Abstract: A product and method of manufacturing a non-woven, industrial hydrophobic absorbent. The absorbent includes a core of cotton ginning byproducts (such as cotton regin) and bicomponent fibers. The cotton regin is processed to create a low-density and, thus, a high-absorbency web. The method includes processing cotton regin to a suitable range of fiber length and particle sizes, mixing the cotton regin with a thermoplastic bonding agent, and depositing the material onto a steadily advancing belt to produce a relatively low density, loosely formed web core. Subsequent processing of the web core in an oven softens or melts the bonding agent, thereby adheres it to other web material to give the web core desired strength and integrity. At least one, dual-layer, continuous, air-permeable scrim is secured or bonded the core to provide additional strength and an exterior surface having enhanced grip and non-slip characteristics.

Abstract: A non-woven industrial absorbent with at least one dual-layer outer scrim. The absorbent includes a core made of cellulose material and bicomponent fibers and has first and second surfaces. A scrim is bonded to at least one of the surfaces. The scrim includes a first layer, the function of which is to adhere to the core, and a second layer, whose function is to provide enhanced grip. The product may be made by processing cellulose to a suitable size, optionally applying a liquid fire-retardant to the cellulose, drying and mixing the cellulose with a thermoplastic bonding agent, and depositing the material onto a belt to produce a web. Subsequent processing of the web softens or melts the bonding agent, thereby adhering it to other web material and giving the web strength and integrity. The one or more scrims or an optional netting provide additional strength or particular surface characteristics.

Abstract: A product including a web and a method of manufacturing such a product. The product may be for use as an industrial absorbent or a thermal or acoustic insulator and includes a web including scrap and/or recycled cellulose, the cellulose being selected from a source of post-industrial cellulose and/or a source of post-consumer cellulose, the cellulose being treated with a fire-retardant, the cellulose being dry before web formation, and opened, individuated bicomponent fibers mixed with the cellulose, at least some of the bicomponent fibers being thermally bonded to at least some of the cellulose. The method may include shredding the cellulose, declumping and sizing the cellulose, metering the cellulose into a spray booth, applying a fire retardant to the cellulose in the spray booth, if the fire retardant is a liquid, drying the cellulose, adding bicomponent fibers to the cellulose, forming a web, and heating the web in an oven.

Abstract: A product and process of manufacturing a non-woven web from cotton regin for use as an industrial hydrophobic absorbent, a filter or insulator. The method of processing the cotton regin creates a low-density and, thus, a high-absorbency web. The finished web has a bulk-to-weight ratio of about 25 to 40 mils/osy. The method includes processing cotton regin to a suitable range of fiber and particle sizes, mixing the cotton regin with a thermoplastic bonding agent, and depositing the material onto a steadily advancing belt to produce a relatively low density, loosely formed web. Subsequent processing of the web in an oven softens or melts the bonding agent, thereby adheres it to other web material to give the web its required strength and integrity. One or more continuous, air-permeable layers of scrim or netting may be incorporated on or within the web to provide additional strength or particular surface characteristics.

Abstract: A product including a web and a method of manufacturing such a product. The product may be for use as an industrial absorbent or a thermal or acoustic insulator and includes a web including scrap and/or recycled cellulose, the cellulose being selected from a source of post-industrial cellulose and/or a source of post-consumer cellulose, the cellulose being treated with a fire-retardant, the cellulose being dry before web formation, and opened, individuated bicomponent fibers mixed with the cellulose, at least some of the bicomponent fibers being thermally bonded to at least some of the cellulose. The method may include shredding the cellulose, declumping and sizing the cellulose, metering the cellulose into a spray booth, applying a fire retardant to the cellulose in the spray booth, if the fire retardant is a liquid, drying the cellulose, adding bicomponent fibers to the cellulose, forming a web, and heating the web in an oven.