Cotton batt and method for producing such

Claim 2

A dry process for producing a cotton batt of high compressive strength comprising the steps of: I. forming a thin web of cotton fibers; Ii. contacting the web with an adhesive amount of particles of a copolymer of vinyl chloride and vinylidene chloride; Iii. forming the web into a batt by laying the web transversely back and forth on a moving belt such that the batt comprises a plurality of webs; and then Iv. heating the batt to a temperature above the sticking point of the copolymer but below the scorching point of the cotton wherein the particles have a size range of 20 to 80 microns, wherein the weight ratio of vinyl chloride to vinylidene chloride is 5:95 to 25:75 and wherein the weight ratio of copolymer to the cotton is 10:90 to 20:80.

Claim 3

The process of claim 1 wherein the thin web is horizontally disposed.

Claim 4

The process of claim 1 wherein the web has a thickness of from 1 to 200 fibers.

Claim 5

The process of claim 1 wherein the copolymer has a sticking point of 300° to 370° F.

Claim 6

The process of claim 1 wherein the contacting of the web with the particles is effected by feeding the particles from a container into the bristles of a first rotating brush which is then contacted with a counter-rotating brush having stiffer bristles, which remove the particles from the first rotating brush permitting the particles to fall on the web under the influence of gravity.

Claim 7

The process of claim 1 wherein the steps are practiced in the order recited.

Claim 8

The process of claim 1 wherein the temperature in step IV is between 300° and 400° F.

Claim 9

The process of claim 1 wherein the heating is conducted for a period of from 1 to 20 minutes.

Claim 10

A completely dry process for producing a cotton batt of high compressive strength comprising in sequence the steps of: I. forming a horizontally disposed, thin, planar web of waste cotton fibers, said web being from 1 to 100 fibers thick; Ii. contacting the web with particles of a copolymer of vinyl chloride and vinylidene chloride while the web is in contact with and supported by a moving belt thereby inhibiting the passage of particles through the web; A. wherein the copolymer contains 90% vinylidene chloride, B. wherein the weight ratio of the copolymer to the cotton is 10:90 to 20:80, C. wherein the copolymer particles have a size range of 20 microns to 80 microns, D. wherein the copolymer has a sticking point of 300° to 370° F, Iii. passing the web and adhering particles through the nip of two rotating rolls to impress the particles into the web; Iv. forming the web into a batt by laying the web transversely back and forth on moving belt such that the batt comprises a plurality of webs; V. heating the batt to a temperature of 325° to 375° F for a period of 2 to 10 minutes while the batt is being passed through an oven between two parallel foraminous belts while hot air is forced through the belts and through the batt; thereby producing a cotton batt of high compressive strength.

Claim 11

A completely dry process for producing a cotton batt of high compressive strength comprising in sequence the steps of: I. forming a horizontally disposed, thin, planar web of waste cotton fibers, said web being from 1 to 100 fibers thick; Ii. contacting the web with particles of a copolymer of vinyl chloride and vinylidene chloride while the web is in contact with and supported by a moving belt thereby inhibiting the passage of particles through the web; A. wherein the copolymer contains 90% vinylidene chloride, B. wherein the weight ratio of the copolymer to the cotton is 10:90 to 20:80, C. wherein the copolymer particles have a size range of 20 microns to 80 microns, D. wherein the copolymer has a sticking point of 300° to 370° F, Iii. passing the web and adhering particles through the nip of two rotating rolls to impress the particles into the web; Iv. forming the web into a batt by laying the web transversely back and forth on moving belt such that the batt comprises a plurality of webs; V. heating the batt to a temperature of 325° to 375° F for a period of 2 to 10 minutes while the batt is being passed through an oven between two parallel foraminous belts while hot air is forced through the belts and through the batt; thereby producing a cotton batt of high compressive strength.

Claim 12

A completely dry process for producing a cotton batt of high compressive strength comprising in sequence the steps of: I. forming a horizontally disposed, thin, planar web of waste cotton fibers, said web being from 1 to 100 fibers thick; Ii. contacting the web with particles of a copolymer of vinyl chloride and vinylidene chloride while the web is in contact with and supported by a moving belt thereby inhibiting the passage of particles through the web; A. wherein the weight ratio of vinyl chloride to vinylidene chloride is 5:95 to 25:75, B. wherein the weight ratio of the copolymer to the cotton is 10:90 to 20:80, C. wherein the copolymer particles have a size range of 20 microns to 80 microns, D. wherein the copolymer has a sticking point of 300° to 370° F, Iii. passing the web and adhering particles through the nip of two rotating rolls to impress the particles into the web; Iv. forming the web into a batt by laying the web transversely back and forth on a moving belt such that the batt comprises a plurality of webs; V. heating the batt to a temperature of 325° to 375° F for a period of 2 to 10 minutes while the batt is being passed through an oven between two parallel foraminous belts while hot air is forced through the belts and through the batt; thereby producing a cotton batt of high compressive strength.

Claim 13

A completely dry process for producing a cotton batt of high compressive strength comprising in sequence the steps of: I. forming a horizontally disposed, thin, planar web of waste cotton fibers, said web being from 1 to 100 fibers thick; Ii. contacting the web with particles of a copolymer of vinyl chloride and vinylidene chloride while the web is in contact with and supported by a moving belt thereby inhibiting the passage of particles through the web; A. wherein the weight ratio of vinyl chloride to vinylidene chloride is 5:95 to 25:75, B. wherein the weight ratio of the copolymer to the cotton is 10:90 to 20:80, C. wherein the copolymer particles have a size range of 20 microns to 80 microns, D. wherein the copolymer has a sticking point of 300° to 370° F, Iii. passing the web and adhering particles through the nip of two rotating rolls to impress the particles into the web; Iv. forming the web into a batt by laying the web transversely back and forth on a moving belt such that the batt comprises a plurality of webs; V. heating the batt to a temperature of 325° to 375° F for a period of 2 to 10 minutes while the batt is being passed through an oven between two parallel foraminous belts while hot air is forced through the belts and through the batt; thereby producing a cotton batt of high compressive strength.