Air-cured batting insulation

Abstract

Air-cured batting includes a nonwoven web. The batting contains 75 to 97.5 wt % of fiber mixture, and 2.5 to 25 wt % of resin comprising a cross-linked copolymer of butyl acrylate and methyl methacrylate, wherein the resin is present on a first surface of the batting, and on a second surface of the batting, the second surface being parallel to the first surface, and wherein the resin is adhered to fibers of the fiber mixture, thereby forming a bonded structure, such that, by virtue of the resin, the air-cured batting has structural integrity that imparts handleability of the batting in sheet form. Articles comprising the air-cured batting and methods of making the air-cured batting are also provided.

Description

CROSS REFERENCE TO RELATED APPLICATIONS[0001]This application claims priority to U.S. provisional application No. 62 / 415,137, filed on Oct. 31, 2016, the entire contents of which are hereby incorporated by reference herein.FIELD OF THE INVENTION[0002]The present invention generally relates to air-cured batting, to articles comprising the batting, and to methods of making the batting.BACKGROUND OF THE INVENTION[0003]In order to make batting (e.g., synthetic batting such as polyester batting), a binder resin or a low melt fiber is used in order to bond a web of fibers together, thereby reinforcing and giving structure and / or strength to the batting. The resins and binder fibers that are used require heat in order to bond the fibers together. In practice, this is accomplished by passing the web through an oven. Ovens typically used are single pass, 3-pass, or 5 pass ovens (i.e., the web is passed through the oven once, three, or five times). The heat from the oven either cures the resi...

AI Technical Summary

Benefits of technology

The present invention provides a solution for making more efficient and eco-friendly batting for use in various processes. The solution involves using a resin solution that is applied to a fiber mixture to create a bonded structure that imparts handleability to the batting in sheet form. This process requires less energy, avoids the use of hazardous environmental risks, and reduces waste of nonrenewable resources. The technical effects of the invention include improved efficiency, reduced energy expenditure, and eco-friendliness.

Problems solved by technology

Thus, heat readily escapes and there is a need to use excessive energy to maintain a desired temperature in the oven.

As ovens are typically heated using oil, coal, electricity, or gas, processes of record for making batting are high in energy consumption, can pollute the environment by releasing carbon monoxide due to composition, and can be draining on nonrenewable resources.

In addition to their high energy usage, in view of their open ends in particular, ovens can create a hazardous environment, posing risks of, for example, potential burning and heat exhaustion.

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