US20140178592A1

US20140178592A1 - Resin application system and method

Info

Publication number: US20140178592A1
Application number: US14/134,599
Authority: US
Inventors: Ira Goldstein; Garry E. Balthes; Yasser Moussa
Original assignee: Individual
Current assignee: Individual
Priority date: 2012-12-19
Filing date: 2013-12-19
Publication date: 2014-06-26

Abstract

Non-woven matrices and, more particularly, cotton shoddy and/or natural fiber matrices, and systems and methods for producing the matrices are described herein.

Description

CROSS-REFERENCE TO THE RELATED APPLICATION

The present application claims the benefit of the provisional patent application Ser. No. 61/739,376, filed Dec. 19, 2012, which is incorporated herein by reference.

BACKGROUND

The subject matter disclosed herein relates generally to non-woven matrices and, more particularly, to cotton shoddy and/or natural fiber matrices and systems and methods for producing cotton shoddy matrices.
Commercially available technology exists today for the purpose of applying liquids to a non-woven matrix, such as a matrix constructed from natural fiber and/or cotton shoddy. One technology includes dipping a continuous feed of a non-woven matrix into a tank of emulsion resin, then squeezing the resin-saturated matrix to remove excess content, while a second technology includes converting emulsion resin into a dense foam using a foam generating system, and injecting the foam into the matrix under pressure using a specially designed application head made for this purpose. While both of these technologies may work to some degree for certain natural fiber non-woven matrices, neither is well suited to resin-saturate cotton shoddy.
Several disadvantages exist with conventional foam injection processes. Foam injection requires a continuous feed of a non-woven matrix. After foam is injected into the non-woven matrix, the non-woven matrix is cut to appropriate size requirements and dried prior to final processing. Further, foam injection requires a wider matrix than an actual foam application area. This excess material provides an edge seal to prevent foam from escaping from an edge area of the continuously moving matrix during foam impregnation. This process does not allow the recycling of the excess of material after cutting to size before resin impregnation. In addition, only one side of the continuously feed matrix can be injected with foam having a certain desired uniformity of application. This, therefore, requires two passes of the non-woven matrix through the foam injection applicator in order to completely resonate the non-woven matrix. Foam injection also tends to be expensive. Capital costs are higher, process application of resonating matrix is slower, and therefore this is an undesirable means of applying a liquid resin into non-woven matrix.
Several disadvantages also exist with conventional dip and squeeze processes. The conventional dip and squeeze process is often undesirable because of problems associated with accuracy of application. However, dip and squeeze may have a better throughput capability than conventional foam injection processes. Similar to the foam injection process, conventional dip and squeeze technology requires the product to be run using a continuous feed of non-woven matrix. It does not allow the recycling of the excess material after cutting to size before resin impregnation.
It is desirable to develop an application system that utilizes the simplicity of a dip and squeeze process or applying the resin on a scrim and then laminating the scrim on a matrix made of thermoplastic and cotton shoddy and/or natural fibers, and achieves the accuracy results of a foam injection process, while doing so with a feed of precut matrix blanks as opposed to roll goods required for existing technology.

SUMMARY

In one aspect, a process system incorporates a modified dip and squeeze process system combined with a modified injection system that pumps non-foam resin directly into a non-woven matrix while the non-woven matrix remains substantially submerged in a resin contained within a resin tank.
In another aspect, a method for producing cotton shoddy and/or natural fiber matrices includes a modified dip and squeeze process combined with a modified injection process that pumps non-foam resin directly into the non-woven matrix while the non-woven matrix remains substantially submerged in a resin contained within a resin tank.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of an exemplary device for impregnating a matrix blank with a resin;

FIG. 2A is a schematic view of the device shown in FIG. 1, with the framing and support structure removed for clarity;

FIG. 2B is a schematic view of an exemplary device for impregnating a matrix blank with a resin including a plurality of compression squeeze rolls;

FIG. 3 is a schematic view of an exemplary application line including the device shown in FIGS. 1 and 2A, coupled to a microwave forced air drying oven; and

FIG. 4 is a schematic view of an exemplary application line including the device shown in FIGS. 1 and 2A, coupled to a hot air drying oven.

DETAILED DESCRIPTION

The embodiments described herein are directed to a non-woven matrix, such as a non-phenol formaldehyde cotton shoddy matrix, for example, and a process system for the application of a suitable emulsify resin, such as an Acrodur™ resin available from BASF Aktiengesellschaft Corp., Ludwigshafen am Rhein, Germany, for example, that substantially completely saturates the cotton shoddy matrix through a thickness of the cotton shoddy matrix. In certain embodiments, the process system is scalable to meet any application requirement. In addition and for means of practicality, in certain embodiments the system design intent includes the ability to resonate individual cut sheet sizes without the need for a continuous feed of matrix. This will facilitate recycling the excess of material after cutting to size before resin impregnation.
In the following description, the embodiments are described in relation to a cotton shoddy matrix. This is by way of example only, it being understood that the embodiments may be implemented for use with suitable natural fiber non-woven matrices.
In one embodiment, the process system incorporates a modified dip and squeeze process system combined with a modified injection system that pumps non-foam resin directly into the non-woven matrix while the non-woven matrix remains substantially submerged in a resin contained within a resin tank, as described in greater detail below with reference to FIGS. 1-4. Unlike conventional dip and squeeze systems, the process system described herein allows for the use of precut matrix blanks prior to resonating. In a particular embodiment, the process system includes two open weave, glass fiber belts coated with a Teflon™ coating to carry each matrix blank through the resin application process to significantly reduce the strain on the non-woven matrix blank during saturation, and further reduce or eliminate any tensile pull on the matrix blank during the process, an undesirable affect caused by conventional systems. This system allows to dip and squeeze material in both directions (machine direction and cross-machine direction) which is not reasonably possible in conventional foam injection and continuous dip and squeeze systems.
Resonating cotton shoddy with a liquid resin product is virtually impossible to achieve using existing dip and squeeze technology. A cotton shoddy non-woven matrix does not have sufficient tensile strength to carry the matrix through a conventional dip and squeeze system without tearing under the nominal tensile pulls that are typically exerted on a product during a resin application and post-matrix drying. Additionally, the wet pick up rate (the rate of added weight of resin and water to fully impregnate the cotton shoddy matrix) adds more than 110% additional weight to a pre-resonated matrix weight. The additional weight, in addition to the weak strengths of short fiber cotton shoddy, renders existing technologies impractical to adopt for this purpose.
Referring to FIGS. 1-4, an exemplary process system 10 includes a resin application station 12, a drying station 14 and a palletizing station 16 operatively coupled in series. Referring further to FIGS. 1, 2A and 2B, resin application station 12 includes a tank, such as a stainless steel tank 20 configured to contain a suitable amount of an aqueous solution of a resin material and water. In a particular embodiment, the aqueous solution comprises an Acrodur™ resin and water. A first or lower carrying belt 22 is operatively coupled to and supported by a frame 24. In one embodiment, lower carrying belt 22 is a fiberglass-reinforced, Teflon™ coated open webbing belt, although other belts can be used as lower carrying belt 22. As shown in FIG. 1, frame 24 is a stainless steel construction frame configured to support the associated components of resin application station 12, for example, associated belts, bearings, and drives. Resin application station 12 also includes one or more belt rolls 26 and a fixed compression roll 28 to further support lower carrying belt 22, and a bottom belt drive unit 30 configured to drive lower carrying belt 22 about belt rolls 26. In one embodiment, belt drive unit 30 includes a PLC-controlled, AC inverter drive with gear reductions for lower carrying belt 32, as well as for a cooperating upper carrying belt 32.
In one embodiment, upper carrying belt 32 is a fiberglass-reinforced, Teflon™ coated open webbing belt, as described above with reference to lower carrying belt 22, although other belts can be used as upper carrying belt 32. In other embodiments, upper carrying belt 32 may be the same as or different than lower carrying belt 22. Upper carrying belt 32 is operatively coupled to and supported by stainless steel frame 24, one or more belt rolls 36, and an adjustable compression roll 38. A belt drive unit 40 is configured to drive upper carrying belt 32 about belt rolls 36. In one embodiment, belt drive unit 40 includes a PLC-controlled, AC inverter drive with gear reductions for upper carrying belt 32. Alternatively, belt drive unit 30 may include a PLC-controlled, AC inverter drive with gear reductions for upper carrying belt 32, as well as for lower carrying belt 22.
Referring again to FIG. 1, a level 42 of the aqueous solution is maintained in tank 20 to sufficiently submerge a matrix blank 43, securely positioned between lower carrying belt 22 and upper carrying belt 32, in the aqueous solution. In one embodiment, level 42 is maintained by using a sonic level control device or other suitable level control device, which adds a desired amount of pre-mixed aqueous solution to tank 20 as required.
In one embodiment, electrically-driven screw jacks 44, shown in FIG. 1, are configured to move or urge adjustable compression roll 38 with respect to fixed compression roll 28. In a particular embodiment, screw jacks 44 are activated to move adjustable compression roll 38 to a predetermined point with respect to an outer surface of fixed compression roll 28 to define a gap 46, shown in FIG. 2A, through which lower carrying belt 22 and upper carrying belt 32 carry matrix blank 43 saturated with resin. A gap clearance is adjustable through the activation of screw jacks 44 to set a compression force applied to the saturated matrix blank 43 as matrix blank 43 is carried by lower carrying belt 22 and upper carrying belt 32 through gap 46. As the saturated matrix blank 43 moves continuously through gap 46 under a desired compression force applied by the cooperating adjustable compression roll 38 and fixed compression roll 28, excess resin and water is flushed from the saturated matrix blank 43 providing an impregnated matrix blank 43 having an amount of resin/water solution equal to a total wet pickup required to achieve a desired percentage of resin dry solids add-on. As shown in FIG. 2B, in one embodiment, resin application system 12 includes a plurality of adjustable compression roll sets, such as a series of three adjustable compression roll sets 38A, 38B, and 38C, to facilitate removing excess resin and water from the saturated matrix blank 43.
Referring to FIG. 3, the impregnated matrix blank 43 is transferred from resin application station 12 to drying station 14 by a transfer belt 50. In this embodiment, drying station 14 includes a microwave drying oven 60 having an air suction fan 62 configured to remove water vapor as means to accelerate drying time. Drying oven size depends on dimensions, such as a width, of matrix blanks 43 being dried, as well as a linear flow speed of matrix blanks 43 through drying oven 60. In a particular embodiment, drying oven 60 is a 75 Kw magnetron microwave drying oven capable of drying resonated matrix blanks 43 having a width of 1.5 meters traveling through drying oven 60 at linear flow speed of 5 meters per minute. Microwave drying oven 60, as described herein, provides for an overall size reduction in the line foot print of process system 10 and a reduction in energy cost to remove excess water, for example, when compared with conventional drying stations. Once the impregnated matrix blank 43 is dried, the impregnated matrix blank 43 is transferred from an outlet of drying oven 60 to an automatic stacking device 70 of palletizing station 16 by a dry matrix blank conveyor 72 to form a stack of dry matrix blanks 43.
Alternatively, referring to FIG. 4, the impregnated matrix blank 43 is transferred from resin application station 12 to drying station 14 by a transfer belt 50. In this embodiment, drying station 14 includes a hot air drying oven 80. Like microwave drying oven 60 described above, hot air drying oven size depends on dimensions, such as a width, of matrix blanks 43 being dried, as well as a linear flow speed of matrix blanks 43 through drying oven 60. Once the impregnated matrix blank 43 is dried, the impregnated matrix blank 43 is transferred from an outlet of hot air drying oven 80 to an automatic stacking device 70 of palletizing station 16 by a dry matrix blank conveyor 72 to form a stack of dry matrix blanks 43.
Process system 10 as described with reference to drying station 14 shown in FIGS. 3 and 4 can be utilized with either pre-cut matrix blanks 43 or a matrix roll 82 of desired material, as shown in FIG. 4. With process system 10 operating with matrix roll 82 to supply a continuous feed of material, a guillotine cross-cutter 84 cuts matrix blanks 43 from the continuously fed matrix prior to palletizing, for example, as the continuous feed of matrix material exits drying oven 80 onto conveyor 72, as shown in FIG. 4.
Referring again to FIGS. 1-4, a method for forming impregnated matrix blanks 43 with process system 10 as described herein includes, in one embodiment, placing a precut matrix blank 43 of cotton shoddy, or another suitable fibrous non-woven matrix that will absorb an aqueous resin solution, on a top surface of lower carrying belt 22 coated with a suitable coating, such as a Teflon™ coating. Lower carrying belt 22 moves at a speed equal to a speed at which upper cooperating carrying belt 32 moves. In this embodiment, upper carrying belt 32 is also coated with a suitable coating, such as a Teflon™ coating.
Lower carrying belt 22 and upper carrying belt 32 meet to secure or trap the precut matrix blank 43 between lower carrying belt 22 and upper carrying belt 32 prior to or as matrix blank 43 enters tank 20 containing a liquid resin, such as an aqueous solution of a resin and water. As lower carrying belt 22 and upper carrying belt 32 move through tank 20, matrix blank 43 secured between opposing and cooperating lower carrying belt 22 and upper carrying belt 32 is submerged into the aqueous solution contained within tank 20 at a suitable speed to ensure that matrix blank 43 is submerged in the aqueous solution for a sufficient exposure time so that full saturation of the resin throughout matrix blank 43 is achieved. For highly absorbent and dense products, such as cotton shoddy, lower carrying belt 22 and upper carrying belt 32 slide between two stainless steel spring loaded plates that cover a full width of the belts and at least 24 inches of a running length of the belts at any time. One or more nozzles are positioned in a middle portion of each plate in a machine direction, and run across the width of the each plate. Resin is pumped through the one or more nozzles at a predetermined velocity to force resin into a center of matrix blank 43 while matrix blank 43 moves in the machine direction. An added length of the plates ensures that pressure is focused in a desired treatment area. Pre-load spring pressure is sufficient to keep the nozzles and pressure plates compressed to each belt, thereby forming a seal to prevent resin blow by. Resin is forced under pressure into matrix blank 43 to facilitate accelerating absorption of the resin to a center core of matrix blank 43. Other matrices can be resonated similarly to accelerate the resonating speed, but this is the only process which ensures cotton shoddy is fully resonated throughout a Z dimension.
At the end of the submersion process, lower carrying belt 22 and upper carrying belt 32 carrying the resin impregnated non-woven matrix blank 43 tum 90 degrees upwards ascending above tank 20 and entering a squeeze process to remove excess liquid resin to achieve the desired application rate. Using cooperating fixed compression roll 28 and adjustable compression roll 38, with lower carrying belt 22 and upper carrying belt 32 securing matrix blank 43 therebetween, matrix blank 43 moves into and through the squeeze rolls. In one embodiment, three compression roll sets are used, one above the other, to facilitate extracting excess resin from the resonated matrix blank. Each of the three vertical compression rolls, as shown in FIG. 2B, is set at a particular gap to provide less strain on matrix blank 43, and at the same time applying three different rates of pressure on the wetted matrix blank 43 to optimize solution extraction. (FIG. 1 shows only one set of such compression rolls). This squeeze action allows excess resin to flush out of matrix blank 43, flowing equally on opposing sides of the incoming pre-squeezed matrix blank 43 to maintain consistent and uniform liquid exposure equally to opposing sides of matrix blank 43. Exiting squeeze rolls, upper carrying belt 32 separates from matrix blank 43 to allow lower carrying belt 22 to deliver matrix blank 43 into a drying oven for downstream final processing.

EXAMPLES

Example of formulation for application of liquid resin is as follows.

- Resonated cotton shoddy matrix at desired dry weight=1000 gsm.
- Based weight of composite matrix pre-resonating=770 gsm at 0% moisture. Active resin required to meet resonated gram weight of matrix=230 gsm. Acrodur™ resin as supplied by BASF=50% water, 50% active dry solids resin. Required active dry solids solution to apply resin to cotton shoddy=25%.
- True wet pick required to apply 230 gsm dry solids resin=(100/25)=3×230=690 gsm or 89%.

Wet pick up for cotton shoddy to fully wet out matrix blank during solution application is greater than 125% or 1250 gsm of aqueous solution, pick up during dipping matrix in solution or 55%′ greater dilution in solution mix in order to apply 230 gsm dry solids resin. Therefore the aqueous solution mix needs to be further diluted to (100/18)=5.55×230=1276 gsm.
After resin impregnation, the impregnated matrix blank 43 is dried of excess water prior to use. Because the rate of water evaporation is very high compared to the final matrix blank weight (up to 70%), conventional technology using air impingement driers to perform this task requires ovens lengths often exceeding 50 feet and normally greater than 100 feet in length to run at any appreciable speed. This large foot print takes up valuable floor space and, as a means of energy utilization for drying, is one of the least efficient means to control drying costs. Based on test results, adopting microwave technology in the processing line reduces operating costs and reduces floor space requirements. Microwave oven technology works on the principal of exciting water molecules through energy waves causing the water molecules to vibrate rapidly. Further, microwave technology works on the mass inside out, a more desirable drying method than conventional air impingement ovens that work through transpiration or wicking water from the inside to the drier outside. Because final moisture content is critical to thermal processing (Acrodur™ resin requires moisture to be present in a sufficient quantity to cross-link resin), microwave heating and the ability to precisely control the amount of applied energy allows the process system to deliver matrix blank 43 having a desired pre-set moisture content exiting the drying oven without overheating matrix blank 43. Also, due to the intense focused energy microwave technology offers, the footprint required for oven drying is reduced by 75% over conventional hot air impingement-type drying. Therefore, in contrast to a conventional air oven that must be about 100 feet long to dry matrix blanks, a microwave drying oven, such as described herein, may be less than 25 feet in length. With the use of focused energy, the amount of energy required to dry the same material in the same time cycle is also greatly reduced.
In certain embodiments, cotton shoddy was formulated to include, without limitation, the following: cotton shoddy comprising cotton shoddy ranging from 10% to 90% of dry composite matrix weight, and hi-component polyester fiber ranging from 10% to 90% of composite matrix weight, and natural fiber comprising one or more of the following: jute, tossa, hemp, cori, sisal, curaua, kenaf and other similar fibers ranging from 5% to 90% of composite matrix weight, and polyester fiber ranging from 10% to 90% of matrix weight.
An exemplary Composite Matrix Weight 770 gsm, comprises the following:
10% hi-component polyester=(770×0.10)=77 grams. 1.
35% natural fiber of any fiber type above=(770×0.35)=269.5 grams. 2
55% cotton shoddy=(770×0.55)=432.5 grams. 3
Another exemplary Composite Matrix has the same weight as follows:
10% bi-component polyester=(770×0.10)=77 grams. 1
90% cotton shoddy=(770×0.90)=693 grams. 2
Yet another exemplary Composite Matrix has the same weight as follows:
10% hi-component polyester=(770×0.10)=77 grams. 1
35% polyester fiber of any fiber type above=(770×0.35)=269.5 grams. 2
55% cotton shoddy=(770×0.55)=432.5 grams. 3
Yet another exemplary Composite Matrix has the same weight as follows:
10% bi-component polyester=(770×0.10)=77 grams. 1
20% polyester fiber of any fiber type above=(770×0.20)=154 grams. 2
45% cotton shoddy=(770×0.45)=346.5 grams. 3
25% natural fiber of any fiber type above=(770×0.25)=192.5 grams. 4
The combination of fiber types used can be in any percent always requiring two or more of the above fiber types. The percentage and combination of blends is dependent on the application requirements.
This combination of systems provides a unique opportunity to apply liquid resins to a fibrous matrix, such as a cotton shoddy matrix, that is sensitive to line process strain and resistant to absorption due to density. The system viewed in whole, may include one or more of the following in various embodiments.

- 1. Resonating matrix blanks of non-woven matrix, which can include matrix made with one or more of the following materials: cotton shoddy, natural bast fiber including, but not limited to, jute, kenaf, curaua, hemp, and other similar cellulous fibers.
- 2. Using twin belts to carrying matrix blanks into a resin tank.
- 3. Using twin belts to limit any strain associated with a dip and squeeze or direct injection application of any liquid including resins, adhesives or other such products used as a binder in matrix.
- 4. Twin plate injection system spring load to apply predetermined load during direct liquid injection.
- 5. Flow design of system, including upper and lower belts, belt types and direction of flow.
- 6. Direct pump resin system.
- 7. Parallel resin flow back under squeeze rolls to keep resin contact equally on both sides.

Additional Data is attached as Appendix A, noting the following:

- 1. Sample A, B, C, D, E & L are made with 90% cotton Shoddy and 10% Bico
- 2. Sample F, G and H are made with 20% Hemp+25% Regenerated Polyester+10% Bico+45% Cotton Shoddy
- 3. Sample I & J are made with 50% PP+40% shoddy+10% Bico
- 4. All the samples with Jute (K samples) are from old runs and they are all made with 90% Jute (coffee bag)+10% Shoddy.

The described system and methods are not limited to the specific embodiments described herein. In addition, components of each system and/or steps of each method may be practiced independent and separate from other components and method steps, respectively, described herein. Each component and method also can be used in combination with other systems and methods.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

APPENDIX A

Sample 1& 2 cut to size 20″ × 65¼″

	1*	1014.1	0.0894	923.43		11.00%	60	3680	2585.92	2.55	284.45	1207.88	30.80%	23.55%	1413	1329
	2*	1053.4	0.0894	959.24		11.00%	60	3550	2496.59	2.37	274.62	1233.86	28.63%	22.26%	1444	1357

Sample D10 cut to size 20″ × 65½″

D10*

1043

841.8

0.0894

766.56

7.00%

60

3150

2308.18

2.7419

161.57

928.13

21.08%

17.41%

1086

1021

Sample E10 cut to size 20″ × 65-½″

	E10*	946	743.4	0.0894	676.91	11.00%	60	3000	2256.63	3.0357	248.23	925.14	36.67%	26.83%	1082	1018

Sample L cut to size 20″ × 65½″

														Dry to	Dry to
														17%	10%	Dry to 5%

L1	0.0	1038.6	0.0894	945.73	11.00%	60	3500	2461.42	2.37	270.76	1216.48	28.63%	22.26%	1423	1338	1277
L2		1170.2	0.0894	1065.60	11.00%	60	3850	2679.79	2.29	294.78	1360.37	27.66%	21.67%	1592	1496	1428
L3		983.1	0.0894	895.25	11.00%	60	3500	2516.85	2.56	276.85	1172.11	30.92%	23.62%	1371	1289	1231
L4		1014.5	0.0894	923.80	11.00%	60	3500	2485.51	2.45	273.41	1197.20	29.60%	22.84%	1401	1317	1257
L5		1116.1	0.0894	1016.29	11.00%	60	3750	2633.93	2.36	289.73	1306.03	28.51%	22.18%	1528	1437	1371
L6		1038.6	0.0894	945.73	11.00%	60	3500	2461.42	2.37	270.76	1216.48	28.63%	22.26%	1423	1338	1277

Dry to

Weight after

17%

10%

Drying

Sample L6 cut to size 12″ × 12″

L6
1	0.0	114.2	0.0894	104.03	11.00%	60	385	270.76	2.37	29.78	133.81	28.63%	22.26%	157	147	159
2		103.9	0.0894	94.57	11.00%	60	350	246.14	2.37	27.08	121.65	28.63%	22.26%	142	134	144
3		114.2	0.0894	104.03	11.00%	60	385	270.76	2.37	29.78	133.81	28.63%	22.26%	157	147	151
4		101.5	0.0894	92.41	11.00%	60	342	240.52	2.37	26.46	118.87	28.63%	22.26%	139	131	142
5		108.9	0.0894	99.17	11.00%	60	367	258.10	2.37	28.39	127.56	28.63%	22.26%	149	140	148

Sample L5 cut to size 12″ × 12″

L5
1	0.0	109.5	0.0894	99.73	11.00%	60	368	258.48	2.36	28.43	128.16	28.51%	22.18%	150	141	150
2		116.7	0.0894	106.24	11.00%	60	392	275.33	2.36	30.29	136.52	28.51%	22.18%	160	150	156
3		112.5	0.0894	102.44	11.00%	60	378	265.50	2.36	29.21	131.65	28.51%	22.18%	154	145	148
4		127.4	0.0894	115.99	11.00%	60	428	300.62	2.36	33.07	149.06	28.51%	22.18%	174	164	166
5		131.8	0.0894	120.06	11.00%	60	443	311.15	2.36	34.23	154.29	28.51%	22.18%	181	170	169

Sample L4 cut to size 12″ × 12″

L4
1	0.0	84.1	0.0894	76.54	11.00%	60	290	205.94	2.45	22.65	99.20	29.60%	22.84%	116	109	125
2		89.0	0.0894	81.03	11.00%	60	307	218.01	2.45	23.98	105.01	29.60%	22.84%	123	116	126
3		100.6	0.0894	91.59	11.00%	60	347	246.42	2.45	27.11	118.69	29.60%	22.84%	139	131	137
4		95.4	0.0894	86.84	11.00%	60	329	233.64	2.45	25.70	112.54	29.60%	22.84%	132	124	135
5		113.0	0.0894	102.94	11.00%	60	390	276.96	2.45	30.47	133.40	29.60%	22.84%	156	147	157

Sample L3 cut to size 12″× 12″

L3
1	0.0	91.0	0.0894	82.87	11.00%	60	324	232.99	2.56	25.63	108.50	30.92%	23.62%	127	119	140
2		104.5	0.0894	95.15	11.00%	60	372	267.51	2.56	29.43	124.58	30.92%	23.62%	146	137	151
3		99.4	0.0894	90.55	11.00%	60	354	254.56	2.56	28.00	118.55	30.92%	23.62%	139	130	138
4		96.6	0.0894	87.99	11.00%	60	344	247.37	2.56	27.21	115.20	30.92%	23.62%	135	127	135
5		103.4	0.0894	94.13	11.00%	60	368	264.63	2.56	29.11	123.24	30.92%	23.62%	144	136	144

Sample L2 cut to size 12″ × 12″

L2
1	0.0	109.4	0.0894	99.64	11.00%	60	360	250.58	2.29	27.56	127.20	27.66%	21.67%	149	140	147
2		107.6	0.0894	97.98	11.00%	60	354	246.40	2.29	27.10	125.08	27.66%	21.67%	146	138	144
3		110.6	0.0894	100.75	11.00%	60	364	253.36	2.29	27.87	128.62	27.66%	21.67%	150	141	148
4		115.5	0.0894	105.18	11.00%	60	380	264.50	2.29	29.09	134.27	27.66%	21.67%	157	148	154
5		115.5	0.0894	105.18	11.00%	60	389	264.50	2.29	29.09	134.27	27.66%	21.67%	157	148	162

	Dry to	Weight after
	17%	Drying

Jute Fiber samples K2 & K3 cut to size 12″ × 12″

K3
1	0.0	120.5	0.06	113.23	11.00%	60	418	297.54	2.47	32.73	145.96	28.90%	22.42%	171	173
2		113.5	0.06	106.73	11.00%	60	394	280.46	2.47	30.85	137.58	28.90%	22.42%	161	157
3		117.0	0.06	109.98	11.00%	60	406	289.00	2.47	31.79	141.77	28.90%	22.42%	166	163
4		115.9	0.06	108.90	11.00%	60	402	286.15	2.47	31.48	140.38	28.90%	22.42%	164	159
5		111.8	0.06	105.11	11.00%	60	388	276.18	2.47	30.38	135.49	28.90%	22.42%	159	155
6		119.3	0.06	112.15	11.00%	60	414	294.69	2.47	32.42	144.57	28.90%	22.42%	169	169
7		112.4	0.06	105.65	11.00%	60	390	277.61	2.47	30.54	136.19	28.90%	22.42%	159	140
8		117.0	0.06	109.98	11.00%	60	400	289.00	2.47	31.79	141.77	28.90%	22.42%	166	153
9		110.1	0.06	103.48	11.00%	60	382	271.91	2.47	29.91	133.39	28.90%	22.42%	156	155
10		108.9	0.06	102.40	11.00%	60	378	269.07	2.47	29.60	131.99	28.90%	22.42%	154	145
11		123.3	0.06	115.94	11.00%	60	428	304.66	2.47	33.51	149.45	28.90%	22.42%	175	170
12		113.5	0.06	106.73	11.00%	60	394	280.46	2.47	30.85	137.58	28.90%	22.42%	161	161
13		114.7	0.06	107.82	11.00%	60	398	283.30	2.47	31.16	138.98	28.90%	22.42%	163	161
14		121.0	0.06	113.78	11.00%	60	420	298.96	2.47	32.89	146.66	28.90%	22.42%	172	171
15		131.4	0.06	123.53	11.00%	60	456	324.59	2.47	35.70	159.23	28.90%	22.42%	186	189
K2
1	0.0	123.1	0.06	115.73	11.00%	60	426	302.88	2.46	33.32	149.05	28.79%	22.35%	174	175
2		122.5	0.06	115.19	11.00%	60	424	301.46	2.46	33.16	148.35	28.79%	22.35%	174	174
3		130.1	0.06	122.25	11.00%	60	450	319.94	2.46	35.19	157.45	28.79%	22.35%	184	185
4		119.1	0.06	111.93	11.00%	60	412	292.92	2.46	32.22	144.15	28.79%	22.35%	169	168
5		115.6	0.06	108.67	11.00%	60	400	284.39	2.46	31.28	139.95	28.79%	22.35%	164	161
6		121.4	0.06	114.10	11.00%	60	420	298.61	2.46	32.85	146.95	28.79%	22.35%	172	170
7		122.0	0.06	114.65	11.00%	60	422	300.03	2.46	33.00	147.65	28.79%	22.35%	173	173
8		122.5	0.06	115.19	11.00%	60	424	301.46	2.46	33.16	148.35	28.79%	22.35%	174	173
9		113.9	0.06	107.04	11.00%	60	394	280.13	2.46	30.81	137.85	28.79%	22.35%	161	161
10		120.2	0.06	113.02	11.00%	60	416	295.77	2.46	32.53	145.55	28.79%	22.35%	170	171
11		104.0	0.06	97.80	11.00%	60	360	255.95	2.46	28.15	125.96	28.79%	22.35%	147	146
12		115.0	0.06	108.13	11.00%	60	398	282.97	2.46	31.13	139.25	28.79%	22.35%	163	164
13		123.1	0.06	115.73	11.00%	60	426	302.88	2.46	33.32	149.05	28.79%	22.35%	174	174
14		121.4	0.06	114.10	11.00%	60	420	298.61	2.46	32.85	146.95	28.79%	22.35%	172	170
15		126.6	0.06	118.99	11.00%	60	438	311.41	2.46	34.26	153.25	28.79%	22.35%	179	182

Acrodur dry

solid Resin

950 L

Post

weight rate

Acrodur

Mat weight

Squeeze

Dry Resin

based on dry

Base weight

Nominal

Dry Base

Solids Ratio

Soak Time

after

Wet Pickup

% solution

Solids Pickup

Mat Dry

base weight

Mat weight

Weight after

SAMPLE #

GSM Weight

(gr)

Mositure (%)

Weight (gr)

to Water (%)

(sec)

squeeze (gr)

Rate (gr)

pick up rate

Rate (gr)

Weight (gr)

(gr)

Drying

TEST # 01 (A) (90% Shoody + 10% Bico)

A2	1134	1700	0.0894	1548.02	11.00%	60	6200	4500	264.71%	495	2043.02	31.98%	24.23%	2200
A5	1161	1750	0.0894	1593.55	11.00%	60	6250	4500	257.14%	495	2088.55	31.06%	23.70%	2300
A6	1117	1650	0.0894	1502.49	11.00%	60	6100	4450	269.70%	489.5	1991.99	32.58%	24.57%	2200
A8	1069	1600	0.0894	1456.96	11.00%	60	6100	4500	281.25%	495	1951.96	33.97%	25.36%	2100
A10	1140	1700	0.0894	1548.02	11.00%	60	6200	4500	264.71%	495	2043.02	31.98%	24.23%	2250

TEST # 02 (B) (90% Shoody + 10% Bico)

B3	1172	1750	0.0894	1593.55	7.00%	60	6300	4550	260.00%	318.5	1912.05	19.99%	16.66%	2100
B4	1229	1800	0.0894	1639.08	7.00%	60	6450	4650	258.33%	325.5	1964.58	19.86%	16.57%	2200
B6	1203	1800	0.0894	1639.08	7.00%	60	6450	4650	258.33%	325.5	1964.58	19.86%	16.57%	2150
B7	1225	1850	0.0894	1684.61	7.00%	60	6600	4750	256.76%	332.5	2017.11	19.74%	16.48%	2250
B8	1184	1750	0.0894	1593.55	7.00%	60	6400	4650	265.71%	325.5	1919.05	20.43%	16.96%	2150

TEST # 03 (C) (90% Shoody + 10% Bico)

C2	1274	1850	0.0894	1684.61	5.00%	60	6550	4700	254.05%	235	1919.61	13.95%	12.24%	2150
C3	1251	1850	0.0894	1684.61	5.00%	60	6450	4600	248.65%	230	1914.61	13.65%	12.01%	2100
C4	1274	1900	0.0894	1730.14	5.00%	60	6550	4650	244.74%	232.5	1962.64	13.44%	11.85%	2150
C5	1255	1850	0.0894	1684.61	5.00%	60	6500	4650	251.35%	232.5	1917.11	13.80%	12.13%	2100
C6	1263	1900	0.0894	1730.14	5.00%	60	6350	4450	234.21%	222.5	1952.64	12.86%	11.39%	2100

TEST # 04 (D) (90% Shoody + 10% Bico)

D5	1046	1550	0.0894	1411.43	7.00%	60	5850	4300	2.77	301	1712.43	21.33%	17.58%	1900
D6	1013	1550	0.0894	1411.43	7.00%	60	5950	4400	2.84	308	1719.43	21.82%	17.91%	1850
D7	1009	1500	0.0894	1365.9	7.00%	60	5800	4300	2.87	301	1666.9	22.04%	18.06%	1850
D8	1042	1550	0.0894	1411.43	7.00%	60	5900	4350	2.81	304.5	1715.93	21.57%	17.75%	1900
D9	1002	1500	0.0894	1365.9	7.00%	60	5650	4150	2.77	290.5	1656.4	21.27%	17.54%	1800

TEST # 05 (E) (90% Shoody + 10% Bico)

E1	971	1450	0.0894	1320.37	11.00%	60	5900	4450	3.07	489.5	1809.87	37.07%	27.05%	2000
E2	994	1450	0.0894	1320.37	11.00%	60	5650	4200	2.90	462	1782.37	34.99%	25.92%	2000
E3	993	1450	0.0894	1320.37	11.00%	60	5750	4300	2.97	473	1793.37	35.82%	26.37%	2000
E5	908	1350	0.0894	1229.31	11.00%	60	5700	4350	3.22	478.5	1707.81	38.92%	28.02%	1900
E6	921	1350	0.0894	1229.31	11.00%	60	5750	4400	3.26	484	1713.31	39.37%	28.25%	1900

TEST # 06 (F) (45% Shoody + 25% PET + 20% Hemp + 10% Bico)

F3	1028	1546	0.05	1468.7	11.00%	60	6450	4904	3.17	539.44	2008.14	36.73%	26.86%	2150
F4	1033	1554	0.05	1476.3	11.00%	60	6450	4896	3.15	538.56	2014.86	36.48%	26.73%	2150
F7	993	1510	0.05	1434.5	11.00%	60	6200	4690	3.11	515.9	1950.4	35.96%	26.45%	2100
F9	1025	1550	0.05	1472.5	11.00%	60	6250	4700	3.03	517	1989.5	35.11%	25.99%	2100
F10	990	1476	0.05	1402.2	11.00%	60	5850	4374	2.9634	481.14	1883.34	34.31%	25.55%	2050

TEST # 07 (G) (45% Shoody + 25% PET + 20% Hemp + 10% Bico)

G3	1092	1642	0.05	1559.9	7.00%	60	6300	4658	2.84	326.06	1885.96	20.90%	17.29%	2000
G4	1114	1676	0.05	1592.2	7.00%	60	6100	4424	2.64	309.68	1901.88	19.45%	16.28%	2050
G6	1166	1754	0.05	1666.3	11.00%	60	6650	4896	2.79	538.56	2204.86	32.32%	24.43%	2400
G8	1145	1722	0.05	1635.9	11.00%	60	6600	4878	2.83	536.58	2172.48	32.80%	24.70%	2350
G9	1162	1748	0.05	1660.6	11.00%	60	6550	4802	2.75	528.22	2188.82	31.81%	24.13%	2300

TEST # 08 (H) (45% Shoody + 25% PET + 20% Hemp + 10% Bico)

H2	1390	2090	0.05	1985.5	5.00%	60	6950	4860	2.33	243	2228.5	12.24%	10.90%	2450
H4	1388	2088	0.05	1983.6	5.00%	60	7250	5162	2.47	258.1	2241.7	13.01%	11.51%	2450
H5	1400	2106	0.05	2000.7	5.00%	60	7050	4944	2.35	247.2	2247.9	12.36%	11.00%	2400

50% PP + 40% Shoddy + 10% Bico

Test # 09 (I)

Test # 09 (J)

Sample #	GSM	weight (gr)	Sample #	GSM	weight (gr)

I-1	1247	1896	J-1	1444	2302
I-2	1150	1748	J-2	1438	2292
I-3	1171	1780	J-3	1435	2288
I-4	1168	1776	J-4	1292	2060
I-5	1253	1904	J-5	1355	2160
I-6	1154	1754	J-6	1413	2252
I-7	1167	1774	J-7	1395	2224
I-8	1238	1882	J-8	1359	2166
I-9	1132	1720	J-9	1403	2236
I-10	1151	1749	J-10	1408	2244

										Dry		Acrodur dry	Acrodur dry
				Dry						Resin	Mat	solid Resin	solid Resin	Weight cible	Weight cible
		Base	Nominal	Base	950 L Acrodur	Soak	Mat weight	Post Squeeze		Solids	Dry	weight rate	weight rate	after drying =	after drying =
SAMPLE	GSM	weight	Mositure	Weight	Solids Ratio to	Time	after squeeze	Wet Pickup Rate	% solution pick	Pickup	Weight	based on dry	based on dry	1.17 × dry mat	1.10 × dry mat
#	Weight	(gr)	(%)	(gr)	Water (%)	(sec)	(gr)	(gr)	up rate	Rate (gr)	(gr)	base weight (gr)	Mat weight (gr)	weight (gr)	weight (gr)

M1-1		1500	0.06	1410	6.00%	30	6000	4500	300.00%	270	1680	19.15%	16.07%	1965.6	1848
M1-2		1450	0.06	1363	6.00%	30	5950	4500	310.34%	270	1633	19.81%	16.53%	1910.61	1796.3
M1-3		1350	0.06	1269	6.00%	30	5900	4550	337.04%	273	1542	21.51%	17.70%	1804.14	1696.2
M1-4		1450	0.06	1363	6.00%	30	5950	4500	310.34%	270	1633	19.81%	16.53%	1910.61	1596.3
M1-5		1350	0.06	1269	6.00%	30	5850	4500	333.33%	270	1539	21.28%	17.54%	1800.63	1692.9
M1-6		1700	0.06	1598	6.00%	30	6400	4700	276.47%	282	1880	17.65%	15.00%	2199.6	2068
M1-7		1550	0.06	1457	6.00%	30	6150	4600	296.77%	276	1733	18.94%	15.93%	2027.61	1906.3
M1-8		1700	0.06	1598	6.00%	30	6350	4650	273.53%	279	1877	17.46%	14.86%	2196.09	2064.7
M1-9		1500	0.06	1410	6.00%	30	6200	4700	313.33%	282	1692	20.00%	16.67%	1979.64	1861.2
M1-10		1700	0.06	1598	6.00%	30	6350	4650	273.53%	279	1877	17.46%	14.86%	2196.09	2064.7

		Acrodur %
Test #	Recipe	Target	GSM

1	Jute FR	35%	12%	1000
	Bico	20%
	Shoddy	45%

Acudur Test May 31, 2011

	Acrodure Solution used: 3515	25% Resine
		75% H2O
	Drying Process	Convection
		Temp (C.) = 121

1A

Dipping and squeezing process

sample

Exit Airlay Conditions

wet Pad

Sol Acr (g)

Resine

H2O

ID	Composition	Weight (g)	gsm	(g)	W (g)	% Pick-up	W (g)	%	W (g)	%

1-A	100% polyester	109	1214	256	147	135%	37	14%	110	43%
2-A	90% jute + 10Bico	83	921	280	197	237%	49	18%	148	53%
3-A	90% shoddy + 10% Bico	98	1086	248	150	153%	38	15%	113	45%
4-A*	63% shoddy + 20% Hollow + 17% Bico	134	1486	339	205	153%	51	15%	154	45%
5-A**	62% shoddy + 20% Hollow + 18% Bico	133	1473	331	198	149%	50	15%	149	45%
6-A	90% cotton + 10% Bico	69	767	204	135	196%	34	17%	101	50%

*Rieter Tilsonburg

**Rieter Oregon

2A

Dipping and squeezing process

sample

Exit Airlay Conditions

wet Pad

Sol Acr (g)

Resine

H2O

ID	Composition	Weight (g)	gsm	Dray Pad	(g)	W (g)	% Pick-up	W (g)	%	W (g)	%

4-A*	63% shoddy + 20% Hollow + 17% Bico	134	1486	122.02	339	205	153%	51	15%	154	45%

Test Date: May 31, 2011

Drying process

Dry Pad

Resine

H2O

Drying

H2Oevp

% H2O

	(g)	W (g)	%	W (g)	%	(min)	(g)	evp

1B

178	37	21%	32	18%	25	78	71%
160	49	31%	28	17%	29	120	81%
157	38	24%	22	14%	17	91	81%
224	51	23%	39	17%	26	115	75%
224	50	22%	42	19%	23	107	72%
125	34	27%	22	18%	10	79	78%

2B

	224	51	23%	39	17%	26	115	75%

3A

								Post
					950 L			Squeeze		Dry
					Acrodur			Wet		Resin	Mat
			Nominal		Solids Ratio	Soak	Mat weight	Pickup		Solids	Dry
		Base weight	Mositure	Dry Base	to Water	Time	after	Rate	% solution	Pickup	Weight
SAMPLE #	GSM Weight	(gr)	(%)	Weight (gr)	(%)	(sec)	squeeze (gr)	(gr)	pick up rate	Rate (gr)	(gr)

4-A*	1486	134	0.0894	122.02	25.0%	60	339	205	153.0%	51.25	173.3
4-A*	1486	134	0.05	127.3	25.0%	60	339	205	153.0%	51.25	178.6
4-A*	1486	134	0.13	116.58	25.0%	60	339	205	153.0%	51.25	167.8
4-A*	1486	134	0.135	115.91	25.0%	60	339	205	153.0%	51.25	167.2
5-A**	1374	133	0.135	115.045	25.0%	60	331	198	148.9%	49.5	164.5
3A	1086	98	0.135	84.77	25.0%	60	248	150	153.1%	37.5	122.3
3A	1086	98	0.0895	89.229	25.0%	60	248	150	153.1%	37.5	126.7
3A	1086	98	0.05	93.1	25.0%	60	248	150	153.1%	37.5	130.6
1-A	1214	109	0	109	25.0%	60	265	156	143.1%	39	148

3B

		Weight	Weight
Acrodur	Acrodur	cible	cible
dry solid	dry solid	after	after
Resin	Resin	drying =	drying =
weight	weight	1.17 ×	1.10 ×
rate based	rate based	dry	dry
on dry	on dry	mat	mat
base	Mat	weight	weight
weight (gr)	weight (gr)	(gr)	(gr)

42.00%	29.58%	202.7	191
40.26%	28.70%	208.9	196
43.96%	30.54%	196.4	185
44.22%	30.66%	195.6	184
43.03%	30.08%	192.5	181
44.24%	30.67%	143.1	134
42.03%	29.59%	148.3	139
40.28%	28.71%	152.8	144
35.78%	26.35%	173.2	163

Acrodur Samples Jun. 22, 2010

1A

TEST # 01 (A)

												Acrodur dry	Acrodur dry
												solid Resin	solid Resin	Weight cible
					950 L			Post				weight rate	weight rate	after drying =
					Acrodur		Mat weight	Squeeze		Dry Resin		based on dry	based on dry	1.10 × dry
SAMPLE	GSM	Base weight	Nominal	Dry Base	Solids Ratio	Soak Time	after	Wet Pickup	% solution pick up	Solids Pickup	Mat Dry	base weight	Mat weight	mat weight
#	Weight	(gr)	Mositure (%)	Weight (gr)	to Water (%)	(sec)	squeeze (gr)	Rate (gr)	rate	Rate (gr)	Weight (gr)	(gr)	(gr)	(gr)

A1	1082	1600	0.0894	1456.96	11.00%	60	6000	4400	275.00%	484	1940.96	33.22%	24.94%	2135.056
A2	1134	1700	0.0894	1548.02	11.00%	60	6200	4500	264.71%	495	2043.02	31.98%	24.23%	2247.322
A3	1096	1600	0.0894	1456.96	11.00%	60	6150	4550	284.38%	500.5	1957.46	34.35%	25.57%	2158.206
A4	1088	650	0.0894	1502.49	11.00%	60	6150	4500	272.73%	49%	997.49	32.95%	24.78%	2297.239
A5	1161	1750	0.0894	1593.55	11.00%	60	6250	4500	257.14%	495	2088.55	31.06%	23.70%	2297.405
A6	1117	1650	0.0894	1502.49	11.00%	60	6100	4450	269.70%	489.5	1991.99	32.58%	24.57%	2191.189
A7	1096	1650	0.0894	1502.49	11.00%	60	6200	4550	275.76%	500.5	2002.99	33.31%	24.99%	2203.289
A8	1069	1600	0.0894	1456.96	11.00%	60	6100	4500	281.25%	495	1951.96	33.97%	25.36%	2147.156
A9	1115	1700	0.0894	1548.02	11.00%	60	6250	4550	267.65%	500.5	2048.52	32.33%	24.43%	2253.372
A10	1140	1700	0.0894	1548.02	11.00%	60	6200	4500	264.71%	495	2043.02	31.98%	24.23%	2247.322

SOLUTION to prepare 11% solid acrodur

3 × total solution 91 liter solution acrodur 950 L (50% resine) = 20 liter water = 3 × 71 liter

1B

2100	−35.056	−1.54%	8.46%
2200	−47.322	−1.98%	8.02%
2200	46.794	2.04%	12.04%
2182	−16.239	−0.65%	9.35%
2300	2.595	0.11%	10.11%
2200	8.811	0.38%	10.38%
2200	−3.289	−0.14%	9.86%
2100	−47.156	−2.06%	7.94%
2200	−53.372	−2.23%	7.77%
2250	2.678	0.11%	10.11%

2A

TEST # 01 (A)

												Acrodur dry	Acrodur dry
												solid Resin	solid Resin	Weight cible	Weight cible
					950 L			Post				weight rate	weight rate	after drying =	after drying =
		Base	Nominal		Acrodur		Mat weight	Squeeze	% solution	Dry Resin		based on dry	based on dry	1.17 × dry	1.10 × dry
SAMPLE	GSM	weight	Mositure	Dry Base	Solids Ratio	Soak Time	after	Wet Pickup	pick up	Solids Pickup	Mat Dry	base weight	Mat weight	mat weight	mat weight
#	Weight	(gr)	(%)	Weight (gr)	to Water (%)	(sec)	squeeze (gr)	Rate (gr)	rate	Rate (gr)	Weight (gr)	(gr)	(gr)	(gr)	(gr)

A1	1082	1600	0.05	1520	11.00%	60	6000	4400	275.00%	484	2004	31.84%	24.15%	2344.68	2204.4
A2	1134	1700	0.05	1615	11.00%	60	6200	4500	264.71%	495	2110	30.65%	23.46%	2468.7	2321
A3	1096	1600	0.05	1520	11.00%	60	6150	4550	284.38%	500.5	2020.5	32.93%	24.77%	2363.985	2222.55
A4	1088	1650	0.05	1567.5	11.00%	60	6150	4500	272.73%	495	2062.5	31.58%	24.00%	2413.125	2268.75
A5	1161	1750	0.05	1662.5	11.00%	60	6250	4500	257.14%	495	2157.5	29.77%	22.94%	2524.275	2373.25
A6	1117	1650	0.05	1567.5	11.00%	60	6100	4450	269.70%	489.5	2057	31.23%	23.80%	2406.69	2262.7
A7	1096	1650	0.05	1567.5	11.00%	60	6200	4550	275.76%	500.5	2068	31.93%	24.20%	2419.56	2274.8
A8	1069	1600	0.05	1520	11.00%	60	6100	4500	281.25%	495	2015	32.57%	24.57%	2357.55	2216.5
A9	1115	1700	0.05	1615	11.00%	60	6250	4550	267.65%	500.5	2115.5	30.99%	23.66%	2475.135	2827.05
A10	1140	1700	0.05	1615	11.00%	60	6200	4500	264.71%	495	2110	30.65%	23.46%	2468.7	2821

Acrodur Solid	base dry weight

12.00	88	13.64%
13.00	87	14.94%
14.00	86	16.28%
15.00	85	17.65%
16.00	84	19.05%
17.00	83	20.48%
18.00	82	21.95%
19.00	81	23.46%
20.00	80	25.00%
21.00	79	26.58%
22.00	78	28.21%
23.00	77	29.87%
24.00	76	31.58%
25.00	75	33.33%
26.00	74	35.14%
27.00	73	36.99%
28.00	72	38.89%
29.00	71	40.85%
30.00	70	42.86%
31.00	69	44.93%
32.00	68	47.06%

2B

2100	−104.4	−4.45%	5.55%		2104.2
2200	−121	−4.90%	5.10%
2200	−22.55	−0.95%	9.05%
2182	−86.75	−3.59%	6.41%	2182
2300	−73.25	−2.90%	7.10%
2200	−62.7	−2.61%	7.39%
2200	−74.8	−3.09%	6.91%
2100	−116.5	−4.94%	5.06%
2200	−127.05	−5.13%	4.87%
2250	−71	−2.88%	7.12%

3A

									33.00	67	49.25%
									34.00	66	51.52%
									35.00	65	53.85%
A4	1088	1650	0.135	1427.25	11.00%	60	6150	4500	272.73%	495	1922.25	34.68%	25.75%	2249.033	2114.475
A4	1088	1650	0.14	1419	11.00%	60	6150	4500	272.73%	495	1914	34.88%	25.86%	2239.38	2105.4

3B

2400	150.9675	6.71%	23.71%
2400	160.62	7.17%	24.17%

Impregnation Acrodur November 2011

												Acrodur dry	Acrodur dry
									%	Dry Resin		solid Resin	solid Resin	Weight cible	Weight cible
		Base	Nominal	Dry Base	950 L Acrodur	Soak	Mat weight	Post Squeeze	solution	Solids	Mat Dry	weight rate	weight rate	after drying =	after drying =
SAMPLE	GSM	weight	Mositure	Weight	Solids Ratio to	Time	after squeeze	Wet Pickup Rate	pick	Pickup	Weight	based on dry	based on dry	1.17 × dry mat	1.10 × dry mat
#	Weight	(gr)	(%)	(gr)	Water (%)	(sec)	(gr)	(gr)	up rate	Rate (gr)	(gr)	base weight (gr)	Mat weight (gr)	weight (gr)	weight (gr)

M1-1		1500	0.06	1410	6.00%	30	6000	4500	300.00%	270	1680	19.15%	16.07%	1965.6	1848
M1-2		1450	0.06	1363	6.00%	30	5950	4500	310.34%	270	1633	19.81%	16.53%	1910.61	1793.3
M1-3		1350	0.06	1269	6.00%	30	5900	4550	337.04%	273	1542	21.51%	17.70%	1804.14	1696.2
M1-4		1450	0.06	1363	6.00%	30	5950	4500	310.34%	270	1633	19.81%	16.53%	1910.61	1796.3
M1-5		1350	0.06	1269	6.00%	30	5850	4500	333.33%	270	1539	21.28%	17.54%	1800.63	1692.9
M1-6		1700	0.06	1598	6.00%	30	6400	4700	276.47%	282	1880	17.65%	15.00%	2199.6	2068
M1-7		1550	0.06	1457	6.00%	30	6150	4600	296.77%	276	1733	18.94%	15.93%	2027.61	1906.3
M1-8		1700	0.06	1598	6.00%	30	6350	4650	273.53%	279	1877	17.46%	14.86%	2196.09	2064.7
M1-9		1500	0.06	1410	6.00%	30	6200	4700	313.33%	282	1692	20.00%	16.67%	1979.64	1861.2
M1-10		1700	0.06	1598	6.00%	30	6350	4650	273.53%	279	1877	17.46%	14.86%	2196.09	2064.7

		Acrodur %
Test #	Recipe	Target	GSM

1	Jute FR	35%	12%	1000
	Bico	20%
	Shoddy	45%

Summary - Samples July 2011

Acrodur dry

solid Resin

950 L

Post

weight rate

Acrodur

Mat weight

Squeeze

Dry Resin

based on dry

Base weight

Nominal

Dry Base

Solids Ratio

Soak Time

after

Wet Pickup

% solution

Solids Pickup

Mat Dry

base weight

Mat weight

Weight after

SAMPLE #

GSM Weight

(gr)

Mositure (%)

Weight (gr)

to Water (%)

(sec)

squeeze (gr)

Rate (gr)

pick up rate

Rate (gr)

Weight (gr)

(gr)

Drying

TEST # 01 (A) (90% Shoody + 10% Bico)

TEST # 02 (B) (90% Shoody + 10% Bico)

TEST # 03 (C) (90% Shoody + 10% Bico)

TEST # 04 (D) (90% Shoody + 10% Bico)

TEST # 05 (E) (90% Shoody + 10% Bico)

TEST # 06 (F) (45% Shoody + 25% PET + 20% Hemp + 10% Bico)

TEST # 07 (G) (45% Shoody + 25% PET + 20% Hemp + 10% Bico)

TEST # 08 (H) (45% Shoody + 25% PET + 20% Hemp + 10% Bico)

50% PP + 40% Shoddy + 10% Bico

Test # 09 (I)

Test # 09 (J)

Sample #	GSM	weight (gr)	Sample #	GSM	weight (gr)

I-1	1247	1896	J-1	1444	2302
I-2	1150	1748	J-2	1438	2292
I-3	1171	1780	J-3	1435	2288
I-4	1168	1776	J-4	1292	2060
I-5	1253	1904	J-5	1355	2160
I-6	1154	1754	J-6	1413	2252
I-7	1167	1774	J-7	1395	2224
I-8	1238	1882	J-8	1359	2166
I-9	1132	1720	J-9	1403	2236
I-10	1151	1749	J-10	1408	2244

indicates data missing or illegible when filed

Claims

What is claimed is:

1. A system for producing cotton shoddy and/or natural fiber matrices comprising a modified dip and squeeze process system combined with a modified injection system configured to impregnate a non-foam resin directly into a non-woven matrix while the non-woven matrix remains substantially submerged in a resin contained within a resin tank.

2. A method for producing cotton shoddy and/or natural fiber matrices comprising a modified dip and squeeze process combined with a modified injection process that impregnates a non-foam resin directly into a non-woven matrix while the non-woven matrix remains substantially submerged in a resin contained within a resin tank.