Non-woven fibre product comprising fibres of recycled material

Abstract

The present invention concerns an air-laid non-woven fibre product comprising recycled material and manufactured by a dry forming process, said product comprising: a first portion of up to 99% dust material, where the dust material is preferably recovered dust from manufacturing or the like of fibrous textile material, preferably cotton textiles, and a second portion at least 1% bi-component fibres having a length between 2-75 mm, preferably 2-25 mm in length.

1 .- 20 . (canceled) 
     
     
         21 . A non-woven fibre product comprising recycled material and manufactured by a dry forming process, said product comprising:
 a first portion of up to 99% dust material, where the dust material is recovered dust from manufacturing or the like of fibrous textile material, and   a second portion at least 1% bi-component fibres having a length between 2-75 mm.   
     
     
         22 . A product according to  claim 21 , wherein there is provided a third portion of shredded textile material, comprising recycled fibres from textile materials of so-called shoddy obtained by shredding the recycled textile material into fibres. 
     
     
         23 . A product according to  claim 21 , wherein at least 50% of the portion of bi-component fibres are crimped fibres with a length between 2 to 50 mm. 
     
     
         24 . A product according to  claim 21 , wherein at least the first portion of fibrous material is provided with an additive, and at least the first portion of fibrous dust material is impregnated with a material for wetting the dust material. 
     
     
         25 . A product according to  claim 22 , wherein at least the third portion of shoddy is impregnated with a material for wetting the third portion of fibrous material. 
     
     
         26 . A product according to  claim 24 , wherein the impregnating material is a fire-retarding chemical in liquid or powder form. 
     
     
         27 . A product according to  claim 26 , wherein the fire-retarding chemical is selected from a group comprising borax, boric acid, ammonium sulphate or aluminium sulphate and/or citrus based compounds. 
     
     
         28 . A product according to  claim 21 , wherein the dry-formed fibre mat is provided with fire-retarding chemical in liquid or powder form. 
     
     
         29 . A product according to  claim 21 , wherein the grammar weight of the air-laid product is between 8 kg/m 3  and 200 kg/m 3 . 
     
     
         30 . A method of manufacturing a non-woven product of the kind mentioned in  claim 21  by dry forming a product of fibrous material, said method comprising the steps of:
 providing a fibre mixture for providing a fibrous material, where said fibrous material comprises 
 a first portion of up to 99% dust material, where the dust material is recovered dust from manufacturing or the like of fibrous textile material, preferably cotton textiles, and 
 a second portion at least 1% bi-component fibres having a length between 2-75 mm, preferably 2-25 mm in length and comprising a core and an outer sheathing, said outer sheathing having a first melting temperature which is lower than the second melting temperature of the core; 
 advancing said fibrous material into a forming medium to form a web of dry-laid fibres; 
 heating the web of fibres formed on the forming wire to a temperature above the first melting temperature; and 
 advancing the fibrous web through a pressing section whereby a fibrous product web with a predetermined density is formed. 
 
     
     
         31 . A method according to  claim 30 , whereby a fluidized binder is sprayed into the forming box and onto the fibres therein. 
     
     
         32 . A method according to  claim 30 , whereby there is supplied a third portion of shredded textile material, comprising recycled fibres from textile materials of so-called shoddy obtained by shredding the recycled textile material into fibres and/or cellulose fibres. 
     
     
         33 . A method according to  claim 30 , whereby at least the first portion of fibrous material is provided with an additive. 
     
     
         34 . A method according to  claim 30 , whereby at least the third portion of shoddy is impregnated with a material for wetting the third material portion. 
     
     
         35 . The use of fibrous dust material recovered from textile material processing equipment in a non-woven fibre product according to  claim 21 . 
     
     
         36 . The use of fibrous dust material recovered from textile material processing equipment in a non-woven fibre product according to  claim 30 .