Patent ID: 6296795
Filing Date: 2001-10-02
Classification: B27N,C08L

Abstract:
A process for producing a shaped article from a bonded, non-woven, fibrous batt of fibers comprising the steps of:I. providing a dry, solid, heat-responsive fiber-binder,II. providing a moisture-responsive fiber-binder which is a dry, solid, particulate, raw, ungelled starch which swells and becomes sticky upon contact with moisture; and thenIII. contacting fiber-binding amounts of the heat-responsive fiber-binder with the fibers to form a raw batt with the heat-responsive fiber-binder loosely adhering to the fibers of the batt; andIV. contacting fiber-binding amounts of the moisture-responsive fiber-binder with the fibers to form a raw batt with the moisture-responsive fiber-binder loosely adhering to the fibers of the batt; andV. heating the raw batt to a temperature above the binding temperature of the heat responsive fiber-binder but below the scorching or melting point of the fibers thereby activating the heat-responsive fiber-binder whereupon the heat-responsive fiber-binder engages the intersections of the fibers binding the fibers together at their intersections thereby converting the raw batt into a partially cured batt; andVI. contacting the partially cured batt with water, and molding the partially cured batt in a mold thereby causing the moisture-responsive fiber binder to swell, become sticky and further bind the fibers thereby producing a molded shaped article.