System for forming floor underlayment
View Patent ↗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.
1. A method for producing a textile fiber matt comprising:
a) providing fibers into a blowline;
b) providing a liquid adhesive having a content of less than about 20% by Weight of the fibers into the blowline to treat the fibers;
c) pressing the fibers to form a flexible 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 providing a liquid adhesive having a content of less than about 20% by weight to the blowline comprises providing a liquid polymeric MDI containing adhesive having a diisocyanate into the blowline.
3. The method of claim 2 , wherein the polymeric MDI containing adhesive has a diisocyanate content of about 8% by weight or less.
4. The method of claim 2 , wherein the polymeric MDI containing adhesive has a diisocyanate content of about 6% by weight or less.
5. The method of claim 2 , wherein the liquid polymeric MDI containing adhesive is emulsifiable.
6. The method of claim 5 , wherein the emulsifiable polymeric MDI containing adhesive is emulsified.
7. The method of claim 1 , wherein the flexible fiber matt is water repellent.
8. A method for producing a fiber matt comprising:
a) providing fibers selected from the group consisting of polyethylene, polyester, polypropylene, and mixtures thereof to a blowline;
b) providing adhesive binder into the blowline;
c) mixing an adhesive binder in the blowline to treat the fibers to form a mixture having less than 8% by weight adhesive binder and more than 85% by weight textile 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.
9. The method of claim 8 , wherein the adhesive binder has a diisocyanate content of about 8% by weight or less.
10. The method of claim 8 , wherein the flexible textile fiber matt comprises an adhesive binder content of about 6% by weight or less.
11. The method of claim 8 , further comprising mixing an isocyanurate adhesive binder with the textile fibers in the blow line.
12. The method of claim 8 , further comprising mixing natural fibers with the textile fibers in the blow line.
13. A method for producing a textile fiber matt comprising:
a) providing fibers selected into a blowline;
b) providing binder into the blowline to form a mixture of fibers and binder; and
c) pressing the fibers in the presence of heat 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 and mixture having less than 8% by weight binder and more than 85% by weight textile fibers.
14. The method of claim 13 , further comprising providing an adhesive binder having a diisocyanate content of about 10% by weight or less into the blowline.
15. The method of claim 13 , further comprising mixing an adhesive binder in the blowline to treat the fibers to form a mixture having less than 8% by weight adhesive and more than 85% by weight fibers.
16. The method of claim 13 , wherein the fibers comprise natural fibers.