslinking cellulose fibers
US5582644A (en) * 1991-12-17 1996-12-10 Weyerhaeuser Company Hopper blender system and method for coating fibers
US6039821A (en) * 1996-05-09 2000-03-21 Buck; George S. Bonding fibrous batts with thermosetting fiber-binders of certain epoxy resins
US5804005A (en) * 1996-05-09 1998-09-08 Buck; George S. Bonding fibrous batts with thermosetting fiber-binders of certain expoxy resins
US6296795B1 (en) 2000-05-19 2001-10-02 George S. Buck Non-woven fibrous batts, shaped articles, fiber binders and related processes
EP1162297A1 (en) * 2000-05-19 2001-12-12 BUCK, George S. Non-woven fibrous batts, shaped articles, fiber binders and related processes
US20060027944A1 (en) * 2004-08-09 2006-02-09 Rachelle Bentley Apparatus and method for in-line manufacturing of disposable hygienic absorbent products and product produced by the apparatus and methods
US20060143869A1 (en) * 2004-12-21 2006-07-06 Kronatec Ag Process for the production of a wood fiber insulating material board or mat and wood fiber insulating material boards or mats produced by this process
US8273201B2 (en) * 2004-12-21 2012-09-25 Kronotic Ag Process for the production of a wood fiber insulating material board or mat and wood fiber insulating material boards or mats produced by this process
US20150252530A1 (en) * 2014-03-07 2015-09-10 Seiko Epson Corporation Sheet manufacturing apparatus
US9540768B2 (en) * 2014-03-07 2017-01-10 Seiko Epson Corporation Sheet manufacturing apparatus
US9617103B2 (en) 2014-03-07 2017-04-11 Seiko Epson Corporation Sheet manufacturing apparatus
US9890005B2 (en) 2014-03-07 2018-02-13 Seiko Epson Corporation Sheet manufacturing apparatus

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