System for forming floor underlayment
View Patent ↗A process for making a fibrous panel member. 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.
1. A method for producing a textile fiber matt comprising:
a) providing textile fibers comprising binder fibers selected from the group consisting of polyethylene, polyester, polypropylene, and mixtures thereof to a blowline;
b) providing a polymeric MDI containing binder having a diisocyanate content of less than about 20% by weight to the blowline to treat the fibers;
c) at least partially drying the treated fibers; and
d) pressing the treated fibers to form a flexible textile fiber matt having a compression resistance at a compression of 25% of the original thickness of greater than about 20 psi.
2. The method of claim 1 , wherein the polymeric MDI containing binder has a diisocyanate content of about 10% by weight or less.
3. The method of claim 2 , wherein the polymeric MDI containing binder has a diisocyanate content of about 8% by weight or less.
4. The method of claim 3 , wherein the polymeric MDI containing binder has a diisocyanate content of about 6% by weight or less.
5. The method of claim 1 , wherein the polymeric MDI containing binder is emulsifiable.
6. The method of claim 5 , wherein the emulsifiable polymeric MDI is emulsified.
7. The method of claim 1 , wherein the textile fiber matt is water repellent.
8. The method of claim 1 , wherein the polymeric MDI contains isocyanurate modification.
9. The method of claim 1 , wherein the textile fibers comprise polymer fibers.
10. The method of claim 9 , wherein the textile fibers are selected from the group consisting of polymer fibers, agricultural fibers, and mixtures thereof.
11. The method of claim 1 , wherein the polymeric MDI further includes at least one release agent disposed on an exterior surface of the fiber batts.
12. A method for producing a textile fiber matt comprising:
a) providing textile fibers comprising binder fibers selected from the group consisting of polyethylene, polyester, polypropylene, and mixtures thereof to a blowline;
b) mixing a polymeric MDI containing binder having a diisocyanate with the textile fibers in the blowline to treat the fibers to form a mixture having less than 8% by weight MDI adhesive and more than 85% by weight reinforcement fibers; and
c) pressing the treated fibers to form a flexible textile fiber matt having a density of greater than about 13.3 pounds per cubic foot and having a compression resistance at a compression of 25% of the original thickness of greater than about 20 psi.
13. The method of claim 12 , wherein the polymeric MDI containing binder has a diisocyanate content of about 10% by weight or less.
14. The method of claim 12 , wherein the polymeric MDI containing binder has a diisocyanate content of about 8% by weight or less.
15. The method of claim 14 , wherein the polymeric MDI containing binder has a diisocyanate content of about 6% by weight or less.
16. The method of claim 12 , wherein the polymeric MDI contains isocyanurate modification.
17. The method of claim 12 , wherein the textile fibers comprise natural fibers.