NZ623187B2 - Method of forming a web from fibrous materials - Google Patents
Method of forming a web from fibrous materials Download PDFInfo
- Publication number
- NZ623187B2 NZ623187B2 NZ623187A NZ62318712A NZ623187B2 NZ 623187 B2 NZ623187 B2 NZ 623187B2 NZ 623187 A NZ623187 A NZ 623187A NZ 62318712 A NZ62318712 A NZ 62318712A NZ 623187 B2 NZ623187 B2 NZ 623187B2
- Authority
- NZ
- New Zealand
- Prior art keywords
- web
- glass fibers
- pack
- fibers
- exemplary embodiment
- Prior art date
Links
- 239000002657 fibrous material Substances 0.000 title abstract description 41
- 239000003365 glass fiber Substances 0.000 claims abstract description 118
- 239000002706 dry binder Substances 0.000 claims abstract description 76
- 239000011521 glass Substances 0.000 claims abstract description 10
- 239000006060 molten glass Substances 0.000 claims description 18
- 238000004806 packaging method and process Methods 0.000 claims description 9
- 238000002844 melting Methods 0.000 claims description 3
- 239000002356 single layer Substances 0.000 claims description 3
- 239000000835 fiber Substances 0.000 abstract description 94
- 239000000463 material Substances 0.000 abstract description 62
- 239000011230 binding agent Substances 0.000 abstract description 58
- 238000010924 continuous production Methods 0.000 abstract description 11
- 239000010410 layer Substances 0.000 description 49
- 239000000203 mixture Substances 0.000 description 27
- 230000000670 limiting Effects 0.000 description 23
- 239000000314 lubricant Substances 0.000 description 22
- 239000007789 gas Substances 0.000 description 21
- 238000000034 method Methods 0.000 description 18
- 238000005520 cutting process Methods 0.000 description 13
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 11
- 239000003921 oil Substances 0.000 description 10
- 235000019198 oils Nutrition 0.000 description 10
- 239000000428 dust Substances 0.000 description 9
- 238000007688 edging Methods 0.000 description 9
- 239000002365 multiple layer Substances 0.000 description 8
- PPBRXRYQALVLMV-UHFFFAOYSA-N styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 8
- 239000002699 waste material Substances 0.000 description 8
- 239000000839 emulsion Substances 0.000 description 7
- 238000004519 manufacturing process Methods 0.000 description 7
- 238000004064 recycling Methods 0.000 description 7
- 150000002500 ions Chemical class 0.000 description 6
- -1 length Chemical class 0.000 description 6
- 229920001187 thermosetting polymer Polymers 0.000 description 6
- 230000036698 Distribution coefficient Effects 0.000 description 5
- 239000000843 powder Substances 0.000 description 5
- 239000000654 additive Substances 0.000 description 4
- 239000000853 adhesive Substances 0.000 description 4
- 230000001070 adhesive Effects 0.000 description 4
- 229920001400 block copolymer Polymers 0.000 description 4
- 150000001875 compounds Chemical class 0.000 description 4
- 239000003085 diluting agent Substances 0.000 description 4
- 230000002708 enhancing Effects 0.000 description 4
- 239000002480 mineral oil Substances 0.000 description 4
- 235000010446 mineral oil Nutrition 0.000 description 4
- 239000002245 particle Substances 0.000 description 4
- 229920001296 polysiloxane Polymers 0.000 description 4
- 239000007921 spray Substances 0.000 description 4
- 238000005507 spraying Methods 0.000 description 4
- 229920001169 thermoplastic Polymers 0.000 description 4
- 239000004416 thermosoftening plastic Substances 0.000 description 4
- 235000015112 vegetable and seed oil Nutrition 0.000 description 4
- 239000008158 vegetable oil Substances 0.000 description 4
- 230000000996 additive Effects 0.000 description 3
- 230000015572 biosynthetic process Effects 0.000 description 3
- 238000007664 blowing Methods 0.000 description 3
- 238000007906 compression Methods 0.000 description 3
- 239000002557 mineral fiber Substances 0.000 description 3
- 239000007787 solid Substances 0.000 description 3
- UIIMBOGNXHQVGW-UHFFFAOYSA-M NaHCO3 Chemical compound [Na+].OC([O-])=O UIIMBOGNXHQVGW-UHFFFAOYSA-M 0.000 description 2
- 239000004952 Polyamide Substances 0.000 description 2
- 239000004743 Polypropylene Substances 0.000 description 2
- 229920002803 Thermoplastic polyurethane Polymers 0.000 description 2
- 239000004433 Thermoplastic polyurethane Substances 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- 230000001276 controlling effect Effects 0.000 description 2
- 238000005137 deposition process Methods 0.000 description 2
- 238000003379 elimination reaction Methods 0.000 description 2
- 239000005038 ethylene vinyl acetate Substances 0.000 description 2
- 239000012530 fluid Substances 0.000 description 2
- 229920001903 high density polyethylene Polymers 0.000 description 2
- 239000004700 high-density polyethylene Substances 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 229920001684 low density polyethylene Polymers 0.000 description 2
- 239000004702 low-density polyethylene Substances 0.000 description 2
- 239000000155 melt Substances 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 230000035515 penetration Effects 0.000 description 2
- 239000012071 phase Substances 0.000 description 2
- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 description 2
- 229920002647 polyamide Polymers 0.000 description 2
- 239000011528 polyamide (building material) Substances 0.000 description 2
- 229920000728 polyester Polymers 0.000 description 2
- 229920000642 polymer Polymers 0.000 description 2
- 229920001155 polypropylene Polymers 0.000 description 2
- 238000003860 storage Methods 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 239000000758 substrate Substances 0.000 description 2
- 238000011144 upstream manufacturing Methods 0.000 description 2
- 238000003466 welding Methods 0.000 description 2
- KUDUQBURMYMBIJ-UHFFFAOYSA-N 2-prop-2-enoyloxyethyl prop-2-enoate Chemical compound C=CC(=O)OCCOC(=O)C=C KUDUQBURMYMBIJ-UHFFFAOYSA-N 0.000 description 1
- 229940035295 Ting Drugs 0.000 description 1
- 238000004026 adhesive bonding Methods 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 230000001143 conditioned Effects 0.000 description 1
- 239000000498 cooling water Substances 0.000 description 1
- 229920001577 copolymer Polymers 0.000 description 1
- 230000000875 corresponding Effects 0.000 description 1
- 238000004132 cross linking Methods 0.000 description 1
- UBHZUDXTHNMNLD-UHFFFAOYSA-N dimethylsilane Chemical compound C[SiH2]C UBHZUDXTHNMNLD-UHFFFAOYSA-N 0.000 description 1
- 238000011143 downstream manufacturing Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000000605 extraction Methods 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- 238000005755 formation reaction Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 230000002401 inhibitory effect Effects 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 230000002452 interceptive Effects 0.000 description 1
- 230000001050 lubricating Effects 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 238000011084 recovery Methods 0.000 description 1
- 230000002829 reduced Effects 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 239000011435 rock Substances 0.000 description 1
- BLRPTPMANUNPDV-UHFFFAOYSA-N silane Chemical compound [SiH4] BLRPTPMANUNPDV-UHFFFAOYSA-N 0.000 description 1
- 229910000077 silane Inorganic materials 0.000 description 1
- 239000002893 slag Substances 0.000 description 1
- 229910000030 sodium bicarbonate Inorganic materials 0.000 description 1
- 235000017557 sodium bicarbonate Nutrition 0.000 description 1
- 239000007790 solid phase Substances 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
- 229920005992 thermoplastic resin Polymers 0.000 description 1
- 239000004634 thermosetting polymer Substances 0.000 description 1
- 238000009966 trimming Methods 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
- C03B37/00—Manufacture or treatment of flakes, fibres, or filaments from softened glass, minerals, or slags
- C03B37/01—Manufacture of glass fibres or filaments
- C03B37/04—Manufacture of glass fibres or filaments by using centrifugal force, e.g. spinning through radial orifices; Construction of the spinner cups therefor
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C25/00—Surface treatment of fibres or filaments made from glass, minerals or slags
- C03C25/10—Coating
- C03C25/1095—Coating to obtain coated fabrics
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4209—Inorganic fibres
- D04H1/4218—Glass fibres
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4374—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece using different kinds of webs, e.g. by layering webs
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
- D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
- D04H1/488—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation in combination with bonding agents
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
- D04H1/498—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres entanglement of layered webs
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
- D04H1/60—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in dry state, e.g. thermo-activatable agents in solid or molten state, and heat being applied subsequently
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
- D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
- D04H1/724—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged forming webs during fibre formation, e.g. flash-spinning
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H13/00—Other non-woven fabrics
- D04H13/008—Glass fibre products; Complete installations for making them
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/002—Inorganic yarns or filaments
- D04H3/004—Glass yarns or filaments
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/608—Including strand or fiber material which is of specific structural definition
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/608—Including strand or fiber material which is of specific structural definition
- Y10T442/609—Cross-sectional configuration of strand or fiber material is specified
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/659—Including an additional nonwoven fabric
- Y10T442/666—Mechanically interengaged by needling or impingement of fluid [e.g., gas or liquid stream, etc.]
- Y10T442/667—Needled
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/659—Including an additional nonwoven fabric
- Y10T442/67—Multiple nonwoven fabric layers composed of the same inorganic strand or fiber material
Abstract
Fibrous material webs and methods of making the fibrous material webs. Binderless webs can be formed in a continuous process where fibre material, such as glass, is melted (102) and formed into fibres (104). The fibres are formed into a web of binderless glass fibres (106) or a web with a dry binder (292). The binderless web or the web with dry binder can be layered (108) and/or the fibres that make up the web can be mechanically entangled (302), for example, by needling. In the case where a Binderless web is created steps (292, 108, 294) pertaining to adding binder may be omitted. The glass fibres may have a diameter from about 9 HT to 35 HT (2.3 micron to 8.9 micron) and a length from about 0.25 inches to 10 inches (6.4 mm to 254 mm). The layered web of glass fibres comprises a first web, with at least one additional web placed on top. The first web may have an area weight of about 5 to 50 grams per square foot (54 to 540 grams per square metre). (292). The binderless web or the web with dry binder can be layered (108) and/or the fibres that make up the web can be mechanically entangled (302), for example, by needling. In the case where a Binderless web is created steps (292, 108, 294) pertaining to adding binder may be omitted. The glass fibres may have a diameter from about 9 HT to 35 HT (2.3 micron to 8.9 micron) and a length from about 0.25 inches to 10 inches (6.4 mm to 254 mm). The layered web of glass fibres comprises a first web, with at least one additional web placed on top. The first web may have an area weight of about 5 to 50 grams per square foot (54 to 540 grams per square metre).
Description
METHOD OF FORMING A WEB FROM FIBROUS MATERIALS
RELATED APPLICATIONS
This application claims priority from provisional ation number 61/541,162 filed
on September 30, 2011, titled “Method of Forming a Pack from Fibrous Materials.”
Provisional application number 61/541,162 is incorporated herein by reference in its entirety.
BACKGROUND
Fibrous material can be formed into various products including webs, packs, batts and
blankets. Packs of fibrous material can be used in many applications, including the non—
limiting examples of tion and sound—proofing for buildings and building components,
appliances and aircraft. Packs of fibrous material are typically formed by processes that
include fiberizers, forming hoods, ovens, ng and packaging machines. Typical
processes also include the use of wet binders, binder reclaim water and washwater systems.
SUMMARY
] Unless the context clearly requires otherwise, throughout the description and
the , the words ‘comprise’, ‘comprising’ and the like are to be construed in an inclusive
sense as opposed to an exclusive or exhaustive sense; that is to say in the sense of “including
but not limited to”.
The present application discloses multiple exemplary embodiments of fibrous
al webs and methods of making the fibrous al webs. Binderless webs or webs
with dry binder can be formed in a continuous process where fiber material, such as glass is
melted and formed into fibers. The fibers are formed into a web of binderless glass fibers or
a web with a dry binder. The binderless web or the web with dry binder can be layered
[followed by page la]
and/or the fibers that make up the web can be mechanically entangled, for example, by
needling.
Other advantages of the webs, batts, and methods of producing the webs and batts will
become apparent to those skilled in the art from the following detailed description, when read
in View of the anying drawings.
[0004a] In one aspect, there is provided a method for forming a pack of glass fibers
comprising:
melting glass into molten glass;
processing the molten glass to form glass fibers;
n the glass fibers have a er range of in a range of from about 9 HT to
about 35 HT;
wherein the glass fibers have a length range from about 0.25 inches to about 10.0
inches;
forming a binderless web of the glass fibers;
lapping the binderless web of glass fibers to form a layered pack of glass fibers that '
includes folded edges of the binderless web; and
mechanically entangling the glass fibers of the layered pack of glass fibers by
needling.
[followed by page 2]
PCTfU82012i058339
BRIEF DESCRIPTION OF THE GS
Figure 1A is a flowchart of an exemplary ment of method for forming a
binderless layered web or pack of glass fibers;
Figure 1B is a flowchart of an exemplary embodiment of a method for forming a
binderless entangled web of glass fibers;
Figure 1C is a flowchart of an exemplary embodiment of a method for forming a
less layered and entangled web or pack of glass fibers;
Figure 2A is a flowchart of an ary embodiment of method for forming a
layered web or pack of glass fibers with dry binder;
Figure 2B is a flowchart of an ary embodiment of a method for forming a
binderless entangled web of glass fibers with dry binder;
Figure 2C is a flowchart of an exemplary embodiment of a method for forming a
binderless layered and entangled web or pack of glass fibers with dry binder;
Figure 2D is a flowchart of an ary embodiment of a method for forming a
binderless layered and entangled web or pack of glass fibers with dry ;
Figure 3A is a schematic illustration of an exemplary apparatus for forming a
binderless layered web or pack of glass fibers;
Figure 3B is a schematic illustration of an exemplary apparatus for forming a
binderless entangled web of glass fibers;
Figure 3C is a schematic illustration of an exemplary apparatus for forming a
binderless layered and entangled web or pack of glass fibers;
Figure 4 is a schematic illustration of a forming apparatus for forming a web of glass
fibers;
Figure 5 is a schematic illustration of an exemplary apparatus for g a web or
pack of glass fibers with a dry binder;
WO 2013049835 PCTIU82012/058339
Figure 6 is a schematic representation, in elevation of a process for forming a pack of
fibrous materials; and
Figure 7 is a schematic representation, in plan View, of a process for forming a pack
from fibrous materials.
DETAILED PTION OF THE INVENTION
The present invention will now be described with occasional reference to the specific
exemplary embodiments of the invention. This ion may, however, be embodied in
different forms and should not be construed as limited to the embodiments set forth herein.
Rather, these embodiments are provided so that this disclosure will be thorough and
complete, and will fully convey the scope of the invention to those skilled in the art.
Unless otherwise defined, all technical and scientific terms used herein have the same
meaning as commonly understood by one of ordinary skill in the art to which this invention
belongs. The terminology used in the description of the invention herein is for describing
particular embodiments only and is not intended to be limiting of the invention. As used in
the ption of the invention and the appended claims, the singular forms "a,H Han," and
"the" are intended to include the plural forms as well, unless the context clearly indicates
otherwise.
Unless otherwise indicated, all numbers expressing quantities of ions such as
length, width, height, and so forth as used in the specification and claims are to be understood
as being d in all ces by the term "about," Accordingly, unless otherwise
indicated, the numerical properties set forth in the specification and claims are
approximations that may vary depending on the desired properties sought to be obtained in
embodiments of the t invention. Notwithstanding that the numerical ranges and
parameters setting forth the broad scope of the invention are approximations, the cal
values set forth in the specific examples are reported as precisely as possible. Any numerical
values, r, ntly contain certain errors necessarily resulting from error found in
their respective ements.
The description and figures disclose an improved method of forming a pack from
fibrous materials. lly, the improved uous methods replace the traditional
PCTIU82012/058339
methods of applying a wet binder to fiberized materials with new methods ofmaking a batt or
pack of fibers without any binder (i.e. material that binds fibers together) and/or new methods
of making a batt or pack of fibers with dry binders.
The term "fibrous materials", as used herein, is defined to mean any material formed
from drawing or attenuating molten materials. The term "pack", as used herein, is defined to
mean any product formed by fibrous materials that are joined together by an adhesive and/or
by ical entanglement.
Figures 1A and 3A illustrate a first exemplary ment of a continuous process or
method 100 of forming a pack 300 (see Figure 3A) from fibrous als. The dashed line
101 around the steps of the method 100 indicates that the method is a continuous method, as
will be described in more detail below. The methods and packs will be described in terms of
glass fibers, but the methods and packs are applicable as well to the manufacture of fibrous
products formed from other l materials, such as the non—limiting examples of rock,
slag and basalt.
Referring to Figure 1A, glass is melted 102. For example, Figure 3A schematically
illustrates a melter 314. The melter 314 may supply molten glass 312 to a forehearth 316.
Melters and forehearths are known in the art and will not be described herein. The molten
glass 312 can be formed from various raw als combined in such proportions as to give
the d al composition.
Referring back to Figure 1A, the molten glass 312 is processed to form 104 glass
fibers 322. The molten glass 312 can be processed in a variety of different ways to form the
fibers 322. For example, in the example illustrated by Figure 3A, the molten glass 312 flows
from the forehearth 316 to one or more rotary fiberizers 318. The rotary fiberizers 18 receive
the molten glass 312 and subsequently form veils 320 of glass fibers 322. As will be
discussed in more detail below, the glass fibers 322 formed by the rotary fiberizers 318 are
long and thin. Accordingly, any desired er, rotary or otherwise, sufficient to form long
and thin glass fibers 322 can be used. While the ment illustrated in Figure 3A shows
one rotary fiberizer 318, it should be appreciated that any desired number of rotary fiberizers
318 can be used.
WO 2013049835 PCT/U82012/058339
The long and thin fibers may take a wide variety of different forms. In an exemplary
embodiment, the long and thin fibers have a length in a range of from about 0.25 inches to
about 10.0 inches and a diameter dimension in a range of from about 9 HT to about 35 HT.
HT stands for hundred thousandths of an inch. In an exemplary embodiment, the fibers 322
have a length in a range of from about 1.0 inch to about 5.0 inches and a diameter dimension
in a range of fiom about 14 HT to about 25 HT. In an exemplary embodiment, the fibers 322
have a length of about 3 inches and an average diameter of about 16-17 HT. While not being
bound by the theory, it is believed the use of the relatively long and thin fibers
advantageously provides a pack having better thermal and acoustic insulative performance, as
well as better strength properties, such as higher tensile strength and/or higher bond th,
than a similar sized pack having shorter and thicker fibers.
In the exemplary ments described herein, the glass fibers 322 can optionally
be coated or partially coated with a lubricant after the glass fibers are formed. For example,
the glass fibers 322 can be coated with any lubricating al that does not bind the glass
fibers together. In an ary embodiment, the lubricant can be a silicone compound, such
as siloxane, dimethyl siloxane and/or silane. The lubricant can also be other materials or
combinations of materials, such as, oil or an oil emulsion. The oil or oil emulsion may be a
mineral oil or mineral oil emulsion and/or a vegetable oil or vegetable oil emulsion.
The glass fibers can be coated or partially coated with a lubricant in a wide y of
different ways. For example, the lubricant can be sprayed onto the glass fibers 322. In an
ary embodiment, the lubricant is configured to prevent damage to the glass fibers 322
as the glass fibers 322 move through the manufacturing process and come into contact with
various apparatus as well as other glass fibers. The lubricant can also be useful to reduce dust
in the manufacturing process. The application of the optional lubricant can be precisely
controlled by any desired structure, mechanism or device.
Referring to Figure 1A, a web 321 of fibers without a binder or other material that
binds the fibers er is formed 106. The web 321 can be formed in a wide variety of
different ways. In the e illustrated by Figure 3A, the glass fibers 322 are gathered by
an optional gathering member 324. The gathering member 324 is shaped and sized to receive
the glass fibers 322. The gathering member 324 is configured to divert the glass fibers 322 to
a duct 330 for er to downstream sing stations, such as for example forming
PCT/U82012/058339
apparatus 332, which forms the web 321. In other embodiments, the glass fibers 322 can be
gathered on a conveying mechanism (not shown) to form the web.
The forming apparatus 332 can be red to form a continuous dry web 321 of
fibrous material having a d thickness. In one exemplary embodiment, the dry webs 321
disclosed in this application can have a thickness in the range of about 0.25 inches to about 4
inches thick and a density in the range of about 0.2 lb/ft3 to about 0.6 lb/ft3 . In one exemplary
embodiment, the dry webs 321 disclosed in this application can have a thickness in the range
of about 1 inch to about 3 inches thick and a density in the range of about 0.3 lb/ft3 to about
0.5 lb/ft3. In one exemplary ment, the dry webs 321 disclosed in this application can
have a thickness of about 1.5 inches and a density of about 0.4 lb/ft3. The forming apparatus
332 can take a wide variety of different forms. Any arrangement for forming a dry web 321
of glass fibers can be used.
In one exemplary embodiment, the forming apparatus 332 includes a rotating drum
with formng surfaces and areas of higher or lower pressure. Referring to Figure 4, the
pressure P1 on a side 460 of the forming e 462 where the fibers 322 are collected is
higher than the pressure P2 on the opposite side 464. This re drop AP causes the fibers
322 to collect on the forming surface 462 to form the dry web 321. In one exemplary
embodiment, the re drop AP across the forming surface 462 is controlled to be a low
pressure and produce a low area weight web. For example, the pressure drop AP can be from
about 0.5 inches ofwater and 30 inches of water. A velocity V of the air traveling through
the web being formed that results in this low pressure drop AP may be up to 1,000 feet per
minute.
A low area weight web 321 having an area weight of about 5 to about 50 grams per
square foot. The low area weight web may have the density and thickness ranges mentioned
above. The low area weight web may have a ess in the range of about 0.25 inches to
about 4 inches thick, about 1 inch to about 3 inches thick, or about 1.5 inches. The low area
weight web may have a density in the range of about 0.2 lb/ft3 to about 0.6 1b/ft3, about 0.3
lb/i’t3 to about 0.5 lb/fi3 or about 0.4 lb/ft3. Referring to Figure 3A, the dry web 321 leaves
the g apparatus 332. In one exemplary ment, the low area weight web 321 has
a measured area weight distribution Coefficient of Variation = Sigma (One rd
Deviation)/Mean (Average) x 100% = of between 0 and 40%. In exemplary embodiments,
PCT/U52012/058339
the weight distribution Coefficient of Variation is less than 30%. Less than 20% or less than
%. In one exemplary embodiment, the weight distribution Coefficient of Variation is
between 25% and 30%, such as about 28%.. In one exemplary ment, the weight
distribution Coefficient of Variation is about 28%. The weight distribution Coefficient of
Variation by measuring multiple small sample area sizes, for example, 2” x 2”, of a large
sample, for example a 6ft by 10 fi sample with a light table.
In the e illustrated by Figure 1A, the web 321 or multiple webs are layered
108. For example, a single web 321 may be lapped in the machine direction or cross-lapped
at ninety degrees to the machine direction to form a d web 350. In another
embodiment, the web may be cut into portions and the portions are stacked on top of one
another to form the layered web. In yet another exemplary embodiment, one or more
duplicate fiberizers 318 and forming apparatus 332 can be implemented such that two or
more webs are continuously produced in parallel. The parallel webs are then stacked on top
of each other to form the layered web.
In one ary embodiment, the layering mechanism 332 is a lapping mechanism
or a cross-lapping mechanism that functions in association with a conveyor 336. The
conveyor 336 is configured to move in a machine direction as indicated by the arrow D1. The
lapping or lapping mechanism is configured to receive the continuous web 321 and
deposit alternating layers of the continuous web on the first conveyer 336 as the first
conveyor moves in machine direction D1. In the deposition process, a lapping mechanism
334 would form the alternating layers in a machine direction as ted by the arrows D1 or
the lapping mechanism 334 would form the alternating layers in a cross-machine
direction. Additional webs 321 may be formed and lapped or cross—lapped by additional
g or cross—lapping mechanisms to increase the number of layers and hput
capacity.
In one exemplary embodiment, a cross-lapping mechanism is configured to ely
control the movement of the continuous web 321 and deposit the continuous web on the
conveyor 336 such that the continuous web is not damaged. The cross-lapping mechanism
can include any desired structure and can be configured to e in any desired manner. In
one ary embodiment, the cross-lapping mechanism includes a head (not shown)
red to move back and forth at 90 degrees to the machine direction D]. In this
W0 2013I049835 PCT/U82012/058339
embodiment, the speed of the moving head is coordinated such that the movement of the head
in both cross-machine directions is substantially the same, thereby providing uniformity of
the ing layers of the fibrous body. In an exemplary embodiment, the cross-lapping
mechanism comprises vertical conveyors (not shown) configured to be centered with a
centerline of the conveyor 336. The vertical conveyors are further configured to swing from a
pivot mechanism above the conveyor 336 such as to t the continuous web on the
conveyor 336. While multiple examples of cross lapping isms have been described
above, it should be appreciated that the cross-lapping mechanism can be other structures,
mechanisms or devices or combinations thereof.
The layered web 350 can have any desired thiclmess. The ess of the layered
web is a function of several variables. First, the thickness of the layered web 350 is a function
of the ess of the continuous web 321 formed by the forming apparatus 332. Second, the
thickness of the layered web 350 is a function of the speed at which the layering mechanism
334 deposits layers of the continuous web 321 on the conveyer 336. Third, the thickness of
the layered web 334 is a function of the speed of the or 336. In the illustrated
embodiment, the layered web 350 has a thickness in a range of from about 0.1 inches to about
.0 inches. In an exemplary embodiment, a cross lapping mechanism 334 may form a
layered web 350 having from 1 layer to 60 layers. Optionally, a cross—lapping mechanisms
can be able, thereby allowing the cross-lapping isms 334 and 334 to form a
pack having any desired width. In certain embodiments, the pack can have a general width in
a range of from about 98.0 inches to about 236.0 inches.
In one exemplary embodiment, the layered web 350 is produced in a uous
process indicated by dashed box 101 in Figure 1A. The fibers produced by the fiberizer 318
are sent directly to the forming tus 332 (i.e. the fibers are not collected and packed and
then unpacked for use at a remote forming apparatus). The web 321 is provided directly to
the layering device 352 (i.e. the web is not formed and rolled up and then unrolled for use at a
remote ng device 352). In an exemplary embodiment of the uous process, each of
the processes (forming and layering in Figure 1A) are connected to the fiberizing s,
such that fibers from the fiberizer are used by the other processes without being stored for
later use.
WO 49835 PCTfU82012/058339
In one exemplary embodiment, the web 321 is relatively thick and has a low area
, yet the continuous s has a high throughput. For example, a single layer of the
web 321 may have an area weight of about 5 to about 50 grams per square foot. The low area
weight web may have the density and thickness ranges mentioned above. The high output
continuous process may produce between about 750 lbs/hr and 1500 lbs/hr, such as at least
900 lbs/hr or at least 1250 lbs/hr. The layered web 350 can be used in a wide variety of
ent applications.
Figures 1B and 3B illustrate a second exemplary embodiment of a method 150 of
forming a pack 300 (see Figure 38) from fibrous materials without the use of a binder. The
dashed line 151 around the steps of the method 150 indicates that the method is a continuous
method .Referring to Figure 18, glass is melted 102. The glass may be melted as described
above with respect to Figure 3A. The molten glass 312 is processed to form 104 glass fibers
322. The molten glass 312 can be processed as described above with respect to Figure 3A to
form the fibers 322. A web 321 of fibers without a binder or other material that binds the
fibers together is formed 106. The web 321 can be formed as described above with respect to
Figure 3A.
Referring to Figure 1B, the fibers 322 of the web 321 are mechanically entangled 202
to form an entangled web 352 (see Figure 3B). Referring to Figure 3B, the fibers of the web
321 can be mechanically entangled by an entangling mechanism 345, such as a ng
device. The entanglement mechanism 345 is configured to entangle the individual fibers 322
of the web 321. Entangling the glass fibers 322 ties the fibers of the web together. The
entanglement causes mechanical properties of the web, such as for example, tensile strength
and shear strength, to be improved. In the illustrated embodiment, the entanglement
mechanism 345 is a needling mechanism. In other embodiments, the entanglement
mechanism 345 can include other structures, mechanisms or devices or combinations thereof,
ing the non-limiting e of stitching mechanisms.
The entangled web 352 can have any d thickness. The thickness of the
entangled web is a function of the thickness of the continuous web 321 formed by the
g apparatus 332 and the amount of compression of the continuous web 321 by the
entanglement ism 345. In an exemplary embodiment, the entangled web 352 has a
ess in a range of from about 0.1 inches to about 2.0 inches. In an exemplary
W0 2013I049835
ment, the entangled web 352 has a thickness in a range of from about 0.5 inches to
about 1.75 inches. For example, in one exemplary embodiment, the thickness of the
entangled web is about V2”.
In one exemplary embodiment, the entangled web 352 is produced in a continuous
process 151. The fibers ed by the fiberizer 318 are sent directly to the forming
apparatus 332 (i.e. the fibers are not collected and packed and then unpacked for use at a
remote forming apparatus). The web 321 is provided ly to the entangling device 345
(i.e. the web is not formed and rolled up and then unrolled for use at a remote entangling
device 345). The entangled web 352 can be used in a wide variety of different ations.
In an exemplary embodiment of the continuous process, each of the processes (forming and
entangling in Figure 1B) are connected to the fiberizing process, such that fibers from the
fiberizer are used by the other processes without being stored for later use.
Figures 1C and 3C illustrate a third exemplary embodiment of a method 170 of
forming a pack 370 (see Figure 3C) from fibrous als without the use of a binder.
ing to Figure 1C, glass is melted 102. The dashed line 171 around the steps of the
method 170 indicates that the method is a continuous method The glass may be melted as
described above with respect to Figure 3A. Referring back to Figure 1C, the molten glass
312 is processed to form 104 glass fibers 322. The molten glass 312 can be processed as
described above with respect to Figure 3A to form the fibers 322. Referring to Figure 1C, a
web 321 of fibers without a binder or other material that binds the fibers er is formed
106. The web 321 can be formed as described above with respect to Figure 3A. Referring to
Figure 1C, the web 321 or multiple webs are layered 108. The web 321 or multiple webs can
be d as described above with respect to Figure 3A. Referring to Figure 1C, the fibers
322 of the layered webs 350 are mechanically entangled 302 to form an entangled pack 370
of layered webs.
[0045} ing to Figure 3C, the fibers of the layered webs 350 can be mechanically
entangled by an entangling mechanism 345, such as a needling device. The entanglement
mechanism 345 is configured to le the individual fibers 322 forming the layers of the
layered web. Entangling the glass fibers 322 ties the fibers of the d webs 350 together
to form the pack. The mechanical entanglement causes mechanical properties, such as for
example, tensile strength and shear strength, to be improved. In the illustrated embodiment,
W0 20131049835 PCT/U82012/058339
the entanglement mechanism 345 is a needling mechanism. In other embodiments, the
entanglement mechanism 345 can include other structures, mechanisms or devices or
combinations thereof, including the non-limiting example of stitching mechanisms.
The entangled pack 370 of layered webs 350 can have any desired thickness. The
thickness of the entangled pack is a function of several variables. First, the ess of the
entangled pack is a function of the thickness of the continuous web 321 formed by the
forming apparatus 332. Second, the thickness of the entangled pack 370 is a function of the
speed at which the lapping or cross-lapping mechanism 334 deposits layers of the continuous
web 321 on the conveyer 336. Third, the thickness of the entangled pack 370 is a function of
the speed of the conveyor 336. Fourth, the ess of the entangled pack 370 is a function
of the amount of compression of the d webs 350 by the entanglement mechanism 345.
The entangled pack 370 can have a ess in a range of from about 0.1 inches to about
.0 inches. In an exemplary embodiment, the entangled pack 370 may having from 1 layer
to 60 layers. Each entangled web layer 352 may be from 0.1 to 2 inches thick. For example,
each entangled web layer may be about 0.5 inches thick.
In one exemplary embodiment, the entangled pack 370 is ed in a continuous
process. The fibers produced by the fiberizer 318 are sent directly to the forming apparatus
332 (i.e. the fibers are not collected and packed and then unpacked for use at a remote
forming apparatus). The web 321 is provided directly to the layering device 352 (Le. the web
is not formed and rolled up and then unrolled for use at a remote layering device 352). The
d web 350 is provided directly to the entangling device 345 (Le. the layered web is not
formed and rolled up and then unrolled for use at a remote entangling device 345). In an
exemplary ment of the continuous s, each of the processes (forming, layering,
and entangling in Figure 1C) are connected to the fiberizing process, such that fibers from the
fiberizer are used by the other processes without being stored for later use.
In one ary embodiment, the entangled pack 370 of layered webs is made from
a web 321 or webs that is relatively thick and has a low area weight, yet the continuous
process has a high throughput. For e, a single layer of the web 321 may have the area
weights, thicknesses, and densities mentioned above. The high output continuous process
may produce between about 750 lbs/hr and 1500 lbs/hr, such as at least 900 lbs/hr or at least
1250 lbs/hr. In an ary embodiment, the combination of high web throughput and
PCTIUS2012/058339
ical entanglement, such as needling, of a continuous s is facilitated by layering
of the web 321, such as lapping or cross-lapping of the web. By layering the web 321, the
linear speed of the material moving h the layering device is slower than the speed at
which the web is formed. For example, in a continuous process, a two layer web will travel
through the entangling apparatus 345 at V2 the speed at which the web is formed (3 layers -l/3
the speed, etc). This reduction in speed allows for a continuous process where a high
hput, low area weight web 321 is formed and converted into a multiple layer,
mechanically entangled pack 370. The entangled pack 370 of layered webs can be used in a
wide variety of different applications.
In an exemplary embodiment, the layering and entangling of the long, thin fibers
results in a strong web 370. For example, the entanglement of the long, thin glass fibers
described in this application results in a layered, led web with a high tensile strength
and a high bond strength. Tensile strength is the strength of the web 370 when the web is
pulled in the direction of the length or width of the web. Bond strength is the strength of the
web when the web 370 is pulled apart in the direction of the thickness of the web.
Tensile strength and bond strength may be tested in a wide variety of different ways.
In one exemplary embodiment, a machine, such as an Instron machine, pulls the web 370
apart at a fixed speed (12 inches per second in the examples described below) and measures
the amount of force required to pull the web apart. Forces required to pull the web apart,
including the peak force applied to the web before the web rips or fails, are recorded.
In one method of g tensile th, the tensile th in the length direction is
measured by clamping the ends of the web along the width of the web, pulling the web 370
along the length of the web with the machine at the fixed speed (12 inches per second in the
examples provided below), and recording the peak force applied in the direction of the length
of the web. The tensile th in the width direction is measured by clamping the sides of
the web along the width of the web, pulling the web 370 along the width of the web at the
fixed speed (12 inches per second in the examples ed below), and recording the peak
force applied. The tensile strength in the length direction and the tensile strength in the width
direction are ed to determine the tensile strength of the sample.
PCTfUS2012/058339
In one method of testing bond strength, a sample of a ermined size (6” by 6” in
the examples described below) is provided. Each side of the sample is bonded to a substrate,
for example by gluing. The substrates on the opposite side of the sample are pulled apart
with the machine at the fixed speed (12 inches per second in the es provided below),
and recording the peak force applied. The peak force applied is d by the area of the
sample (6” by 6” in the examples described below) to provide the bond strength in terms of
force over area.
The following examples are ed to illustrate the increased th of the
layered, entangled web 370. In these examples, no binder is included. That is, no aqueous or
dry binder is included. These examples do not limit the scope of the present invention, unless
expressly recited in the claims. Examples of layered, entangled webs having 4, 6, and 8
layers are provided. r, the layered entangled web 370 may be ed with any
number of layers. The layered, entangled web 370 sample length, width, ess, number
of laps, and weight may vary depending on the application for the web 370.
In one exemplary embodiment, a web 370 sample that is 6 inches by 12 inches, has
multiple layers, such as two laps (i.e. four layers), is between 0.5 inches thick and 2.0 inches
thick, has a weight per square foot between 0.1 and 0.3 lbs/sq ft, has a tensile strength that is
greater than 3 lbf, and has a tensile th to weight ratio that is greater than 40 m,
such as from about 40 to about 120 lbf/lbm. In an exemplary embodiment, a bond strength of
this sample is greater than 0.1 lbs/sq ft. In an exemplary embodiment, the tensile strength of
the sample described in this paragraph is greater than 5 lbf. In an exemplary embodiment, the
e th of the sample described in this paragraph is greater than 7.5 lbf. In an
exemplary embodiment, the tensile strength of the sample described in this paragraph is
greater than 10 lbf. In an exemplary embodiment, the tensile th of the sample
described in this paragraph is greater than 12.5 lbf. In an exemplary embodiment, the tensile
strength of the sample described in this paragraph is greater than 13.75 lbf. In an exemplary
embodiment, the tensile strength of the sample described in this paragraph is between 3 and
lbf. In an exemplary embodiment, the bond strength of the sample described in this
paragraph is greater than 2 lbs/sq ft. In an exemplary ment, the bond strength of the
sample described in this paragraph is greater than 5 lbs/sq ft. In an exemplary embodiment,
the bond strength of the sample described in this paragraph is greater than 10 lbs/sq ft. In an
exemplary embodiment, the bond strength of the sample described in this paragraph is greater
2012/058339
than 15 lbs/sq ft. In an exemplary embodiment, the bond strength of the sample described in
this paragraph is greater than 20 lbs/sq it. In an ary embodiment, the tensile strength
of the sample described in this paragraph is greater than 5 lbf and the bond strength is greater
than 2 lbs/sq it. In an exemplary embodiment, the tensile strength of the sample described in
this paragraph is greater than 7.5 lbf and the bond th is greater than 7.5 lbs/sq ft. In an
exemplary embodiment, the tensile th of the sample described in this paragraph is
greater than 10 lbf and the bond strength is r than 10 lbs/sq ft. In an exemplary
embodiment, the tensile th of the sample described in this paragraph is greater than
12.5 lbf and the bond strength is greater than 15 lbs/sq ft. In an exemplary embodiment, the
tensile th of the sample bed in this paragraph is greater than 13.75 lbf and the
bond strength is greater than 20 lbs/sq ft. In an exemplary embodiment, the tensile strength
of the sample described in this paragraph is between 3 and 15 lbf and the bond strength is
between 0.3 and 301bs/ sq ft.
In one exemplary ment, a web 370 sample that is 6 inches by 12 inches, has
multiple layers, such as two laps (i.e. four layers), is between 0.5 inches thick and 1.75 inches
thick, has a weight per square foot between 0.12 and 0.27 lbs/sq ft, has a tensile strength that
is greater than 3 lbf, and has a tensile strength to weight ratio that is greater than 40 lbf/lbm,
such as from about 40 to about 120 lbf/lbm, and a bond strength that is greater than I lb/sq ft.
In an exemplary embodiment, the tensile strength of the sample described in this paragraph is
greater than 5 lbf. In an exemplary ment, the tensile strength of the sample described
in this paragraph is r than 7.5 lbf. In an exemplary embodiment, the tensile strength of
the sample described in this paragraph is r than 10 lbf. In an ary embodiment,
the tensile strength of the sample described in this paragraph is greater than 12.5 lbf. In an
exemplary embodiment, the tensile strength of the sample described in this paragraph is
greater than 13.75 lbf. In one exemplary embodiment, the tensile strength of the sample
described in this paragraph is between 3 and 15 lbf. In an exemplary embodiment, the bond
strength of the sample described in this paragraph is greater than 2 lbs/sq fr. In an exemplary
embodiment, the bond th of the sample described in this paragraph is greater than 5
lbs/sq ft. In an exemplary embodiment, the bond strength of the sample bed in this
paragraph is greater than 10 lbs/sq it. In an exemplary embodiment, the bond strength of the
sample described in this paragraph is greater than 15 lbs/sq it. In an exemplary embodiment,
the bond strength of the sample described in this paragraph is greater than 20 lbs/sq ft. In an
exemplary embodiment, the tensile strength of the sample described in this paragraph is
WO 49835 PCT/U82012/058339
greater than 5 lbf and the bond strength is greater than 2 lbs/sq it. In an ary
embodiment, the tensile strength of the sample described in this paragraph is greater than 7.5
lbf and the bond strength is r than 7.5 lbs/sq ft. In an exemplary embodiment, the
tensile strength of the sample described in this paragraph is greater than 10 lbf and the bond
strength is greater than 10 lbs/sq ft. In an exemplary embodiment, the tensile strength of the
sample described in this paragraph is greater than 12.5 lbf and the bond strength is greater
than 15 lbs/sq ft. In an exemplary ment, the e strength of the sample described
in this paragraph is greater than 13.75 lbf and the bond strength is r than 20 lbs/sq it. In
an exemplary embodiment, the tensile strength of the sample described in this paragraph is
between 3 and 15 lbf and the bond th is between 0.3 and 30 lbs/ sq ft.
In one exemplary embodiment, a web 370 sample that is 6 inches by 12 inches, has
multiple layers, such as two laps (i.e. four layers), is n 0.5 inches thick and 1.25 inches
thick, has a weight per square foot between 0.2 and 0.3 lbs/sq ft, has a tensile strength that is
greater than 10 lbf, and has a tensile strength to weight ratio that is greater than 75 lbf/lbm,
such as from about 75 about 120 lbf/lbm. In an exemplary embodiment, the tensile strength
of the sample described in this paragraph is greater than 12.5 lbf. In an exemplary
embodiment, the tensile th of the sample described in this paragraph is greater than
13.75 lbf. In one exemplary embodiment, the tensile strength of the sample described in this
aph is between 3 and 15 lbf. In one exemplary embodiment, the bond th of the
sample described in this paragraph is greater than 3 lb/sq it. In an exemplary embodiment,
the bond strength of the sample described in this paragraph is greater than 10 lb/sq ft. In an
ary ment, the bond strength of the sample described in this paragraph is greater
than 15 lb/sq it. In one exemplary embodiment, the tensile strength of the sample described
in this paragraph is greater than 10 lbf and the bond strength is greater than 3 lb/sq ft. In an
exemplary embodiment, the tensile strength of the sample described in this paragraph is
greater than 12.5 lbf and the bond strength is greater than 10 lb/sq ft. In an exemplary
ment, the tensile strength of the sample described in this paragraph is greater than
l3.75 lbf and the bond strength is greater than 15 lb/sq ft.
In one exemplary embodiment, a web 370 sample that is 6 inches by 12 inches, has
multiple layers, such as three laps (i.e. six layers), is between 1.0 inches thick and 2.25 inches
thick, has a weight per square foot between 0.15 and 0.4 lbs/sq ft, has a tensile strength that is
greater than 5 lbf, and has a tensile strength to weight ratio that is greater than 40 lbf/lbm,
W0 49835 PCTIUS20122’058339
such as from about 40 to about 140 lbf/lbrn. In an exemplary embodiment, the bond strength
of this sample is greater than 0.1 lbs/sq fi. In an exemplary embodiment, the tensile strength
of the sample described in this paragraph is greater than 7.5 lbf. In an exemplary
embodiment, the e strength of the sample bed in this paragraph is greater than 10
lbf. In an exemplary embodiment, the tensile strength of the sample described in this
paragraph is greater than 12.5 lbf. In an exemplary embodiment, the tensile strength of the
sample described in this paragraph is greater than 13.75 lbf. In an ary embodiment,
the tensile strength of the sample described in this paragraph is between 5 and 20 lbf. In an
exemplary embodiment, the bond strength of the sample described in this paragraph is greater
than 0.5 lbs/sq ft. In an exemplary embodiment, the bond strength of the sample described in
this paragraph is greater than 1.0 lbs/sq ft. In an exemplary ment, the bond strength of
the sample described in this paragraph is greater than 1.5 lbs/sq ft. In an exemplary
embodiment, the bond strength of the sample bed in this paragraph is greater than 2.0
lbs/sq ft. In an exemplary ment, the bond strength of the sample described in this
paragraph is greater than 2.5 lbs/sq ft. In an ary embodiment, the bond strength of the
sample described in this paragraph is greater than 3.0 lbs/sq ft. In an exemplary embodiment,
the tensile strength of the sample described in this aph is greater than 7.5 lbf and the
bond strength is greater than 0.40 lbs/sq ft. In an exemplary embodiment, the tensile strength
of the sample described in this paragraph is greater than 10 lbf and the bond strength is
greater than 0.6 lbs/ sq it. In an exemplary embodiment, the tensile strength of the sample
described in this aph is greater than 12.5 lbf and the bond strength is greater than 0.9
lbs/ sq ft. In an exemplary embodiment, the tensile th of the sample described in this
paragraph is between 5 and 20 lbf and the bond strength is between 0.1 and 4 lbs/sq ft.
In one exemplary embodiment, a web 370 sample that is 6 inches by 12 inches, has
multiple layers, such as three laps (i.e. six layers), is between 1.0 inches thick and 1.50 inches
thick, and has a weight per square foot between 0.25 and 0.4 lbs/sq ft, has a e strength
that is greater than 9 lbf, and has a tensile strength to weight ratio that is greater than 50
lbf/lbm, such as from about 50 to about 140 lbf/lbm. In an exemplary embodiment, the
tensile strength of the sample described in this paragraph is greater than 12.51bf. In an
exemplary embodiment, the tensile strength of the sample described in this paragraph is
greater than 13.75 lbf. In one exemplary ment, the tensile strength of the sample
bed in this paragraph is between 9 and 15 lbf. In an exemplary embodiment, the bond
strength of the sample described in this paragraph is greater than 0.5 lbs/sq fi. In an
W0 20131049835 PCT/U82012/058339
exemplary embodiment, the bond strength of the sample described in this paragraph is greater
than 1.0 lbs/sq ft. In an exemplary embodiment, the bond strength of the sample bed in
this paragraph is greater than 1.5 lbs/sq it. In an exemplary ment, the bond strength of
the sample bed in this paragraph is greater than 2.0 lbs/sq it. In an exemplary
ment, the bond strength of the sample described in this paragraph is greater than 2.5
lbs/sq ft. In an exemplary embodiment, the bond strength of the sample bed in this
paragraph is greater than 3.0 lbs/sq ft. In an exemplary ment, the tensile strength of
the sample described in this paragraph is greater than 9 lbf and a bond strength that is greater
than 0.5 lbs/sq ft. In an exemplary embodiment, the tensile strength of the sample described
in this paragraph is greater than f and a bond strength that is greater than 1.0 lbs/sq ft.
In an exemplary embodiment, the tensile strength of the sample described in this paragraph is
greater than 13.75 lbf and a bond strength that is greater than 2 lbs/sq ft.
In one exemplary embodiment, a web 370 sample that is 6 inches by 12 inches, has
multiple layers, such as four laps (i.e. eight layers), is between 0.875 inches thick and 2.0
inches thick, and has a weight per square foot between 0.15 and 0.4 lbs/sq ft, has a tensile
strength that is greater than 3 lbf, and has a tensile strength to weight ratio that is greater than
40 lbf/lbm, such as from about 40 to about 130 lbf/lbm. In one exemplary embodiment, the
web has a bond th that is greater than 0.3 lbs/sq ft. In an exemplary embodiment, the
bond strength of this sample is greater than 0.1 lbs/sq ft. In an exemplary embodiment, the
tensile strength of the sample described in this paragraph is greater than 7.5 lbf. In an
exemplary embodiment, the tensile strength of the sample described in this paragraph is
r than 10 lbf. In one exemplary embodiment, the tensile strength of the sample
described in this paragraph is n 3 and 15 lbf. In an exemplary embodiment, the bond
strength of the sample described in this paragraph is greater than 0.5 lbs/sq ft. In an
exemplary embodiment, the bond strength of the sample described in this aph is greater
than 1.0 lbs/sq ft. In an exemplary embodiment, the bond strength of the sample described in
this paragraph is greater than 2 lbs/sq ft. In an exemplary embodiment, the bond strength of
the sample described in this paragraph is greater than 3 lbs/sq it. In an exemplary
ment, the bond strength of the sample described in this paragraph is greater than 4
lbs/sq ft. In an exemplary ment, the bond th of the sample described in this
paragraph is greater than 5 lbs/sq it. In an exemplary embodiment, the bond strength of the
sample described in this paragraph is greater than 10 lbs/sq ft. In an exemplary embodiment,
the tensile strength of the sample described in this paragraph is greater than 7.5 lbf and the
W0 2013i049835 PCTfU820121058339
bond strength is greater than .5 lbs/sq ft. In an exemplary embodiment, the tensile strength of
the sample described in this paragraph is greater than 10 lbf and the bond strength is greater
than 1.0 lbs/sq ft. In one exemplary embodiment, the tensile strength of the sample described
in this paragraph is between 3 and 15 lbf and the bond strength is between 0.3 and 15 lbs/sq
In one exemplary embodiment, a web 370 sample that is 6 inches by 12 inches, has
multiple layers, such as four laps (i.e. eight ), is between 1.0 inches thick and 2.0 inches
thick, and has a weight per square foot n 0.1 and 0.3 lbs/sq ft, has a tensile th
that is greater than 9 lbf, and has a tensile strength to weight ratio that is greater than 70
lbf/lbm. In an exemplary embodiment, the tensile strength of the sample described in this
aph is greater than 10 lbf. In an exemplary embodiment, the bond strength of the
sample described in this paragraph is greater than 0.5 lbs/sq ft. In an exemplary embodiment,
the bond strength of the sample described in this paragraph is greater than 1.0 lbs/sq ft. In an
exemplary embodiment, the bond strength of the sample described in this paragraph is greater
than 2 lbs/sq it. In an exemplary embodiment, the bond strength of the sample described in
this paragraph is greater than 3 lbs/sq ft. In an exemplary embodiment, the bond strength of
the sample described in this paragraph is greater than 4 lbs/sq it. In an exemplary
embodiment, the bond strength of the sample described in this paragraph is greater than 5
lbs/sq it. In an exemplary embodiment, the bond strength of the sample bed in this
paragraph is r than 10 lbs/sq it. In an exemplary ment, the tensile strength of
the sample described in this paragraph is greater than 10 lbf and the bond strength is greater
than 5 lbs/sq ft.
Figures 2A-2C illustrate exemplary embodiments of methods that are similar to the
embodiments of Figures lA—IC, except the web 521 (see Figure 5) is formed 260 with a dry
or non-aqueous binder. The method 200 of Figure 2A generally corresponds to the method
100 of Figure IA. The method 250 of Figure 2B generally ponds to the method 150 of
Figure IB. The method 270 of Figure 2C lly corresponds to the method 170 of Figure
Figure 2D illustrates a method 290 that is similar to the method 270 of Figure 2C. In
Figure 2D, the steps in boxes with dashed lines are al. In the exemplary embodiment
illustrated by Figure 2D, the dry binder can optionally be added to the web step 292 and/or
PCTIU82012/058339
the layered web at step 294, instead of (or in on to) before the web is formed. For
example, if step 292 is included, the web may be formed without a dry binder, and then the
dry binder is added to the web before layering and/or during layering. If step 294 is included,
the web may be formed and layered without a dry binder, and then the dry binder is added to
the d web.
Referring to Figure 5, the dry binder (indicated by the large arrows) can be added to
the fibers 322 and/or the web 521 at a variety of different points in the process. Arrow 525
indicates that the dry binder can be added to the fibers 322 at or above the ting member.
Arrow 527 tes that the dry binder can be added to the fibers 322 in the duct 330. Arrow
529 indicates that the dry binder can be added to the fibers 322 in the forming apparatus 332.
Arrow 531 indicates that the dry binder can be added to the web 321 after the web leaves the
forming apparatus 332. Arrow 533 indicates that the dry binder can be added to the web 321
as the web is d by the layering apparatus 334. Arrow 535 indicates that the dry binder
can be added to the web 321 afier the web is layered. Arrow 537 indicates that the dry binder
can be added to the web 321 or layered web in the oven 550. The dry binder can be added to
the fibers 322 or the web 321 to form a web 521 with dry binder in any manner.
In one exemplary embodiment, the dry binder is d to the fibers 322 at a location
that is significant distance downstream from the fiberizer 318. For example, the dry binder
may be applied to the fibers at a location where the temperature of the fibers and/or a
temperature of the air surrounding the fibers is significantly lower than the temperature of the
fibers and the surrounding air at the fiberizer. In one exemplary embodiment, the dry binder
is applied at a location where a temperature of the fibers and/or a temperature of air that
nds the fibers is below a temperature at which the dry binder melts or a temperature at
which the dry binder fully cures or reacts. For example, a thermoplastic binder may be
applied at a point in the production line where a temperature of the fibers 322 and/or a
temperature of air that surrounds the fibers are below the melting point of the of the
thermoplastic binder. A thermoset binder may be applied at a point in the production line
where a temperature of the fibers 322 and/or a ature of air that surrounds the fibers are
below a curing temperature of the thermoset binder. That is, the thermoset binder may be
applied at a point where a temperature of the fibers 322 and/or a temperature of air that
nds the fibers is below a point where the thermoset binder fully reacts or full cross—
linking of the thermoset binder occurs. In one exemplary embodiment, the dry binder is
WO 49835 PCT/U82012/058339
applied at a location in the production line where the temperature of the fibers 322 and/or a
temperature of air that nds the fibers are below 250 s F. In one exemplary
embodiment, the temperature of the fibers and/or a temperature of air that surrounds the
fibers at the ons indicated by arrows 527, 529, 531, 533, and 535 in Figure 5 is below a
temperature at which the dry binder melts or fully cures.
In one exemplary embodiment, the binder ator is a sprayer red for dry
powders. The sprayer may be configured such that the force of the spray is adjustable,
thereby allowing more or less penetration of the dry powder into the continuous web of
fibrous material. Alternatively, the binder applicator can be other structures, mechanisms or
devices or combinations thereof, such as for example a vacuum device, sufficient to draw the
dry binder into the continuous web 321 of glass fibers.
The optionai dry binder can take a wide variety of different forms. Any non-aqueous
medium that holds the fibers 322 together to form a web 521 can be used. In one exemplary
embodiment, the dry binder, while being initially applied to the fibers, is comprised of
substantially 100% solids. The term "substantially 100% solids", as used herein, means any
binder material having diluents, such as water, in an amount less than or equal to
approximately two percent, and preferably less than or equal to approximately one percent by
weight of the binder (while the binder is being applied, rather than after the binder has dried
or cured). However, it should be appreciated that certain embodiments, the binder can include
diluents, such as water, in any amount as desired depending on the specific ation and
design requirements. In one exemplary embodiment, the dry binder is a thermoplastic resin-
based material that is not applied in liquid form and r is not water based. In other
embodiments, the dry binder can be other materials or other combinations of materials,
including the non—limiting example of polymeric thermoset resins. The dry binder can have
any form or combinations of forms including the non-limiting es of s,
particles, fibers and/or hot melt. Examples of hot melt polymers e, but are not limited
to, ethylene-vinyl acetate copolymer, ethylene—acrylate mer, low density polyethylene,
high density polyethylene, atactic polypropylene, polybutene-l, styrene block copolymer,
polyamide, thermoplastic polyurethane, styrene block copolymer, polyester and the like. In
one exemplary embodiment, sufficient dry binder is applied such that a cured fibrous pack
can be compressed for packaging, storage and shipping, yet regains its thickness - a process
known as "10ft ry" - when installed.
W0 20131049835 PCT/US20121058339
In the examples illustrated by Figures 2A—2D and 5, the glass fibers 322 can
optionally be coated or partially coated with a lubricant before or after the dry binder is
applied to the glass fibers. In an exemplary embodiment, the lubricant is applied after the dry
binder to enhance the adhesion of the dry binder to the glass fibers 322. The lubricant can be
any of the lubricants described above.
Referring to Figure 5, the continuous web with unreacted dry binder 521 is transferred
from the forming apparatus 332 to the optional layering mechanism 334. The layering
mechanism may take a wide variety of ent forms. For example, the layering mechanism
may be a lapping mechanism that layers the web 321 in the machine ion D1 or a cross-
lapping ism that laps the web in a direction that is substantially orthogonal to the
machine direction. The cross—lapping device described above for layering the binderless web
321 can be used to layer the web 521 with unreacted dry .
In an exemplary embodiment, the dry binder of the continuous web 521 is configured
to be configured to be thermally set in a curing oven 550. In an exemplary embodiment, the
curing oven 550 replaces the entanglement mechanism 345, since the dry binder holds the
fibers 322 together. In another exemplary embodiment, both a curing oven 550 and an
entanglement mechanism 345 are included.
Figures 6 and 7 schematically rate another exemplary ment of a method
for forming a pack from fibrous materials is illustrated lly at 610. Referring to Figure
6, molten glass 612 is supplied from a melter 614 to a forehearth 616. The molten glass 612
can be formed from various raw materials combined in such proportions as to give the
desired chemical composition. The molten glass 612 flows from the forehearth 616 to a
plurality of rotary ers 618.
Referring to Figure 6, the rotary fiberizers 618 receive the molten glass 612 and
subsequently form veils 620 of glass fibers 622 ned in a flow of hot gases. As will be
discussed in more detail below, the glass fibers 622 formed by the rotary fiberizers 618 are
long and thin. Accordingly, any desired er, rotary or otherwise, sufficient to form long
and thin glass fibers 22 can be used. While the embodiment rated in Figures 6 and 7
show a quantity of two rotary fiberizers 618, it should be appreciated that any desired number
ofrotary fiberizers 18 can be used.
PCTIU82012/058339
The flow of hot gases can be created by optional blowing mechanisms, such as the
non-limiting examples of annular blowers (not shown) or annular burners (not shown).
Generally, the blowing mechanisms are configured to direct the veil 620 of glass fibers 622 in
a given direction, usually in a downward manner. It should be understood that the flow of hot
gasses can be d by any desired structure, mechanism or device or any combination
thereof.
As shown in Figure 6, optional spraying mechanisms 626 can be positioned beneath
the rotary fiberizers 618 and configured to spray fine droplets of water or other fluid onto the
hot gases in the veils 620 to help cool the flow of hot gases, protect the fibers 622 from
contact damage and/or enhance the bonding lity of the fibers 622. The spraying
mechanisms 626 can be any desired structure, mechanism or device sufficient to spray fine
droplets ofwater onto the hot gases in the veils 620 to help cool the flow of hot gases, protect
the fibers 622 from contact damage and/or enhance the bonding capability of the fibers 22.
While the embodiment shown in Figure 6 illustrates the use of the ng mechanisms 626,
it should be appreciated that the use of the spraying mechanisms 626 is al and the
method of forming the pack from fibrous als 610 can be practiced without the use of
the spraying mechanisms 626.
Optionally, the glass fibers 622 can be coated with a lubricant after the glass fibers are
formed. In the illustrated ment, a ity of nozzles 628 can be oned around the
veils 620 at a position beneath the rotary fiberizers 618. The nozzles 628 can be red to
supply a lubricant (not shown) to the glass fibers 622 from a source of lubricant (not shown).
The application of the lubricant can be precisely controlled by any desired structure,
ism or device, such as the non-limiting example of a valve (not shown). In certain
embodiments, the lubricant can be a silicone compound, such as siloxane, dimethyl siloxane,
and/or silane. The lubricant can also be other materials or combinations of als, such as
for example an oil or an oil emulsion. The oil or oil on may be a mineral oil or mineral
oil emulsion and/or a vegetable oil or vegetable oil emulsion. In an exemplary embodiment,
the lubricant is applied in an amount of about 1.0 percent oil and/or silicone compound by
weight of the resulting pack of fibrous materials. However, in other ments, the amount
of the lubricant can be more or less than about 1.0 percent oil and/or silicone compound by
weight.
PCTIU52012/058339
While the embodiment shown in Figure 6 illustrates the use of nozzles 628 to supply a
lubricant (not shown) to the glass fibers 622, it should be appreciated that the use of nozzles
628 is optional and the method of g the pack from fibrous materials 610 can be
practiced without the use of the nozzles 628.
In the illustrated ment, the glass fibers 622, entrained within the flow of hot
gases, can be gathered by an optional gathering member 624. The ing member 624 is
shaped and sized to easily receive the glass fibers 622 and the flow of hot gases. The
gathering member 624 is red to divert the glass fibers 622 and the flow of hot gases to
a duct 630 for er to downstream processing stations, such as for example forming
apparatus 632a and 632b. In other embodiments, the glass fibers 622 can be gathered on a
conveying mechanism (not shown) such as to form a blanket or batt (not shown). The batt
can be transported by the conveying mechanism to further processing stations (not shown).
The gathering member 624 and the duct 630 can be any structure having a generally hollow
configuration that is suitable for ing and conveying the glass fibers 622 and the flow of
hot gases. While the embodiment shown in Figure 6 illustrates the use of the gathering
member 624, it should be appreciated that the use of gathering member 624 to divert the glass
fibers 622 and the flow of hot gases to the duct 630 is optional and the method of forming the
pack from fibrous materials 610 can be practiced t the use of the gathering member
624.
In the ment shown in Figures 6 and 7, a single fiberizer 618 is associated with
an individual duct 630, such that the glass fibers 622 and the flow of hot gases from the
single fiberizer 618 are the only source of the glass fibers 622 and the flow of hot gasses
entering the duct 630. Alternatively, an individual duct 630 can be adapted to receive the
glass fibers 622 and the flow of hot gases from multiple fiberizers 618 (not shown).
Referring again to Figure 6, optionally, a header system (not shown) can be
positioned between the forming apparatus 632a and 632b and the fiberizers 618. The header
system can be red as a chamber in which glass fibers 622 and gases flowing from the
plurality of fiberizers 618 can be combined while controlling the characteristics of the
resulting combined flow. In certain embodiments, the header system can e a control
system (not shown) configured to combine the flows of the glass fibers 622 and gases from
the fiberizers 618 and further configured to direct the resulting combined flows to the
W0 20132049835 PCT/U820121158339
forming apparatus 632a and 632b. Such a header system can allow for maintenance and
ng of certain fiberizers 618 without the necessity of shutting down the remaining
fiberizers 618. Optionally, the header system can incorporate any d means for
controlling and directing the glass fibers 22 and flows of gases.
Referring now to Fig. 7, the momentum of the flow of the gases, having the entrained
glass fibers 622, will cause the glass fibers 622 to continue to flow through the duct 630 to
the forming apparatus 632a and 632b. The forming apparatus 632a and 632b can be
red for several functions. First, the forming apparatus 632a and 632b can be
configured to separate the entrained glass fibers 622 from the flow of the gases. Second, the
forming apparatus 632a and 632b can be red to form a continuous thin and dry web of
fibrous material having a d thickness. Third, the forming apparatus 632a and 632b can
be configured to allow the glass fibers 622 to be ted from the flow of gasses in a
manner that allows the fibers to be oriented within the web with any desired degree of
"randomness”. The term "randomness", as used herein, is defined to mean that the fibers 622,
or portions of the fibers 622, can be nonpreferentially oriented in any of the X, Y or 2
dimensions. In certain instances, it may be desired to have a high degree of randomness. In
other ces, it may be desired to control the randomness of the fibers 622 such that the
fibers 622 are non-randomly oriented, in other words, the fibers are substantially coplanar or
substantially el to each other. Fourth, the forming apparatus 632a and 632b can be
configured to transfer the continuous web of fibrous material to other downstream operations.
In the embodiment illustrated in Figure 7, each of the forming apparatus 632a and
632b include a drum (not shown) configured for rotation. The drum can include any desired
quantity of foraminous surfaces and areas of higher or lower pressure. Alternatively, each of
the forming apparatus 332a and 332b can be formed from other structures, mechanisms and
devices, sufficient to te the ned glass fibers 622 from the flow of the gases, form
a continuous web of fibrous material having a desired thickness and transfer the continuous
web of fibrous material to other downstream operations. In the illustrated embodiment shown
in Figure 7, each of the forming apparatus 632a and 632b are the same. However, in other
embodiments, each ofthe g apparatus 632a and 632b can be different from each other.
Referring again to Figure 7, the continuous web of fibrous material is transferred from
the forming apparatus 632a and 632b to an optional binder applicator 646. The binder
PCTIU82012/058339
applicator 646 is configured to apply a "dry binder" to the continuous web of fibrous
material. The term "dry binder", as used herein, is defined to mean that the binder is
comprised of substantially 100% solids while the binder is being applied. The term
"substantially 100% ", as used , is defined to mean any binder material having
diluents, such as water, in an amount less than or equal to approximately two percent, and
preferably less than or equal to approximately one percent by weight of the binder (while the
binder is being d, rather than after the binder has dried and/or cured). However, it
should be iated that certain embodiments, the binder can include diluents, such as
water, in any amount as desired depending on the specific application and design
requirements. The binder may be configured to thermally set in a curing oven 650. In this
application, the terms “cure” and “thermally set” refer to a chemical reaction and/or one or
more phase changes that cause the dry binder to bind the fibers of the web together. For
e, a thermoset dry binder (or set component of the dry binder) cures or
thermally sets as a result of a chemical reaction that occurs as a result of an application of
heat. A plastic dry binder (or thermoplastic component of the dry binder) cures or
thermally sets as a result of being heated to a softened or melted phase and then cooled to a
solid phase.
In an exemplary embodiment, the dry binder is a thermoplastic resin-based material
that is not d in liquid form and further is not water based. In other embodiments, the
dry binder can be other materials or other combinations of mateiials, including the non-
limiting example of polymeric therrnoset resins. The dry binder can have any form or
combinations of forms including the non-limiting examples of s, particles, fibers
and/or hot melt. es of hot melt polymers include, but are not limited to, ethylenevinyl
acetate copolymer, ethylene-acrylate copolymer, low density polyethylene, high density
polyethylene, atactic polypropylene, polybutene—l, styrene block copolymer, polyamide,
thermoplastic polyurethane, styrene block copolymer, polyester and the like. Sufficient dry
binder is applied such that a cured fibrous pack can be compressed for packaging, storage and
shipping, yet s its thickness — a process known as "loft recovery" - when installed.
Applying the dry binder to the continuous web of s al forms a continuous web,
optionally with unreacted binder.
In the embodiment illustrated by Figures 6 and 7, the binder applicator 646 is a
sprayer configured for dry powders. The sprayer is configured such that the force of the spray
2012/058339
is adjustable, thereby allowing more or less penetration of the dry powder into the continuous
web of fibrous material. Alternatively, the binder applicator 646 can be other structures,
mechanisms or devices or combinations thereof, such as for example a vacuum device,
sufficient to draw a "dry binder" into the continuous web of fibrous material.
While the embodiment illustrated in Figure 7 shows a binder applicator 646
configured to apply a dry binder to the continuous web of fibrous material, it is within the
contemplation of this invention that in certain embodiments no binder will be applied to the
continuous web of fibrous material.
Referring again to Figure 7, the continuous web, optionally with unreacted binder is
erred from the binder applicators 646 to the corresponding cross-lapping mechanism
634a and 634b. As shown in Figure 7, forming apparatus 632a is associated with cross—
lapping mechanism 634a and forming apparatus 632b is associated with cross—lapping
mechanism 634b. The cross-lapping mechanisms 634a and 634b function in ation with
a first conveyor 636. The first conveyor 636 is red to move in a machine ion as
indicated by the arrow D1. The cross—lapping mechanism 634a is configured to receive the
continuous web, optionally with ted , from the optional binder applicators 646
and is fiirther configured to deposit alternating layers of the continuous web, optionally with
unreacted binder, on the first conveyer 636 as the first conveyor 636 moves in machine
direction Dl, thereby forming the initial layers of a fibrous body. In the deposition process,
the cross~lapping mechanism 634a forms the alternating layers in a cross—machine ion
as indicated by the arrows D2. ingly, as the deposited continuous web, optionally with
unreacted , from crosslapping mechanism 634a travels in machine direction D1,
additional layers are deposited on the fibrous body by the downstream cross—lapping
mechanism 634b. The resulting layers of the fibrous body deposited by cross-lapping
mechanisms 634a and 634b form a pack.
In the illustrated embodiment, the cross—lapping mechanisms 634a and 634b are
devices configured to precisely control the nt of the continuous web with ted
binder and deposit the continuous web with unreacted binder on the first conveyor 636 such
that the continuous web, optionally with ted binder, is not damaged. The cross-lapping
mechanisms 634a and 634b can include any desired structure and can be configured to
operate in any desired manner. In one example, the cross-lapping mechanisms 634a and 634b
can e a head (not shown) configured to move back and forth in the cross-machine
direction D2. In this embodiment, the speed of the moving head is nated such that the
movement of the head in both cross-machine directions is substantially the same, thereby
providing uniformity of the resulting layers of the fibrous body. In r example, vertical
conveyors (not shown) configured to be centered with a centerline of the first conveyor 636
can be utilized. The vertical conveyors are further configured to swing from a pivot
ism above the first conveyor 636 such as to deposit the continuous web, optionally
with unreacted binder, on the first conveyor 36. While several examples of cross lapping
mechanisms have been described above, it should be appreciated that the cross-lapping
mechanisms 634a and 634b can be other structures, isms or devices or combinations
thereof.
Referring again to Figure 7, optionally the positioning of the continuous web,
optionally with unreacted binder, on the first conveyor 636 can be accomplished by a
controller (not shown), such as to provide improved unifo ity of the pack. The controller
can be any desired structure, mechanism or device or combinations thereof.
The layered web or pack can have any desired thickness. The ess of the pack is
a function of several variables. First, the thickness of the pack is a function of the thickness of
the continuous web, optionally with unreacted binder, formed by each of the forming
apparatus 632a and 632b. Second, the thickness of the pack is a function of the speed at
which the lapping mechanisms 634a and 634b alternately deposit layers of the
continuous web, optionally with ted binder, on the first conveyer 636. Third, the
thickness of the pack is a function of the speed of the first conveyor 636. In the illustrated
embodiment, the pack has a thickness in a range of from about 0.1 inches to about 20.0
inches. In other embodiments, the pack can have a thickness less than about 0.1 inches or
more than about 20.0 .
As sed above, the cross lapping mechanisms 634a and 634b are configured to
t alternating layers of the continuous web, optionally with unreacted binder, on the first
er 636 as the first conveyor 636 moves in machine direction Dl, thereby forming
layers of a fibrous body. In the illustrated embodiment, the cross lapping ism 634a
and 634b and the first conveyor 636 are coordinated such as to form a fibrous body having a
quantity of layers in a range of from about 1 layer to about 60 layers. In other embodiments,
PCT/U52012/058339
the cross g mechanism 634a and 634b and the first conveyor 636 can be coordinated
such as to form a fibrous body having any desired quantity of , including a fibrous body
having in excess of 60 layers.
Optionally, the cross-lapping mechanisms 634a and 634b can be adjustable, thereby
allowing the cross-lapping mechanisms 634a and 634b to form a pack having any desired
width. In certain embodiments, the pack can have a l width in a range of from about
98.0 inches to about 236.0 . Alternatively, the pack can have a general width less than
about 98.0 inches or more than about 236.0 inches.
While the cross-lapping mechanisms 634a and 634b have been described above as
being jointly involved in the formation of a fibrous body, it should be appreciated that in
other embodiments, the cross-lapping mechanisms 634a and 634b can operate independently
of each other such as to form discrete lanes of fibrous bodies.
ing to Figures 6 and 7, the pack, having the layers formed by the lapping
mechanisms 634a and 634b, is carried by the first conveyor 636 to an optional trim
mechanism 640. The optional trim mechanism 640 is red to trim the edges of the
pack, such as to form a desired width of the pack. In an exemplary embodiment, the pack can
have an after-trimmed width in a range of from about 98.0 inches to about 236.0 inches.
Alternatively, the pack can have an after trimmed width less than about 98.0 inches or more
than about 236.0 inches.
In the illustrated ment, the optional trim mechanism 640 includes a saw
system having a plurality of rotating saws (not shown) positioned on either side of the pack.
atively, the trim mechanism 640 can be other structures, mechanisms or devices or
combinations thereof including the non-limiting examples of water jets, compression knives.
In the illustrated embodiment, the trim mechanism 640 is advantageously positioned
upstream from the curing oven 650. Positioning the trim mechanism 640 upstream from the
curing oven 650 allows the pack to be trimmed before the pack is thermally set in the curing
oven 650. Optionally, materials that are trimmed from the pack by the trim mechanism 640
can be returned to the flow of gasses and glass fibers in the ducts 630 and recycled in the
forming apparatus 632a and 632b. Recycling of the trim materials ageously prevents
potential environmental issues connected with the disposal of the trim materials. As shown in
PCT/U82012/058339
Figure 6, ductwork 642 connects the trim mechanism 640 with the ducts 630 and is
configured to facilitate the return of trim materials to the forming apparatus 632a and 632b,
While the ment shown in Figures 6 and 7 illustrate the recycling of the d
materials, it should be appreciated that the ing of the trimmed materials is optional and
the method of forming the pack from fibrous materials 610 can be ced without recycling
of the d materials. In another exemplary embodiment, the trim mechanism 640 is
positioned downstream from the curing oven 650. This positioning is particularly useful if
the trimmed materials are not recycled. Trimming the pack forms a trimmed pack.
The trimmed pack is conveyed by the first conveyor 636 to a second conveyor 644.
As shown in Figure 6, the second conveyor 644 may be positioned to be "stepped down"
from the first conveyor 636. The term "stepped down", as used herein, is defined to mean the
upper surface of the second conveyor 644 is positioned to be vertically below the upper
surface of the first conveyor 636. The ng down of the conveyors will be discussed in
more detail below.
Referring again to Figures 1 and 2, the trimmed pack is carried by the second
conveyor 644 to an optional lement mechanism 645. The entanglement mechanism
645 is configured to entangle the individual fibers 622 forming the layers of the trimmed
pack. Entangling the glass fibers 622 within the pack ties the pack together. In the
embodiments where dry binder is included, entangling the glass fibers 622 advantageously
allows mechanical properties, such as for example, tensile strength and shear strength, to be
ed. In the illustrated embodiment, the entanglement mechanism 645 is a needling
mechanism. In other embodiments, the entanglement mechanism 645 can include other
ures, mechanisms or devices or combinations thereof, including the non—limiting
example of stitching mechanisms. While the ment shown in Figs. 6 and 7 rate the
use of the entanglement mechanism 645, it should be appreciated that the use of the
entanglement mechanism 645 is optional and the method of forming the pack from fibrous
materials 610 can be practiced without the use of the entanglement mechanism 645.
Entangling the fibers within the pack forms an entangled pack.
The second conveyor 644 conveys the pack with optional dry , that is optionally
trimmed, and/or optionally entangled (hereafter both the trimmed pack and the entangled
pack are simply referred to as the "pack") to a third conveyor 648. When the pack includes a
W0 20132049835 PCT/U52012/058339
dry binder, the third conveyor 648 is configured to carry the pack to an optional curing oven
650. The curing oven 650 is configured to blow a fluid, such as for example, heated air
h the pack such as to cure the dry binder and rigidly bond the glass fibers 622 together
in a generally random, three—dimensional structure. Curing the pack in the curing oven 650
forms a cured pack.
As discussed above, the pack optionally includes a dry . The use of the dry
binder, rather than a traditional wet binder, advantageously allows the curing oven 650 to use
less energy to cure the dry binder within the pack. In the illustrated ment, the use of
the dry binder in the curing oven 650 results in an energy savings in a range of from about
.0% to about 80.0% ed to the energy used by conventional curing ovens to cure wet
or aqueous binder. In still other embodiments, the energy savings can be in excess of 80.0%.
The curing oven 650 can be any desired curing ure, mechanism or device or
combinations thereof.
The third conveyor 648 conveys the cured pack to a fourth conveyor 652. The fourth
conveyor 652 is configured to carry the cured pack to a cutting mechanism 654. Optionally,
the cutting mechanism 654 can be configured for several cutting modes. In a first optional
cutting mode, the cutting mechanism is configured to cut the cured pack in vertical directions
along the e direction Dl such as to form lanes. The formed lanes can have any d
widths. In a second optional cutting mode, the cutting mechanism is configured to bisect the
cured pack in a horizontal direction such as to form continuous packs having thicknesses. The
resulting bisected packs can have any desired thicknesses. Cutting the cured pack forms cut
pack.
In the illustrated embodiment, the cutting mechanism 654 includes a system of saws
and knives. Alternatively, the g mechanism 654 can be other structures, mechanisms or
s or combinations thereof. Referring again to Figures 6 and 7, the cutting mechanism
654 is ageously oned such as to allow the capture of dust and other waste
materials formed during the cutting operation. Optionally, dust and other waste materials
stemming from the cutting mechanism can be returned to the flow of gasses and glass fibers
in the ducts 630 and recycled in the forming apparatus 632a and 6321). Recycling of the dust
and waste materials ageously prevents potential environmental issues connected with
the disposal of the dust and waste materials, As shown in Figures 6 and 7, ductwork 655
WO 2013049835 PCT/U82012/058339
connects the cutting mechanism 654 with the ducts 630 and is configured to facilitate the
return of dust and waste materials to the forming tus 632a and 632b. While the
embodiment shown in s 6 and 7 illustrate the recycling of the dust and waste materials,
it should be appreciated that the recycling of the dust and waste als is optional and the
method of forming the pack from fibrous materials 10 can be practiced without recycling of
the dust and waste materials.
Optionally, prior to the conveyance of the cured pack to the g mechanism 654,
the major surfaces of the cured pack can be faced with facing material or materials by facing
mechanisms 662a, 662b as shown in Figure 6. In the illustrated embodiment, the upper major
e of the cured pack is faced with facing material 663a provided by facing mechanism
662a and the lower major surface of the cured pack is faced with facing material 663b
provided by facing mechanism 662b. The facing materials can be any desired materials
including paper, polymeric materials or non-woven webs. The facing mechanisms 662a and
662b can be any desired structures, isms or devices or combinations f. In the
illustrated ment, the facing materials 663a and 663b are applied to the cured pack (if
the pack includes a ) by adhesives. In other embodiments, the facing materials 663a ‘
and 663b can be applied to the cured pack by other methods, including the non-limiting
example of sonic welding, While the ment shown in Figure 6 illustrates the
application of the facing materials 663a and 663b to the major surfaces of the cured pack, it
should be appreciated that the application of the facing materials 663a and 663b to the major
surfaces of the cured pack is optional and the method of forming the pack from fibrous
materials 610 can be practiced without the application of the facing materials 663a and 663b
to the major surfaces of the cured pack.
Referring to Figures 6 and 7, the fourth conveyor 652 conveys the cut pack to an
optional chopping mechanism 656. The chopping mechanism 656 is configured to section the
cut pack into desired s across the machine direction Dl. In the illustrated embodiment,
the chopping mechanism 656 is configured to section the cut pack as the cut pack
continuously moves in the e direction D1. Alternatively, the chopping mechanism 656
can be configured for batch chopping operation. Sectioning the cut pack into lengths forms a
dimensioned pack. The lengths of the chopped pack can have any desired dimension.
Chopping isms are known in the art and will not be described herein. The
chopping mechanism 656 can be any desired structure, mechanism or device or combinations
thereof.
Optionally, prior to the conveyance of the cut pack to the chopping mechanism 656,
the minor surfaces of the cut pack can be faced with edging material or materials by edging
mechanisms 666a, 666b as shown in Figure 7. The edging materials can be any desired
materials including paper, ric materials or nonwoven webs. The edging mechanisms
666a and 666b can be any desired structures, mechanisms or devices or combinations thereof.
In the illustrated embodiment, the edging materials 667a and 667b are applied to the cut pack
by adhesives. In other embodiments, the edging materials 667a and 667b can be d to
the cut pack by other methods, including the non—limiting example of sonic welding. While
the embodiment shown in Figure 7 illustrate the application of the edging materials 667a and
667b to the minor es of the cut pack, it should be appreciated that the application of the
edging materials 667a and 667b to the minor surfaces of the cut pack is optional and the
method of forming the pack from fibrous materials 610 can be practiced without the
application of the edging materials 667a and 667b to the minor es of the cut pack.
Referring again to Figure 6, the fourth conveyor 652 conveys the dimensioned pack to
a fifth conveyor 658. The fifth conveyor 658 is configured to convey the dimensioned pack to
a packaging mechanism 660. The packaging ism 660 is configured to package the
dimensioned pack for future ions. The term "future operations," as used herein, is
defined to e any activity following the forming of the dimensioned pack, including the
non-limiting examples of e, shipping, sales and installation.
In the rated embodiment, the packaging mechanism 660 is configured to form
the ioned pack into a package in the form of a roll. In other embodiments, the
packaging mechanism 660 can form packages having other desired shapes, such as the non-
limiting examples of slabs, batts and irregularly shaped or die cut pieces. The packaging
mechanism 660 can be any desired structure, ism or device or combinations thereof.
Referring again to Fig. 6, the conveyors 636, 644, 648, 652 and 658 are in a “stepped
down" relationship in the machine direction D1. The "stepped down" relationship means that
the upper surface of the successive conveyor is positioned to be vertically below the upper
PCTflJSZOl2/058339
surface of the preceding conveyor. The "stepped down" relationship of the conveyors
advantageously provides a self-threading feature to the conveyance of the pack. In the
illustrated embodiment, the vertical offset between adjacent conveyors is in a range of from
about 3.0 inches to about 10.0 inches. In other embodiments, the vertical offset between
adjacent conveyors can be less than about 3.0 inches or more than about 10.0 inches.
As illustrated in Figures 6 and 7, the method for forming a pack from fibrous
als 610 eliminates the use of a wet , y eliminating the traditional needs for
washwater and washwatcr related ures, such as forming hoods, return pumps and
. The elimination of the use of water, with the exception of cooling water, and the
application of lubricant, color and other optional chemicals, advantageously allows the
overall size of the manufacturing line (or "footprint") to be significantly reduced as well as
ng the costs of implementation, operating costs and maintenance and repair costs.
As further illustrated in Figures 6 and 7, the method for forming a pack from fibrous
materials 610 advantageously allows the uniform and consistent deposition of long and thin
fibers on the forming apparatus 632a and 632b. In the illustrated ment, the fibers 622
have a length in a range of from about 0.25 inches to about 10.0 inches and a diameter
dimension in a range of from about 9 HT to about 35 HT. In other ments, the fibers 22
have a length in a range of from about 1.0 inch to about 5.0 inches and a diameter dimension
in a range of from about 14 HT to about 25 HT. In still other embodiments, the fibers 22 can
have a length less than about 0.25 inches or more than about 10.0 inches and a diameter
dimension less than about 9 HT or more than about 35 HT. While not being bound by the
theory, it is believed the use of the relatively long and thin fibers advantageously provides a
pack having better thermal and acoustic insulative performance than a similar sized pack
having shorter and thicker fibers.
While the embodiment illustrated in Figures 6 and 7 have been generally described
above to form packs of fibrous materials, it should be understood that the same apparatus can
be configured to form "unbonded loosefill tion". The term "unbonded loosefill
tion", as used herein, is defined to mean any conditioned insulation material configured
for application in an airstream.
While ary embodiments of packs and s for forming a pack from fibrous
materials 610 have been described generally above, it should be appreciated that other
embodiments and variations ofthe method 610 are available and will be generally described
below.
W0 2013l049835 PCT/U82012i058339
Referring to Figure 7 in another embodiment of the method 610, the cross lapping
isms 634a and 634b are configured to provide precise deposition of ating layers
of the uous web on the first conveyer 36, thereby allowing elimination of downstream
trim mechanism 40.
] Referring again to Figure 7 in r embodiment of the method 610, the various
layers of the pack can be ”stratified". The term "stratified", as used herein, is defined to mean
that each of the layers can be configured with different characteristics, including the non-
limiting examples of fiber diameter, fiber length, fiber orientation, density, ess and
glass composition. It is contemplated that the associated mechanisms forming a layer, that is,
the associated fiberizer, forming apparatus and cross lapping mechanism can be configured to
provide a layer having specific and desired characteristics. Accordingly, a pack can be
formed from layers having different characteristics.
In another embodiment, the dry binder can include or be coated with additives to
impart desired characteristics to the pack. One non-limiting example of an additive is a fire
retardant material, such as for example baking soda. r non—limiting example of an
additive is a material that inhibits the ission of ultraviolet light through the pack. Still
another non-limiting example of an additive is a material that ts the transmission of
infrared light through the pack.
Referring to Fig. 6 in another embodiment of the method 610 and as discussed above,
a flow of hot gases can be created by optional blowing mechanisms, such as the non—limiting
examples of annular blowers (not shown) or annular burners (not shown). It is known in the
art to refer to the heat created by the annular blowers and the annular s as the "heat of
fiberization". It is contemplated in this embodiment, that the heat of fiberization is captured
ed for use in other isms or devices. The heat of ation can be captured at
several locations in the method 610. As shown in Figures 6 and 7, duct work 670 is
configured to capture the heat emanating from the fiberizers 618 and convey the heat for use
in other mechanisms, such as for example the optional curing oven 650. Similarly, duct work
672 is configured to capture the heat emanating from the flow of hot gases within the duct 30
and. duct work 674 is configured to capture the heat emanating from the forming apparatus
632a and 632b. The recycled heat can also be used for purposes other than the forming of
fibrous packs, such as for example heating an office
PCT/’U520121058339
In certain embodiments, the duct 630 can include heat capturing devices, such as for
example, heat extraction fixtures configured to e the heat without significantly
interfering with the momentum of the flow of the hot gasses and entrained glass fibers 622. In
other embodiments, any desired structure, device or mechanism sufficient to capture the heat
of fiberization can be used.
Referring to Fig. 6 in another embodiment of the method 610, fibers or other materials
having other desired characteristics can be mixed with glass fibers 622 entrained in the flow
of gasses. In this embodiment, a source 676 of other materials, such as for example, tic
or ceramic fibers, coloring agents and/or particles can be provided to allow such materials to
be introduced into a duct 678.
The duct 678 can be connected to the duct 630 such as to allow mixing with the glass
fibers 622 ned in the flow of gasses. In this manner, the teristics of the resulting
pack can be engineered or tailored for desired properties, such as the nonlimiting examples
ic, thermal enhancing or UV inhibiting characteristics.
In still other embodiments, it is contemplated that other materials can be positioned
between the layers deposited by the cross—lapping mechanisms 634a and 634b on the first
conveyor 636. The other materials can include sheet materials, such as for example, facings,
vapor barriers or netting, or other non-sheet materials including the non-limiting examples of
powders, particles or adhesives. The other materials can be positioned between the layers in
any d manner. In this manner, the characteristics of the resulting pack can be further
engineered or ed as desired.
] While the embodiments shown in Figure 6 illustrates the application of a dry binder
by the binder applicator 646, it should be appreciated that in other embodiments, the dry
binder can be d to the glass fibers 622 entrained in the flow of gasses. In this
embodiment, a source 680 of dry binder can be introduced into a duct 682. The duct 682 can
be connected to the duct 630 such as to allow mixing of the dry binder with the glass fibers
622 entrained in the flow of gasses. The dry binder can be red to attach to the glass
fibers in any desired manner, including by electrostatic processes.
While the embodiment rated in Figure 6 illustrates use of the uous web by
the cross-lapping mechanisms 634a and 634b, it should be appreciated that in other
embodiments, the web can be removed from the forming apparatus 632a and 632b and stored
for later use.
W0 20131049835 PCT/U82012/058339
As discussed above, ally the trimmed als can be can be returned to the
flow of gasses and glass fibers in the ducts 630 and recycled in the forming apparatus 632a
and 632b. In an exemplary embodiment, when an optional binder is included in the pack, the
operating temperature of the forming apparatus 332a and 332b is kept below the softening
temperature of the dry binder, thereby preventing the dry binder from curing prior to the
downstream operation of the curing oven 550. In this ment, the maximum operating
temperature of the curing oven 650 is in a range of from about 165°F to about 180°F. In other
embodiments, the maximum operating ature of the curing oven 650 can be less than
about 165°F or more than about 180°F.
l exemplary embodiments of mineral fiber webs and packs and methods of
producing mineral fiber webs and packs are disclosed by this application. Mineral fiber webs
and packs and methods ofproducing l fiber webs and packs in accordance with the
present invention may include any combination or subcombination of the features disclosed
by the present application.
In accordance with the provisions of the patent statutes, the principles and modes of
the improved methods of forming a pack from fibrous materials have been explained and
illustrated in its red embodiment. However, it must be understood that the improved
method of forming a pack from fibrous materials may be practiced otherwise than as
specifically explained and illustrated without departing from its spirit or scope.
Claims (9)
1. A method for forming a pack of glass fibers comprising: melting glass into molten glass; processing the molten glass to form glass fibers; wherein the glass fibers have a diameter range of in a range of from about 9 HT to about 35 HT; n the glass fibers have a length range from about 0.25 inches to about 10.0 inches; forming a binderless web of the glass fibers; lapping the binderless web of glass fibers to form a layered pack of glass fibers that includes folded edges of the binderless web; and mechanically entangling the glass fibers of the layered pack of glass fibers by needling.
2. The method of claim 1 wherein a single layer of the binderless web of glass fibers has an area weight of about 5 to about 50 grams per square foot and a thickness of about 0.25 inches to about 4 inches.
3. The method of claim 1 wherein the method for forming a pack of glass fibers is a uous method which es between about 750 lbs/hr and 1500 lbs/hr of the pack of glass fibers.
4. A layered web of glass fibers comprising: a first web of glass fibers; at least one additional web of glass fibers disposed on the first web of glass fibers; wherein a first portion of the first web is disposed at a top surface of the pack, and a second portion of the first web is disposed at a bottom surface of the pack; wherein the glass fibers of the first web are mechanically entangled with the glass fibers of the at least one additional web by ng; wherein the first web has an area weight of about 5 to about 50 grams per square foot; wherein the glass fibers of the first web and the at least one onal web have a diameter range of in a range of from about 9 HT to about 35 HT; wherein the glass fibers of the first web and the at least one additional web have a length range from about 0.25 inches to about 10.0 .
5. The layered web of glass fibers of claim 4 wherein the glass fibers used to form the layered web have never been compressed for packaging or shipping.
6. A layered web of glass fibers of claim 4 wherein a dry binder is blended with the glass fibers.
7. The method of claim 1 wherein a first portion of the binderless web is disposed at a top surface of the layered pack, and a second portion of the binderless web is disposed at a bottom surface of the d pack.
8. The method of claim 1 wherein the step of lapping the binderless web of glass fibers ses cross—lapping.
9. A method for forming a pack of glass fibers, substantially as herein described with reference to any one of the
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201161541162P | 2011-09-30 | 2011-09-30 | |
US61/541,162 | 2011-09-30 | ||
PCT/US2012/058339 WO2013049835A2 (en) | 2011-09-30 | 2012-10-01 | Method of forming a web from fibrous materails |
Publications (2)
Publication Number | Publication Date |
---|---|
NZ623187A NZ623187A (en) | 2016-05-27 |
NZ623187B2 true NZ623187B2 (en) | 2016-08-30 |
Family
ID=
Similar Documents
Publication | Publication Date | Title |
---|---|---|
CA2850215C (en) | Method of forming a web from fibrous materials | |
US20140364031A1 (en) | Method of forming a web from fibrous materials | |
US20150247270A1 (en) | Insulation pad for pipes and vessels | |
JP6563895B2 (en) | Method for forming a web from a fibrous material | |
CA2986000C (en) | Insulation pad for pipes and vessels | |
NZ623187B2 (en) | Method of forming a web from fibrous materials | |
JP7345004B2 (en) | Method of forming webs from fibrous materials |