Felt and method of manufacturing thereof

Abstract

A felt composition comprising 100% cotton, wherein the 100% cotton is used in an amount ranging between 30% to 40% by weight; polyethylene terephthalate fiber, wherein the polyethylene terephthalate fiber is used in an amount ranging between 15% to 25% by weight; low melting point fiber, wherein the low melting point fiber is used in an amount ranging between 28% to 38% by weight; and melamine polyphosphate, wherein the melamine polyphosphate is used in an amount ranging between 10% to 20% by weight of the felt composition.

Description

[0001] FELT AND METHOD OF MANUFACTURING THEREOF

[0002] FIELD OF THE INVENTION

[0003] The present invention relates to a felt composition and method of manufacturing thereof, in particular the felt composition is subsequently used to manufacture a felt that exhibits both acoustic and thermal insulation properties as well as not hazardous for consumer usage.

[0004] BACKGROUND OF THE INVENTION

[0005] Felt is a type of matted fabric that consists of fibre condensed and pressed together. Felt are commonly made from products such as but not limited to wool, animal fur, acrylic and other forms of synthetic fibre. Some of the felts are known to have fire resistance as well as sound insulation properties. However, it depends on the different type of fabric used to manufacture felt.

[0006] As such, extra time and energy are used to manufacture and combine different types of felts that can exhibit both fire resistance and sound insulation properties. Further, synthetic fibre that may be present in mineral wool and fiberglass containing felts are classified as being hazardous and cancerous to human beings.

[0007] As such, an approach is developed to formulate a felt composition that is subsequently used to manufacture a felt that exhibits both acoustic and thermal insulation properties as well as not hazardous for consumer usage.

[0008] SUMMARY OF THE INVENTION

[0009] The present invention relates to a felt composition comprising 100% cotton, wherein the 100% cotton is used in an amount ranging between 30% to 40% by weight; polyethylene terephthalate fiber, wherein the polyethylene terephthalate fiber is used in an amount ranging between 15% to 25% by weight; low melting point fiber, wherein the low melting point fiber is used in an amount ranging between 28% to 38% by weight; and melamine polyphosphate, wherein the melamine polyphosphate is used in an amount ranging between 10% to 20% by weight of the felt composition. Additional aspects, features and advantages of the invention will become apparent to those skilled in the art upon consideration of the following detailed description of preferred embodiments of the invention.

[0010] BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

[0011] The present invention will be fully understood from the detailed description given herein below and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, wherein:

[0012] In the attached drawings:

[0013] FIGURE 1 represents the results of sound absorption performance for felt of the present invention having a thickness of 40 mm and a density of 2400 gsm.

[0014] FIGURE 2 represents the results of sound absorption performance for felt of the present invention having a thickness of 60 mm and a density of 3200 gsm.

[0015] DETAILED DESCRIPTION OF THE INVENTION

[0016] Detailed description of preferred embodiments of the present invention is disclosed herein. It should be understood, however, the embodiments are merely exemplary of the present invention, which may be embodied in various forms. Therefore, the details disclosed herein are not to be interpreted as limiting, but merely as the basis for the claims and for teaching one skilled in the art of the invention. The numerical data or ranges used in the specification are not to be construed as limiting.

[0017] The present invention relates to a felt composition and method of manufacturing thereof, in particular the felt composition is subsequently used to manufacture a felt that exhibits sound insulation and fire-retardant properties.

[0018] First aspect of the present invention discusses on a felt composition, wherein the felt composition comprises:

[0019] 100% cotton, wherein the 100% cotton is used in an amount ranging between 30% to 40% by weight, preferably 30% to 36% by weight, most preferably 33% by weight of the felt composition. For the purpose of the present invention, the 100% cotton can also be replaced with jute, kenaf or husk fiber; polyethylene terephthalate fiber, wherein the polyethylene terephthalate fiber is used in an amount ranging between 15% to 25% by weight, preferably 14% to 20% by weight, most preferably 17% by weight of the felt composition. For the purpose of the present invention, the polyethylene terephthalate fiber can also be replaced with polypropylene, high density polyethylene (HDPE) or wool; low melting point fiber, wherein the low melting point fiber is used in an amount ranging between 28% to 38% by weight, preferably 30% to 36% by weight, most preferably 33% by weight of the felt composition. For the purpose of the present invention, the low melting point fiber can also be replaced with epoxy resin; and melamine polyphosphate, wherein the melamine polyphosphate is used in an amount ranging between 10% to 20% by weight, preferably 14% to 20% by weight, most preferably 17% by weight of the felt composition. For the purpose of the present invention, the melamine polyphosphate can also be replaced with flame retardant water-based solvent.

[0020] Table 1 shows the chemical components and compositions thereof (as mentioned above) used in the felt composition of the present invention.

[0021] Table 1 : Chemical components and compositions thereof used in the felt composition of the present invention

[0022] Second aspect of the present invention discusses on a method of manufacturing the felt of the present invention, wherein the method comprising the steps of: i. adding 100% cotton, polyethylene terephthalate fiber and low melting point fiber (as summarized in Table 1 ) in the bale opener to produce opened fibres, wherein the machine opens the larger bale into smaller pieces; ii. mixing the opened fibres obtained from step (i) in 3 to 6 chambers to produce mixed fibers; iii. mixing melamine polyphosphate in the resin mixer to produce mixed resin, wherein the mixing process is carried out at a speed ranging between 35 rpm to 45 rpm; iv. mixing the mixed fibres obtained from step (ii) and the mixed resin obtained from step (iii) in the hopper tower to produce a 1stmixture, wherein the mixing is carried out at a speed ranging between 20 rpm to 30 rpm; v. mixing the 1stmixture obtained from step (iv) in a mixer cylinder to produce a fibre sheet, wherein the mixing is carried out at a speed ranging between 7 rpm to 12 rpm; vi. trimming the excess felt present in the fibre sheet obtained from step (v) in the cleaner machine to produce trimmed fibre sheet; and vii. heat pressing the trimmed fibre sheet obtained from step (vi) to produce the felt of the present invention, wherein the heat pressing can be done in a conventional oven.

[0023] For the purpose of the present invention, the felt of the present invention can be used for applications such as but not limited to ceiling panels as well as wall tiles. Still, for the purpose of the present invention, the density of the resultant felt of the present invention is ranging between 600 gsm to 4000 gsm with a thickness ranging between 10 mm to 60 mm.

[0024] The following example is constructed to illustrate the present invention in a nonlimiting sense.

[0025] Test results of the felt of the present invention

[0026] The felt of the present invention is prepared using the chemical components and compositions as summarized in Table 1 adopting a method as described above. The felt of the present invention is tested for fire retardancy in accordance to UL 94 Vertical Flammability Test. This test measures the self-extinguishing time of a vertically oriented polymer specimen, whereby the top of the test specimen is clamped to a stand and the burner is placed directly below the specimen. The specimen is placed in a vertical position and subjected to flame ignition source for a specified duration of time. The flame ignition is applied at least twice for vertical burning test. The ratings of V2, V1 and VO indicate that the material was tested in a vertical position and self-extinguished within a specified time after the ignition source was removed. The vertical ratings also indicate whether the test specimen dripped flaming particles that ignited a cotton indicator located below the specimen.

[0027] Table 2 shows the outcome of fire retardancy test for the felt of the present invention.

[0028] Table 2: Outcome of fire retardancy test for the felt of the present invention

[0029] Remark: Flaming test has been performed for 5 samples

[0030] It is obvious from Table 2 that the felt of the present invention falls under the material class of 94V-0, wherein under class 94V-0, the tested sample: i. May not sustain burning combustion for longer than 10 seconds; ii. Total flaming combustion time is tested for 5 samples, including both controlled-flame applications, which may not exceed 50 seconds; iii. None of the samples may be burned up to the mounting clamp by either flaming or glowing combustion; iv. None of the samples may drip flaming particles that result in the ignition of the surgical cotton below them; and v. Samples may not exhibit glowing combustion for more than 30 seconds.

[0031] The felt of the present invention has also been tested for compliance under Restriction of Hazardous Substance (RoHS) in accordance to IEC 62321 -5:2013. Table 3 below shows the outcome of the results of RoHS compliance test. Table 3: Outcome of Restriction of Hazardous Substance (RoHS) test

[0032] As disclosed in Table 3, it is obvious that the felt of the present invention does not contain hazardous substance, hence it is safe for consumer usage.

[0033] The felt of the present invention is also tested for sound absorption performance. Referring to FIGURE 1, the figure displays the sound absorption performance for the felt of the present invention having a thickness of 40 mm and 2,400 gsm. Further, referring to FIGURE 2, the figure displays the sound absorption performance for the felt of the present invention having a thickness of 60 mm and 3,200 gsm. Based on the figures, it is evident that as the sound frequencies increase, the noise reduction coefficient (NRC) increases as well. This is more significant as the sound frequency reaches the mid-range frequency which is 200 Hz to 2000 Hz and high frequency which is above 2000 Hz.

[0034] As a whole, the felt of the present invention exhibits both acoustic and thermal insulation along with being non-hazardous for consumer usage. The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms "a", "an" and "the" may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprises", "comprising", “including”, and “having” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups therefrom.

[0035] The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed. The use of the expression “at least” or “at least one” suggests the use of one or more elements, as the use may be in one of the embodiments to achieve one or more of the desired objects or results.

Claims

CLAIMS1 . A felt composition comprising100% cotton, wherein the 100% cotton is used in an amount ranging between 30% to 40% by weight; polyethylene terephthalate fiber, wherein the polyethylene terephthalate fiber is used in an amount ranging between 15% to 25% by weight; low melting point fiber, wherein the low melting point fiber is used in an amount ranging between 28% to 38% by weight; and melamine polyphosphate, wherein the melamine polyphosphate is used in an amount ranging between 10% to 20% by weight of the felt composition.

2. The felt composition as claimed in claim 1 , wherein the 100% cotton is used in an amount ranging between 30% to 36% by weight of the felt composition.

3. The felt composition as claimed in claim 1 , wherein the 100% cotton is used in an amount of 33% by weight of the felt composition.

4. The felt composition as claimed in claim 1 , wherein the polyethylene terephthalate fibre is used in an amount ranging between 14% to 20% by weight of the felt composition.

5. The felt composition as claimed in claim 1 , wherein the polyethylene terephthalate fibre is used in an amount of 17% by weight of the felt composition.

6. The felt composition as claimed in claim 1 , wherein the low melting point fibre is used in an amount ranging between 30% to 36% by weight of the felt composition.

7. The felt composition as claimed in claim 1 , wherein the low melting point fibre is used in an amount of 33% by weight of the felt composition.

8. The felt composition as claimed in claim 1 , wherein the melamine polyphosphate is used in an amount ranging between 14% to 20% by weight of the felt composition.

9. The felt composition as claimed in claim 1 , wherein the melamine polyphosphate is used in an amount of 17% by weight of the felt composition.

10. A felt is prepared from a felt composition as claimed in claims 1 to 9.

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