Method for producing a fiberous batt

Claim 2

A completely dry process for producing a fiberous batt comprising the steps of: I. contacting fibers with an adhesive amount of particles of a copolymer of vinyl chloride and maleic acid dibutyl ester; and II. forming the fibers into a batt; and III. heating the batt to a temperature above the melting point of the copolymer but below the scorching or melting point of the fibers; and then IV. cooling the batt.

Claim 3

A completely dry process for producing a fiberous batt comprising the steps of: I. forming a thin web of fibers; and II. contacting the web with an adhesive amount of particles of a copolymer of vinyl chloride and maleic acid dibutyl ester; and III. forming the web into a batt; and IV. heating the batt to a temperature above the melting point of the copolymer but below the scorching or melting point of the fibers, and subsequently V. cooling the batt.

Claim 4

A completely dry process for producing a fiberous batt comprising the steps of: I. forming a thin web of fibers; and II. contacting the web with an adhesive amount of particles of a copolymer of vinyl chloride and maleic acid dibutyl ester; and III. forming the web into a batt; and IV. heating the batt to a temperature above the melting point of the copolymer but below the scorching or melting point of the fibers, and subsequently V. cooling the batt.

Claim 5

The process of claim 2 wherein the thin web is horizontal.

Claim 6

The process of claim 2 wherein the web has a thickness of from 1 to 200 fibers.

Claim 7

The process of claim 2 wherein the weight ratio of maleic acid dibutyl ester to vinyl chloride is 1:99 to 25:75.

Claim 8

The process of claim 2 wherein the weight ratio of the copolymer to the fibers is 1:99 to 40:60.

Claim 9

The process of claim 2 wherein the copolymer particles have a size range of from 1 to 200 microns.

Claim 10

The process of claim 2 wherein the copolymer particles have a size range of from 6 to 25 microns.

Claim 11

The process of claim 2 wherein the copolymer particles have a size range of from 8 to 12 microns.

Claim 12

The process of claim 2 wherein the copolymer has a melting point of 135° to 210° C.

Claim 13

The process of claim 2 wherein the temperature in Step IV is between 149° to 232° C.

Claim 14

The process of claim 2 wherein the heating is conducted for a period of from 1/2 to 20 minutes.

Claim 15

A completely dry process for producing a fiberous batt of high compressive strength comprising in sequence the steps of: I. forming a horizontally disposed, thin, planar web of fibers having a fiber denier from 1 to 22, said web being from 1 to 100 fibers thick; II. contacting the web with particles of an addition copolymer of vinyl chloride and a diester of a vinyl unsaturated dicarboxylic acid while the web is in contact with and supported by a moving conveyor; A. wherein the weight ratio of vinyl unsaturated dicarboxylic acid to vinyl chloride is 3:97 to 20:80, B. wherein the weight ratio of the copolymer to the fibers is 3:97 to 35:65, C. wherein the copolymer particles have a size range of 6 to 25 microns, D. wherein the copolymer has a melting point of 135° to 190° C., E. wherein the diester is dibutyl maleate; and then 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; IV. heating the batt to a temperature of 163° to 218° C. for a period of 1 to 5 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 fiberous batt of high compressive strength.

Claim 16

A completely dry process for producing a fiberous batt of high compressive strength comprising in sequence the steps of: I. forming a horizontally disposed, thin, planar web of fibers having a fiber denier from 1 to 22, said web being from 1 to 100 fibers thick; II. contacting the web with particles of an addition copolymer of vinyl chloride and a diester of a vinyl unsaturated dicarboxylic acid while the web is in contact with and supported by a moving conveyor; A. wherein the weight ratio of vinyl unsaturated dicarboxylic acid to vinyl chloride is 3:97 to 20:80, B. wherein the weight ratio of the copolymer to the fibers is 3:97 to 35:65, C. wherein the copolymer particles have a size range of 6 to 25 microns, D. wherein the copolymer has a melting point of 135° to 190° C., E. wherein the diester is dibutyl maleate; and then 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; IV. heating the batt to a temperature of 163° to 218° C. for a period of 1 to 5 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 fiberous batt of high compressive strength.