Textile Fiber Underlayment with MDI Binder
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Solution Overview
Problem
Existing methods for producing textile fiber mats for floor underlayment are inefficient, costly, and environmentally harmful due to high energy consumption and emissions, slow throughput, and the use of conventional binders.
Innovation Solution
A method involving a blowline process where textile fibers are treated with a polymeric MDI binder containing less than 20% diisocyanate content, which is then dried and activated with steam to create a flexible and rollable textile batt, using a combination of adhesive and reinforcement fibers, and optionally incorporating recycling-compatible or water-soluble adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional binders (needling or meltable binder fibers) are used to form textile pads, then the pads can be formed with structural integrity, but the process results in slow throughput, high energy consumption, and high cost
Solution Approach 1:
The patent changes the chemical parameters of the binder by using polymeric MDI with reduced diisocyanate content (less than 20% by weight) instead of conventional binders. This parameter change enables faster curing and bonding, resulting in improved throughput and reduced energy consumption while maintaining pad structural integrity
Solution Approach 2:
The patent replaces mechanical binding methods (needling) and traditional meltable binder fibers with a chemical adhesive bonding system using polymeric MDI. This substitution eliminates the need for mechanical penetration and prolonged heating, significantly reducing energy consumption and increasing production speed
2Reliability
If conventional binders are used to form textile pads, then structural integrity can be achieved, but the process generates high environmental emissions and is costly
Solution Approach 1:
The patent modifies the chemical composition parameters by using polymeric MDI with low diisocyanate content (less than 20% by weight), which reduces harmful emissions during the bonding process while maintaining reliable structural integrity through effective adhesive bonding
Solution Approach 2:
The patent employs a water-soluble adhesive system that can be easily removed or degraded, replacing persistent conventional binders. This approach reduces environmental accumulation and emissions while providing sufficient structural integrity during the product's service life
3Ease of operation
If polymeric MDI binder with low diisocyanate content is used, then the textile product becomes flexible and rollable, but the adhesive activation requires steam treatment
Solution Approach 1:
The patent adjusts the chemical parameters of the MDI binder (reducing diisocyanate content to less than 20% by weight) to achieve the desired flexibility and rollability. The steam activation step is integrated into the existing manufacturing process, adding minimal complexity while enabling the low-diisocyanate binder to cure properly
4Strength
If textile fibers are treated with polymeric MDI binder and dried, then the fibers are prepared for bonding, but the internal bond strength must be activated through steam
Solution Approach 1:
The patent performs preliminary treatment by applying and drying the polymeric MDI binder to the textile fibers before final bonding. This preliminary action prepares the fibers for subsequent steam activation, ensuring proper adhesion while the steam step completes the bonding process with controlled energy input
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in a flexible, water-resistant, and elastically deformable flooring material with improved physical and mechanical properties, such as higher internal bond strength and reduced edge swelling, while also being recyclable and environmentally friendly.
Implementation Method 1
The fiber/MDI is at least partially dried. The treated fibers are pressed and subjected to steam to activate the adhesive and bind the fibers to provide a flexible textile batt.
Implementation Method 2
The treated fibers are pressed and subjected to steam to activate the adhesive and bind the fibers
Implementation Method 3
polymeric MDI containing binder having a diisocyanate content of less than about 20% by weight is mixed with the textile fibers in the blowline to treat the textile fibers
Implementation Method 4
The treated fibers are pressed and subjected to steam to activate the adhesive and bind the fibers
Data Source
AI summary
A process for making a fibrous panel member and a flooring structure is disclosed. The flooring structure has a subfloor, a surface layer, and an insulative pad disposed between the subfloor and the surface layer. The insulative pad has an MDI binder and reinforcement fibers distributed uniformly and randomly within a first plane. The process includes mixing a porous fiber material with a MDI adhesive. The fiber batt is compressed between a pair of porous belts. Steam and heat are applied to the compressed batt to form a bound flexible batting material.