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1. * GB780064 (A)
Description: GB780064 (A) ? 1957-07-31
A process for the manufacture of sheet materials composed of adhesively-
bonded fibres
Description of GB780064 (A)
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BE522143 (A) FR1088300 (A)
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and information originating from other authorities than the EPO; in
particular, the EPO does not guarantee that they are complete,
up-to-date or fit for specific purposes.
PATENT SPECIFICATION
Date of Application and filing Complete Specification: June 17, 1953.
Application made in Germany on Aug. 16, 1952.
Application made in Germany on Nov. 13, 1952. Complete Specification
Published: July 31, 1957.
Index at acceptance:-Class 140, A(2C:5F:5C4:11B:12:18), C.
International Classification:-D04j.
COMPLETE SPECIFICATION
A Process for the Manufacture of Sheet Materials composed of
Adhesively-bonded Fibres We, BERGIN G.m.b.H., a German Company, of
Lilienstrasse 37, Essen-Bredeney, Federal German Republic, do hereby
declare the invention, for which we pray that a patent may be granted
to us, and the method by which it is to be performed, to be
particularly described in and by the following statement:The present
invention is concerned with the manufacture of sheet materials

2. composed of adhesively-bonded fibres.
According to the present invention there is provided a process for the
manufacture of sheet materials composed of adhesivelybonded fibres,
comprising the steps of drawing off a fibrous carded sheet from a
carding machine in the direction of its production, conveying the
fibrous carded sheet in full width to a lapping machine operating in
the same direction and arranged to deposit the lapped sheet on a
conveyor belt moving at an angle to the previous movement, introducing
rubber or synthetic resin bonding agents in finely divided form into
the -carded sheet during the lapping by distributor means whose
operation is related to the motion of the lapping machine, said
distributor means promoting even distribution of the bonding agents in
the sheet, and converting the lapped sheet into a consolidated product
by pressure, characterised in that said distributor means comprises a
jet located outside the area in which lapping takes place, the jet
injecting the bonding agent in the form of a small cloud into the air
between the layers so that the cloud is applied to the underside of
each layer as it falls.
It has been observed that the materials impregnated with cresol- or
phenol-aldehyde resins have found very wide application as hard
fibrous layer materials in pressings.
Two or more lapping machines may be used and the speed of removal of
the lapped sheets to the conveyor belt may be co-ordinated with the
width of the lapped sheets and [Price Mlte A 6d the motion cycle of
the lapping machine, so that the fibres of successive sheets lie at
right angles to each other.
The sheet material formed from the lapped layers of fibrous material
and containing the 50 bonding substances may be conveyed on the
conveyor belt to a pressure point. Here, the sheet may be subjected to
pressure, for example, adjustable roller pressure, to assist in the
impregnation, by the bonding agents, after 56 which it is dried.
According to the invention, distributor means in the form of jets are
employed, said jets operating synchronously with the layering or
lapping process. The jets are arrangedeo outside the area in which the
layering takes place and with the direction of the spray or dust from
the jets towards the area through which the layers or sheets move
during layering. 65 The sheet material therefore receives bonding
agents in finely divided spray, liquid, or solid form as the sheets
are built up. Each motion of the lapping machine producing one sheet
or layer is accompanied by a cloud-like 70 discharge from the jets so
that between every two layers, some of the bonding agent is
introduced. Several jets are provided, and various weighting, or other
special property giving agents may also be introduced thereby. 75 For
example, liquid synthetic resin may be incorporated in the initial

3. layers to be lapped, in subsequent layers, solid weighting agents in
granular, powder or fibrous form may be introduced, and finally,
wholly or mainly 80 bonding agents, such as liquid synthetic resin,
may be introduced once more. A product may therefore be obtained which
possesses in its layers adjacent to the surfaces a particularly high
content of synthetic resins or other 85 bonding agents, whilst, in the
centre, weighting agents in the form of fibres or granular dust are
incorporated. It is also possible during lapping to introduce hard
fibrous waste, for example jute or hemp, between the 90 780,064 No.
16660153.
780,064 lapped sheets.
By means of the invention, it is also possible to apply, if desired,
colouring agents to the outer layers only of the product, which agents
impart a particularly attractive quality to the web-like product. This
is an economic way to use colouring agents. Furthermore, since the
number of distributors, their disposition and direction of application
may be chosen at will, the edges of the layered material may be
treated differently from the centre parts to achieve particular
effects.
The small cloud formed by spray or dust injection between the layers
as they are built up is drawn in uniformly by each layer as it falls
on or is placed on the preceding layer, thus minute particles are
dusted or sprayed to all points between the layers of material to
produce a sandwich effect. The minute dust or liquid particles do not
remain ineffectually in suspension for some time nor are they
distributed locally and consequently very irregularly (in the manner
of spot bonding) within the layers of material. In the process of the
invention, the dust cloud formed in the air is applied to the
underside of each layer as it falls. By this method of operation a
particularly economical dry form of application may be achieved.
After layering and the application of finely divided substances
consolidation of the extremely loose texture of layers is effected.
This consolidation may be effected by a moistening or wetting
operation, in which case the formed product is subjected to the action
of.a spray of water, or to water or solvent vapour, so that the finely
divided bonding agents are either softened or dissolved. This assists
the even distribution of the bonding agents throughout the layers.
The wad is then rendered rigid by heat and pressure. Alternatively, if
cold polymerising substances of high molecular weight are used as
bonding agents, these may be consolidated by dry pressure.
As a result of the invention, the bonding agent is applied uniformly
to all parts between layers and it is possible to obtainnewproducts
with, for example, exceptional insulating o properties or with
particular electrically conducting or magnetic qualities or with high

4. tensile strength by introducing by said jets during lapping finely
divided solid substances having the appropriate properties.
It has previously been proposed to provide a padding constructed from
a fleece of fibrous material fed on to a conveyor belt moving
continuously and traversing with respect to the direction of feed and
lapped so that superimposed layers overlap to produce the desired
thickness, and to spray a bonding material directly on to the top
surface of the fleece during the lapping operation, and to add a flame
proofing substance to the spraying liquid.
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