Intermediate layer and filler material
Intermediate and filler material are typically produced from wool, cotton, polyester and recycled fibres. Futhermore flame and heat resistant materials can be incorporated. Initially, these fibres can be entangled as fibre balls. The fibre preparation machinery of DiloTemafa opens the fibres and blends the different components according to the desired blending ratio. A card feeder (vibration chute feeder) forms the fibre flocks into a compact uniform mat which is fed to the card. With the help of a belt weigher the flock mat weight is precisely adjusted. The card orientates the fibres and creates a uniform web. To guarantee an even strength distribution in machine and cross direction, a lap drafter VST and a drafting unit VE can be used after the needleloom.
The use of card condenser rolls increases the resilience of coarse (>20 dtex) crimped polyester and recycled fibres. In the subsequent crosslapper, the web is laid down in layers thus defining the final weight of the needlefelt. A high felt volume is sustained by a simultaneous needling. This involves upper and lower needles penetrating the needlefelt at the same time. In a subsequent stage, the needlefelt is thermally bonded. Up to 25 % low-melt fibres are necessary to create the structural strength in the hot-air consolidation.
In addition to manufacture on card-crosslapper installations, the upholstery core material can be manufactured directly by aerodynamic webforming using the Dilo Fiberlofter. The opened fibre flocks are fed directly to a turbo roller via a feeder. The formed, even, voluminous flock mat can then be thermally bonded.