Method of manufacturing molded articles

B - Operations – Transporting – 27 – N

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18/955

B27N 3/00 (2006.01) B01D 39/16 (2006.01) B29C 67/00 (2006.01) B29C 70/44 (2006.01) B29C 70/50 (2006.01) D04H 1/00 (2006.01) B29C 43/12 (2006.01)

Patent

CA 1273465

ABSTRACT OF THE DISCLOSURE A molded article, for example, a filter or a preform used in the manufacture of fiber-reinforced composites, is manufactured from an air laid batt from a single fiber type or a mixture of fibers. The batt is either resinated with a thermoplastic material or includes a thermoplastic binder fiber. The batt is formed into the desired shape of the molded article in a through-air mold and heated sufficiently to set the thermoplastic materail, so that the resulting article retains the desired shape. If the article is to be used as a fluid filter, it can be used either as it is removed from the mold if a filter of uniform density is desired, or the article can be further processed in a compression mold to densify portions of the article to thereby form, for example, a fluid impervious portion used as a gasket. If the article is to be used as a preform for a structural composite, it is then to be transferred to a resin injection mold.

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