Composite web and process for manufacture from post-industrial scrap
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United States of America Patent
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Sep 8, 2009
Grant Date -
Aug 31, 2006
app pub date -
Jan 30, 2006
filing date -
Jan 28, 2005
priority date (Note) -
Expired
status (Latency Note)
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Abstract
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.
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