Composite web and process for manufacture from post-industrial scrap
View Patent ↗A composite web and process for manufacture from post-industrial scrap wherein the fibers are pre-opened and cut to an average fiber length of about 4 mm. A scrap fiber component and a cellulosic component of such fibers are blended into a fiber furnish. The scrap fiber component includes at least 15% synthetic fibers and may include a blend of natural fibers, high melting point synthetic fibers, and low melting point synthetic fibers. The cellulosic component may include post-industrial cotton fibers which may be refined before blending with the scrap fiber component. The fiber furnish is processed into an intermediate web such as by a drylaid or a wetlaid nonwoven process. The intermediate web is saturated with a latex binding agent and pressed and/or dried to form a composite web capable of further processing into molded or formed consumer or industrial products. The process is capable of producing a high basis weight composite web.
1. A process for manufacture of a composite web from post-industrial scrap wherein the scrap fibers are cut, opened, and refined, comprising:
obtaining a furnish of the scrap fibers including a scrap fiber component and a cellulosic component;
processing said fiber furnish to form an intermediate web;
once formed, saturating said intermediate web with a binding agent to form a composite web;
drying said composite web.
2. The process of claim 1 wherein said scrap fiber component includes between about 15% and 30% by weight low melting point synthetic fiber.
3. The process of claim 2 wherein said low melting point synthetic fiber is selected from a group consisting of polypropylene, low-melt polyester and latex chrome.
4. The process of claim 1 wherein said scrap fiber component includes at least 25% high melting point synthetic fiber.
5. The process of claim 4 wherein said high melting point synthetic fiber is selected from a group consisting of nylon, polyester, cellulose acetate, and acrylic.
6. The process of claim 1 wherein said scrap fiber component includes natural fibers.
7. The process of claim 6 wherein said scrap fiber component includes at least 45% by weight natural fibers.
8. The process of claim 6 wherein said natural fibers are selected from a group consisting of cotton, jute, kenaf, linen, and wool.
9. The process of claim 1 wherein said scrap fiber component is a blend of natural fibers, high melting point synthetic fibers, and low melting point synthetic fibers.
10. The process of claim 1 wherein said scrap fiber component is a fiber blend comprising:
between about 45% and 55% by weight natural fibers;
between about 25% and 35% by weight high melting point synthetic fibers;
between about 15% and 25% by weight low melting point synthetic fiber.
11. The process of claim 1 wherein said scrap fiber component is a fiber blend, comprising:
approximately 50% by weight natural fibers;
approximately 30% by weight high melting point synthetic fibers;
approximately 20% by weight low melting point synthetic fiber.
12. A composite web formed from the process of claim 11 .
13. The composite web of claim 12 wherein said composite web comprises:
approximately 50% by weight scrap fiber component;
approximately 25% by weight cellulosic component;
approximately 25% by weight binding agent.
14. The process of claim 12 wherein said composite web has a basis weight greater than 200 lbs./3000 ft. 2 .
15. The process of claim 1 wherein said fibers in said fiber furnish range in length from 1 mm to 10 mm and a diameter of 0.5 denier to 4 denier.
16. The process of claim 1 wherein said fibers in said fiber furnish have an average fiber length of 4 mm.
17. The process of claim 1 where in said cellulosic component is cotton.
18. The process of claim 1 wherein said fiber furnish is further refined prior to processing to form said intermediate web.
19. The process of claim 1 wherein an airlaid process is employed to form said intermediate web from said fiber furnish.
20. The process of claim 1 wherein a wetlaid process is employed to form said intermediate web from said fiber furnish.
21. The process of claim 1 wherein the cellulosic component is refined prior to mixing with said scrap fiber component.
22. The process of claim 21 wherein a polymeric surfactant is added to the fiber furnish prior to processing.
23. The process of claim 22 wherein said polymeric surfactant is a low molecular weight ethylene oxide based urethane block copolymer.
24. The process of claim 1 wherein the composite web is heat pressed after drying.
25. The process of claim 1 wherein pigment material is added to said binding agent.
26. The process of claim 1 wherein an odor absorbing material is added to said binding agent.
27. The process of claim 1 Wherein fragrance producing material is added to said binding agent.
28. A process for manufacture of a composite web from post-industrial scrap wherein the scrap fibers are cut, opened, and refined, comprising:
obtaining a furnish of the scrap fibers including a scrap fiber component and a cellulosic component;
processing said fiber furnish to form an intermediate web;
saturating said intermediate web with a binding agent to provide and adhesive bond between said scrap fiber component and said cellulosic component to form a composite web;
drying said composite web.
29. The process of claim 28 wherein said binding agent further imparts wet/dry strength to said composite web.
30. the process of claim 28 wherein said binding agent further imparts desired physical characteristics to said composite web.