US 12,404,646 B2
Methods of manufacturing synthetic bales
Dan Hargett, Inman, SC (US); and A. V. Moody, Jr., Rutherfordton, NC (US)
Assigned to Geohay, LLC, Inman, SC (US)
Filed by Dan Hargett, Inman, SC (US); and A. V. Moody, Jr., Rutherfordton, NC (US)
Filed on Dec. 12, 2024, as Appl. No. 18/978,910.
Claims priority of provisional application 63/610,857, filed on Dec. 15, 2023.
Prior Publication US 2025/0198103 A1, Jun. 19, 2025
Int. Cl. B29B 13/02 (2006.01); D01G 9/00 (2006.01); D01G 13/00 (2006.01); D04H 1/12 (2006.01); D04H 1/42 (2012.01); D04H 1/435 (2012.01); D04H 1/4382 (2012.01); D04H 1/541 (2012.01); D04H 1/542 (2012.01); D04H 1/55 (2012.01); D04H 1/72 (2012.01); E02B 3/10 (2006.01)
CPC E02B 3/106 (2013.01) [B29B 13/021 (2013.01); D04H 1/435 (2013.01); D04H 1/43825 (2020.05); D04H 1/43835 (2020.05); D04H 1/5418 (2020.05); D04H 1/72 (2013.01); D10B 2505/20 (2013.01); D10B 2505/204 (2013.01)] 21 Claims
OG exemplary drawing
 
1. A method of manufacturing a synthetic bale, the method comprising:
heating a mixture of a first plurality of fibers with a second plurality of fibers, wherein each of the first plurality of fibers and the second plurality of fibers define an outer portion, and wherein the outer portion of the second plurality of fibers melt sufficiently to bond the outer portion of the second plurality of fibers with the first plurality of fibers to thereby create a plurality of bonded fibers;
directing the bonded fibers into a chamber; and
outputting the bonded fibers into a sheath, wherein the first plurality of fibers are 10-25% and the second plurality of fibers are 75-90% by weight, respectively, of the mixture of the first plurality of fibers and the second plurality of fibers.