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A method and apparatus for producing a low density thermal insulation batt. The batt includes binder fibers which have been softened to adhere to and interconnect insulative fibers in the batt, and also includes short stilt fibers which interconnect and space apart the insulative fibers to define in

A method and apparatus for producing a low density thermal insulation batt. The batt includes binder fibers which have been softened to adhere to and interconnect insulative fibers in the batt, and also includes short stilt fibers which interconnect and space apart the insulative fibers to define interstitial air pockets intermediate the insulative fibers.

대표청구항 ▼

A method for forming a thermal insulation batt, including the steps of (a) blending at a first selected temperature insulative fibers to produce a mixture of said insulative fibers in random orientation, said insulative fibers having a melting temperature at which at least certain of said insulative

A method for forming a thermal insulation batt, including the steps of (a) blending at a first selected temperature insulative fibers to produce a mixture of said insulative fibers in random orientation, said insulative fibers having a melting temperature at which at least certain of said insulative fibers melt, said melting temperature being greater than said first selected temperature; (b) feeding said mixture of fibers into processing means to produce a web; (c) blending at a second selected temperature binder fibers with stilt fibers to produce a supplemental mixture comprised of said binder and stilt fibers in random orientation, said stilt fibers having a melting temperature at which at least certain of said stilt fibers melt, said binder fibers having a length in the rang of 0.5 inch to 2.0 inches and having a bonding temperature at which said binder fibers soften and adhere to said insulative fibers and said stilt fibers, said bonding temperature being greater than 130°F. and greater than said first and second selected temperatures and less than said melting temperature of said insulative fibers and said melting temperature of said stilt fibers; (d) transporting at a third selected temperature said web to a lapping machine to be lapped into a batt having (i) a plurality of overlaid folded web layers; and, (ii) a thickness greater than the thickness of said web; (e) folding at a fourth selected temperature said web with said lapping machine to form one of said folded web layers; (f) applying a layer of said supplemental mixture of fibers to said one of said folded web layers to ride on top of said one of said folded layers, said stilt fibers in said supplemental mixture each having a length in the range of 1/16 to ⅜inch and having a melting temperature at which at least certain of said stilt fibers melt; (g) folding said web with said lapping machine to form another of said folded web layers extending over and contacting said layer of said supplemental mixture of said stilt and binder fibers; (h) transporting at a fifth selected temperature said batt from said lapping machine to apparatus for heating said batt to said bonding temperature, said bonding temperature being greater than said third, fourth and fifth selected temperatures; (i) heating said batt with said heating apparatus to said bonding temperature to cause said binder fibers to soften and adhere to said insulative fibers and said stilt fibers such that at least certain of said stilt fibers interconnect insulative fibers in said one of said layers and said another of said layers, and said stilt filers maintain a spacing between said one of said layers and said another of said layers in the range of 1/32 inch to ⅛inch; and, (j) cooling said batt to harden said softened binder fibers, said cooled batt having a density of less than 1.0 pound per cubic foot.