초록 ▼

A method of forming a nonwoven article comprising receiving fibrous material comprising thermoplastic fibers; processing the fibrous material to produce short fibers, wherein the processing step comprises granulation using at least one granulator with a screen; distributing the short fibers approxim

A method of forming a nonwoven article comprising receiving fibrous material comprising thermoplastic fibers; processing the fibrous material to produce short fibers, wherein the processing step comprises granulation using at least one granulator with a screen; distributing the short fibers approximately evenly across an area to form a short fiber web, wherein the distributing step comprises a use of a recyclate spreader; heating the short fiber web to fuse the short fibers to form a nonwoven material; and forming a sheet of the nonwoven material.

대표청구항 ▼

1. A method of forming a nonwoven article, the method comprising: a) receiving fibrous material comprising thermoplastic fibers, wherein at least a portion of the fibrous material is waste material;b) processing the fibrous material to produce short fibers, wherein the processing step comprises gran

1. A method of forming a nonwoven article, the method comprising: a) receiving fibrous material comprising thermoplastic fibers, wherein at least a portion of the fibrous material is waste material;b) processing the fibrous material to produce short fibers, wherein the processing step comprises granulation utilizing at least one granulator with a screen;c) distributing the short fibers approximately evenly across an area to form a short fiber web, wherein the distributing step comprises using a recyclate spreader that reduces clumping of the short fibers by reducing the static charge of the short fibers;d) heating the short fiber web to fuse the short fibers to form a nonwoven material;e) forming a sheet of the nonwoven material; andf) molding the sheet of the nonwoven material into a molded article having a three-dimensional shape wherein the molded article is suitable for use as a sound absorption material. 2. The method of claim 1, wherein the short fibers are blended before the distributing step to achieve a relatively consistent distribution of fibrous material. 3. The method of claim 1, wherein the distributing step distributes the short fibers approximately evenly onto a facing material. 4. The method of claim 3, wherein the facing material is formed of a non-woven preformed web, needle punched material, fabric, or combination thereof. 5. The method of claim 3, wherein a second facing material is placed on top of the short fiber web after the distributing step. 6. The method of claim 1, wherein the method includes a compacting step to achieve a desired density of the nonwoven material. 7. The method of claim 6, wherein the compacting step comprises using at least one set of heated calendar rolls. 8. The method of claim 1, wherein the nonwoven material exhibits selected air flow resistivity of about 275,000 Rayls/m to about 3,000,000 Rayls/m. 9. The method of claim 1, wherein the molded article is surrounded by waste. 10. The method of claim 9: wherein the molded article is separated from the waste. 11. The method of claim 10, wherein the molded article is separated from the waste with a water jet, laser, die, or ultrasonic cutter. 12. The method of claim 10, wherein the waste is recycled at the receiving step. 13. The method of claim 1, wherein the processing step includes shredding with a single shaft shredder before the at least one granulator with the screen. 14. The method of claim 1, wherein the processing step comprises granulation with two or more granulators arranged in series, with each granulator having at least one screen. 15. The method of claim 1, wherein the short fibers after the processing step have an average length of about 2 mm to about 3 mm. 16. The method of claim 1, wherein the heating step comprises a con oven to soften low-melt temperature short fibers and bond the short fibers together. 17. A method of forming a nonwoven article, the method comprising: a) receiving fibrous material comprising thermoplastic fibers;b) processing the fibrous material to produce short fibers, wherein the processing step comprises granulation using at least one granulator with a screen;c) blending the short fibers achieve a relatively consistent distribution of fibrous material;d) distributing the short fibers approximately evenly to form a short fiber web on a facing material, wherein the distributing step comprises use of a recyclate spreader;e) heating the short fiber web and the facing material in an oven to form a nonwoven material;f) compacting the nonwoven material,g) forming a sheet of the nonwoven maternal;h) shaping the sheet of nonwoven material into a molded article surrounded by waste;i) separating the molded article from the waste; andj) recycling the waste into the receiving step without performing melting or disambiguation steps prior to the receiving step, wherein the nonwoven material is suitable for use as a sound absorption material, andwherein the nonwoven, material exhibits a selected air flow resistivity of about 275,000 Rayls/m to about 3,000,000 Rayls/m. 18. The method of claim 17, wherein a second facing material is placed on top of the short fiber web after the distributing step. 19. The method of claim 17, wherein the compacting step comprises using at least one set of heated calendar rolls. 20. The method of claim 1, wherein the waste material does not undergo melting or disambiguation steps prior to the receiving step.