JP6563895B2 - Method for forming a web from a fibrous material - Google Patents

Description

RELATED APPLICATIONS This application claims “Method of Forming a Packing” claiming priority based on US Provisional Patent Application No. 61 / 541,162, filed September 30, 2011 entitled “Method of Forming a Pack from Fibrous Materials”. This is a continuation-in-part of US patent application Ser. No. 13 / 632,895, filed Oct. 1, 2012, entitled “from Fibrous Materials”. US Patent Application No. 13 / 632,895 and US Provisional Patent Application No. 61 / 541,162 are hereby incorporated by reference in their entirety.

  Fibrous materials can be formed into a variety of products including webs, packs, batts and blankets. Fibrous material packs can be used in many applications, including, but not limited to, insulation and sound insulation for buildings, building components, appliances and aircraft. Fibrous material packs are typically formed by a process that includes a fiberizer, a forming hood, a furnace, a trimming and packaging machine. A typical process also includes the use of wet binders, binder recovery water and wash water systems.

US Patent Application Publication No. 2010/0151223 US Pat. No. 6,527,014 US Pat. No. 5,932,499 US Pat. No. 5,523,264 US Pat. No. 5,055,428 U.S. Pat. No. 4,266,960 US Pat. No. 5,603,743 US Pat. No. 4,263,033 International Publication No. 95/30036 US Patent Application Publication No. 2008/0246379 U.S. Pat. No. 3,092,529 International Publication No. 2010/002958 US Pat. No. 7,329,456 US Pat. No. 7,294,218

  The present application discloses a number of exemplary embodiments of a fibrous material web and a method of manufacturing a fibrous material web. A continuous process in which a fibrous material such as glass is melted and formed into fibers can form a binderless web or a web containing a dry binder. The fibers are formed into a binderless glass fiber web or a web containing a dry binder. Binderless webs or webs containing dry binders can be laminated and / or the fibers that make up the web can be mechanically entangled, for example, by needling.

  Other advantages of webs, bats, and methods of manufacturing webs and bats will become apparent to those of ordinary skill in the art upon reading the following detailed description in view of the accompanying drawings.

2 is a flowchart of an exemplary embodiment of a method of forming a glass fiber binderless laminated web or pack. 2 is a flowchart of an exemplary embodiment of a method of forming a glass fiber binderless entangled web. 2 is a flowchart of an exemplary embodiment of a method of forming a binderless lamination of glass fibers and an entangled web or pack. 2 is a flowchart of an exemplary embodiment of a method for forming a laminated web or pack of glass fibers that includes a dry binder. 2 is a flowchart of an exemplary embodiment of a method of forming a glass fiber binderless entangled web comprising a dry binder. 2 is a flow chart of an exemplary embodiment of a method for forming a binderless laminate of glass fibers and a entangled web or pack comprising a dry binder. 2 is a flow chart of an exemplary embodiment of a method for forming a binderless laminate of glass fibers and a entangled web or pack comprising a dry binder. 1 is a schematic illustration of an exemplary apparatus for forming a glass fiber binderless laminated web or pack. 1 is a schematic diagram of an exemplary apparatus for forming a binderless entangled web of glass fibers. 1 is a schematic illustration of an exemplary apparatus for forming a binderless laminate and entangled web or pack of glass fibers. 1 is a schematic illustration of an exemplary apparatus for forming a binderless laminate and entangled web or pack of glass fibers. 1 is a schematic diagram of an exemplary storage configuration. 1 is a schematic diagram of an exemplary shunt configuration. 1 is a schematic view of a forming apparatus for forming a glass fiber web. 1 is a schematic illustration of an exemplary apparatus for forming a glass fiber web or pack comprising a dry binder. 1 is a schematic illustration of an exemplary apparatus for forming a glass fiber web or pack comprising a dry binder. 1 is a schematic illustration of an exemplary apparatus for forming a glass fiber web or pack comprising a dry binder. 1 is a schematic elevational view of a process for forming a pack of fibrous material. FIG. 2 is a schematic plan view of a process for forming a pack from a fibrous material. FIG. 1 is a schematic illustration of an exemplary apparatus for forming a glass fiber web or pack comprising a dry binder. FIG. 9 is a cross-sectional view taken along line 9A-9A of FIG. FIG. 9 is a cross-sectional view taken along line 9A-9A of FIG. 1 is a schematic illustration of an exemplary embodiment of an insulation product. 1 is a schematic illustration of an exemplary embodiment of an insulation product. 1 is a schematic illustration of an exemplary embodiment of an insulation product. 1 is a schematic illustration of an exemplary embodiment of an insulation product. 1 is a schematic illustration of an exemplary embodiment of an insulation product. 1 is a schematic illustration of an exemplary embodiment of an insulation product. 1 is a schematic illustration of an exemplary embodiment of an insulating bat or pack. 1 is a schematic illustration of an exemplary embodiment of an insulating bat or pack. 1 is a schematic illustration of an exemplary embodiment of an insulating bat or pack. 1 is a schematic illustration of a configuration for producing staple fibers. It is a perspective view of a cooking range. It is a perspective view of a cooking range. 1 is a front cross-sectional view illustrating an exemplary embodiment of a fiberglass insulator in a range. FIG. 1 is a front cross-sectional view illustrating an exemplary embodiment of a fiberglass insulator in a range. FIG. FIG. 3 is a side cross-sectional view illustrating an exemplary embodiment of a fiberglass insulator in a range. FIG. 3 is a side cross-sectional view illustrating an exemplary embodiment of a fiberglass insulator in a range. 2 illustrates an exemplary embodiment of a method of manufacturing a compression molded fiberglass product from a binderless or dry binder fiberglass vat. 2 illustrates an exemplary embodiment of a method for manufacturing a compression molded fiberglass product from a binderless or dry binder fiberglass bat. 2 illustrates an exemplary embodiment of a method for manufacturing a compression molded fiberglass product from a binderless or dry binder fiberglass bat. 2 illustrates an exemplary embodiment of a method of manufacturing a vacuum formed fiberglass product from a binderless or dry binder fiberglass vat. 2 illustrates an exemplary embodiment of a method of manufacturing a vacuum formed fiberglass product from a binderless or dry binder fiberglass vat. 2 illustrates an exemplary embodiment of a method of manufacturing a vacuum formed fiberglass product from a binderless or dry binder fiberglass vat.

  The invention will now be described with occasional reference to specific exemplary embodiments of the invention. However, the invention can 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 defined otherwise, 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 description of the present invention and the appended claims, the singular forms “a”, “an”, and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. Has been.

  Unless otherwise indicated, all numbers representing dimensions, such as lengths, widths, heights, etc., as used in the specification and claims are in all cases the term “about”. Should be understood as being modified by Accordingly, unless indicated otherwise, the numerical characteristics set forth in the specification and claims are approximations that can vary depending on the desired characteristics sought to be obtained in the embodiments of the present invention. Although the numerical ranges and parameters describing the broad scope of the present invention are approximate, the numerical values described in the specific examples are reported as accurately as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the error found in their respective measurements.

  The description and drawings disclose an improved method of forming a pack from a fibrous material. In general, an improved continuous process produces the traditional method of applying a wet binder to the spun material without the use of any binder (i.e., the material that binds the fibers together) the fiber bat or pack. Replace with new methods and / or new methods of making fiber vats or packs using dry binders.

  The term “fibrous material” as used herein is defined to mean any material formed by stretching or thinning a molten material. The term “pack” as used herein is defined to mean any product formed by fibrous materials joined together by an adhesive and / or by mechanical entanglement.

  1A and 3A illustrate a first exemplary embodiment of a continuous process or method 100 for forming a pack 300 (see FIG. 3A) from a fibrous material. Dashed line 101 surrounding the steps of method 100 indicates that the method is a continuous method as described in more detail below. Although the method and pack will be described with reference to glass fiber, the method and pack are equally applicable to the manufacture of fibrous products formed from other mineral materials such as rock, slag and basalt, which are non-limiting examples. is there.

  Referring to FIG. 1A, the glass is melted (102). For example, FIG. 3A schematically shows a melting device 314. The melting device 314 can supply the molten glass 312 to the foreground 316. Melting equipment and Fore Haas are known in the art and will not be described here. Molten glass 312 can be formed from a variety of raw materials combined in proportions to provide the desired chemical composition.

  Referring again to FIG. 1A, the molten glass 312 is processed to form glass fibers 322 (104). Molten glass 312 can be processed in a variety of different ways to form fibers 322. For example, in the example shown in FIG. 3A, the molten glass 312 flows from the forehouse 316 to one or more rotary spinning machines 318. The rotary spinning machine 18 receives molten glass 312 and then forms a veil 320 of glass fibers 322. As will be described in more detail later, the glass fibers 322 formed by the rotary spinning machine 318 are long and thin. Thus, any desired spinning machine, rotating or otherwise, sufficient to form long and thin glass fibers 322 can be used. Although the embodiment shown in FIG. 3A shows one rotary spinning machine 318, it should be appreciated that any desired number of rotary spinning machines 318 can be used.

  Long and thin fibers can take a variety of different forms. In an exemplary embodiment, the long thin fibers have a length in the range of about 0.25 inches to about 10.0 inches and a diameter dimension in the range of about 9HT to about 35HT. HT represents 1 / 100,000 inch. In the exemplary embodiment, fiber 322 has a length in the range from about 1.0 inch to about 5.0 inch and a diameter dimension in the range from about 14HT to about 25HT. In the exemplary embodiment, fibers 322 have a length of about 3 inches and an average diameter of about 16-17HT. Without being bound by theory, the use of relatively long and thin fibers results in better heat and sound insulation performance, and higher tensile strength and / or higher adhesion than similarly sized packs with short and thick fibers. It is considered that it provides advantageous strength characteristics such as strength.

  In the exemplary embodiment where the fibers are glass fibers, the term binderless means that the fibrous material, web, and / or pack is 99% or 100% glass only, or 99% or 100% glass. Means including active ingredients. Inert inclusions are any material that does not bond glass fibers together. For example, in the exemplary binderless embodiment 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 material that does not bond the glass fibers together. In an exemplary embodiment, the lubricant can be a silicone compound such as siloxane, dimethylsiloxane and / or silane. The lubricant can also be other materials or combinations of materials such as oils or oil emulsions. The oil or oil emulsion can be a mineral oil or mineral oil emulsion and / or a vegetable oil or vegetable oil emulsion.

  Glass fibers can be coated or partially coated with a lubricant in a variety of different ways. For example, a lubricant can be sprayed onto the glass fiber 322. In an exemplary embodiment, the lubricant is configured to prevent glass fiber 322 from damaging as glass fiber 322 moves through the manufacturing process and contacts various devices as well as other glass fibers. Lubricants can also be useful in reducing dust in the manufacturing process. The application of the optional lubricant can be precisely controlled by any desired structure, mechanism or device.

  Referring to FIG. 1A, a web of fibers 321 is formed 106 that is free of binders or other materials that bind the fibers together. The web 321 can be formed in a variety of different ways. In the example shown in FIG. 3A, the glass fibers 322 are collected by an optional collection member 324. Collection member 324 is shaped and sized to receive glass fiber 322. The collection member 324 is configured to divert the glass fibers 322 into a duct 330 for transfer to a downstream processing station, such as a forming device 332, which forms the web 321. In other embodiments, the glass fibers 322 can be collected on a transport mechanism (not shown) to form a web.

The forming device 332 can be configured to form a continuous dry web 321 of fibrous material having a desired thickness. In one exemplary embodiment, the dry web 321 disclosed in this application has a thickness ranging from about 0.25 inches to about 4 inches, and from about 0.2 lb / ft ³ to about 0.6 lb / It can have a density in the range up to ft ³ . In one exemplary embodiment, the dry web 321 disclosed in this application has a thickness ranging from about 1 inch to about 3 inches, and from about 0.3 lb / ft ³ to about 0.5 lb / ft ^3. Can have a density in the range of up to. In one exemplary embodiment, the dry web 321 disclosed in this application can have a thickness of about 1.5 inches and a density of about 0.4 b / ft ³ . The forming device 332 can take a variety of different forms. Any configuration for forming a glass fiber dry web 321 can be used.

  In one exemplary embodiment, the molding apparatus 332 includes a rotating drum having a molding surface and a higher or lower pressure zone. Referring to FIG. 4, the pressure P1 on the side 460 where the fibers 322 of the forming surface 462 are collected is higher than the pressure P2 on the opposite side 464. This pressure loss ΔP collects the fibers 322 on the forming surface 462 to form a dry web 321. In one exemplary embodiment, the pressure loss ΔP across the forming surface 462 is controlled to be low pressure, producing a low weight per area web. For example, the pressure loss ΔP can be from about 0.5 inch water to 30 inch water. The velocity V of air moving through the forming web resulting in this low pressure drop ΔP can be up to 1,000 feet per minute.

The low area weight web 321 has a weight per area of about 5 to about 50 grams per square foot. Low area weight webs can have the above density and thickness ranges. The low area weight web has a thickness in the range of about 2.5 inches to about 4 inches, a thickness in the range of about 1 inches to about 3 inches, or a thickness of about 1.5 inches. Can do. The low area weight web has a density in the range of about 0.2 lb / ft ³ to about 0.6 lb / ft ³ , a density in the range of about 0.3 lb / ft ³ to about 0.5 lb / ft ³ , Or it can have a density of about 0.4 lb / ft ³ . Referring to FIG. 3A, the dry web 321 emerges from the forming device 332. In one exemplary embodiment, the low area weight web 321 has a measured weight distribution variation per area area coefficient = sigma (1 standard deviation) / average value (average) × 100% = 0% and 40%. Between. In exemplary embodiments, the weight distribution coefficient of variation is less than 30%, less than 20%, or less than 10%. In one exemplary embodiment, the weight distribution coefficient of variation is between 25% and 30%, such as about 28%. In one exemplary embodiment, the weight distribution coefficient of variation is about 28%. The weight distribution variation coefficient is obtained by measuring a plurality of small, for example, 2 inch “× 2” sample area sizes of a large sample, for example, 6 ft × 10 ft, using a light table.

  In the example shown in FIG. 1A, webs 321 or multiple webs are laminated (108). For example, a single web 321 can be folded in the machine direction or cross-wrapped at 90 degrees to the machine direction to form the laminated web 350. In another embodiment, the web can be cut into portions and the portions stacked on top of each other to form a laminated web. In yet another exemplary embodiment, one or more double spinning machines 318 and forming apparatus 332 can be implemented such that two or more webs are manufactured sequentially in parallel. . The parallel webs are then stacked on top of each other to form a laminated web.

  In one exemplary embodiment, the stacking mechanism 332 is a fold or cross fold mechanism that functions in conjunction with the conveyor 336. The conveyor 336 is configured to move in the machine direction indicated by the arrow D1. The fold mechanism or cross fold mechanism is configured to receive the continuous web 321 and deposit alternating layers of continuous web on the first conveyor 336 when the first conveyor is moving in direction D1. . In the deposition process, the folding mechanism 334 will form alternating layers in the machine direction indicated by the arrow D1, or the cross folding mechanism 334 will form alternating layers in the machine crossing direction. Additional webs 321 can be formed and folded or cross-folded with additional fold or cross-fold mechanisms to increase the number of layers and throughput.

  In one exemplary embodiment, the cross fold mechanism is configured to deposit the continuous web on the conveyor 336 with precise control of movement of the continuous web 321 so as not to damage the continuous web. The cross fold mechanism can include any desired structure and can be configured to operate in any desired manner. In one exemplary embodiment, the cross fold mechanism includes a head (not shown) configured to move back and forth at 90 degrees relative to the machine direction D1. In this embodiment, the speed of the movable head is adjusted so that the head motion in both directions of the cross machine direction is substantially the same, thereby providing uniformity of the resulting fibrous body layer. It is supposed to be. In the exemplary embodiment, the cross fold mechanism includes a vertical conveyor (not shown) configured to be centered on the centerline of conveyor 336. The vertical conveyor is further configured to swing by a pivot mechanism above the conveyor 336 to deposit a continuous web on the conveyor 336. Although multiple examples of cross fold mechanisms have been described above, it should be appreciated that the cross fold mechanisms may be other structures, mechanisms or devices or combinations thereof.

  The laminated web 350 can have any desired thickness. The thickness of the laminated web is a function of several variables. First, the thickness of the laminated web 350 is a function of the thickness of the continuous web 321 formed by the forming device 332. Second, the thickness of the laminated web 350 is a function of the rate at which the laminating mechanism 334 deposits the continuous web 321 on the conveyor 336. Third, the thickness of the laminated web 334 is a function of the speed of the conveyor 336. In the illustrated embodiment, the laminated web 350 has a thickness in the range of about 0.1 inches to about 20.0 inches. In an exemplary embodiment, the cross fold feature 334 can form a laminated web 350 having from 1 to 60 layers. Optionally, the cross fold mechanism can be adjustable, thereby allowing the cross fold mechanism 334 to form a pack having any desired width. In certain embodiments, the pack can have an overall width ranging from about 98.0 inches to about 236.0 inches.

  In one exemplary embodiment, the laminated web 350 is manufactured in a continuous process illustrated by the dashed box 101 in FIG. 1A. The fibers produced by the spinning machine 318 are sent directly to the forming device 332 (ie, the fibers are not collected and packaged and then unpacked for use with a remote forming device). . The web 321 is fed directly to the laminator 352 (i.e., the web is formed and rolled up and then not unwound for use in the remote laminator 352). In an exemplary embodiment of a continuous process, each process (forming and laminating in FIG. 1A) is connected to a spinning process so that the fibers from the spinning machine are stored for later use. Rather than being used by other processes. In another exemplary embodiment of a continuous process, the one or more spinning machines 318 may have a greater throughput than is required by the forming device 332 and the laminating device 352. Thus, the fibers need not be continuously fed to the forming device 332 by the spinning machine 318 in order to continue the process. For example, the spinning machine 318 can produce a batch of fibers that are accumulated in the same factory in a continuous process and fed to the forming device 332, which are compressed, shipped, and resumed in a continuous process. It will not be packaged. As another example of a continuous process, the fibers produced by the spinning machine 318 can be alternately distributed to the forming device 332 and to another forming device, or for some other use or product. In another example of a continuous process, a portion of the fiber produced by the spinning machine 318 is continuously diverted to a forming device 332, and the remaining portion of the fiber is directed to another forming device, or some other use or product. Turned around for.

  FIG. 3E shows that in any of the examples shown in FIGS. 3A-3D, fibers 322 can be collected by accumulator 390. Arrow 392 indicates that the fiber 322 is supplied by the accumulator 390 to the forming device 332 in a controlled manner. The fibers 322 can stay in the accumulator 390 for a predetermined time to cool the fibers before being fed to the forming device 332. In one exemplary embodiment, the fibers 322 are fed by the accumulator 390 to the forming device 332 at the same rate that the fibers 322 are fed to the accumulator 390. Therefore, in this exemplary embodiment, the amount of time that the fibers stay and cool in the accumulator is determined by the amount of fibers 322 in the accumulator. In this example, the residence time is a value obtained by dividing the amount of fibers in the accumulator by the speed at which the fibers are supplied to the forming device 332 by the accumulator. In another exemplary embodiment, accumulator 390 can selectively start and stop fiber feeding and / or adjust the rate of fiber feeding.

  FIG. 3F shows that in any of the examples shown in FIGS. 3A-3D, the fibers 322 can be selectively distributed between the forming station 332 and the second forming station 332 ′ by a diverting mechanism 398. . In one exemplary embodiment, the embodiment shown in FIGS. 3A-3D can have both an accumulator 390 and a diversion mechanism 398.

  In one exemplary embodiment, the web 321 is relatively thick and has a low weight per area, yet the continuous process has a high throughput and all the fibers produced by the spinning machine are webs. Used to make. For example, a single layer of web 321 can have a weight per area of about 5 to about 50 grams per square foot. Low area weight webs can have the aforementioned density and thickness ranges. High production volume continuous processes can be produced between about 750 lbs / hr and 1500 lbs / hr, for example at least 900 lbs / hr or at least 1250 lbs / hr. The laminated web 350 can be used for a variety of different applications.

  FIGS. 1B and 3B illustrate a second exemplary embodiment of a method 150 for forming a pack 300 (see FIG. 3B) from a fibrous material without the use of a binder. Dashed line 151 surrounding the steps of method 150 indicates that the method is a continuous method. Referring to FIG. 1B, the glass is melted (102). The glass can be melted as described above with respect to FIG. 3A. The molten glass 312 is processed to form glass fibers 322 (104). Molten glass 312 can be processed as described above with respect to FIG. 3A to form fibers 322. A fiber web 321 is formed 106 that is free of binders or other materials that bind the fibers together. Web 321 may be formed as described above with respect to FIG. 3A.

  Referring to FIG. 1B, the fibers 322 of the web 321 are mechanically entangled (202) to form an entangled web 352 (see FIG. 3B). Referring to FIG. 3B, the fibers of the web 321 can be mechanically entangled by an entanglement mechanism 345 such as a needling device. The entanglement mechanism 345 is configured to entangle individual fibers 322 of the web 321. By intertwining the glass fibers, the fibers of the web are bound together. Entanglement improves mechanical properties such as web tensile and shear strength. 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, including a non-limiting example stitching mechanism.

  The entangled web 352 can have any desired thickness. The thickness of the entangled web is a function of the thickness of the continuous web 321 formed by the forming device 332 and the amount of compression of the continuous web 321 by the entanglement mechanism 345. In the exemplary embodiment, entangled web 352 has a thickness in the range of about 0.1 inches to about 2.0 inches. In the exemplary embodiment, entangled web 352 has a thickness ranging from about 0.5 inches to about 1.75 inches. For example, in one exemplary embodiment, the thickness of the entangled web is about 1/2 ".

  In one exemplary embodiment, the entangled web 352 is manufactured in a continuous process 151. The fibers produced by the spinning machine 318 are sent directly to the forming device 332 (ie, the fibers are collected and packaged and then not unpacked for use in a remote forming device). . The web 321 is fed directly to the entanglement device 345 (i.e., the web is formed and rolled up and then not unwound for use in the remote entanglement device 345). The entangled web 352 can be used for a variety of different applications. In an exemplary embodiment of a continuous process, each process (molding and entanglement in FIG. 1B) is connected to a spinning process so that the fibers from the spinning machine are stored for later use. Without being used by other processes. In another exemplary embodiment of a continuous process, the one or more spinning machines 318 may have a greater processing capacity than required by the forming device 332 and / or the entanglement device 345. Therefore, the fibers need not be continuously fed by the spinning machine 318 to the forming device 332 in order to continue the process. For example, the spinning machine 318 can produce a batch of fibers that are accumulated in the same factory in a continuous process and fed to the forming device 332, which are compressed, shipped, and resumed in a continuous process. It will not be packaged. As another example of a continuous process, the fibers produced by the spinning machine 318 can be alternately distributed to the forming device 332 and to another forming device, or for some other use or product. In another example of a continuous process, a portion of the fiber produced by the spinning machine 318 is continuously diverted to a forming device 332, and the remaining portion of the fiber is directed to another forming device, or some other use or product. It is turned around for.

  FIG. 3D shows an exemplary embodiment of an apparatus similar to the embodiment shown in FIG. 3B for forming a single layer high density pack. For example, the embodiment shown in FIG. 3D can produce a pack 300 that is denser than the highest density pack produced by the embodiment shown in FIG. 3B. The apparatus of FIG. 3D corresponds to the embodiment of FIG. 3B, but in that a compression mechanism 375 is provided between the molding station 332 and the entanglement mechanism 345 and / or the entanglement mechanism 345 includes a compression mechanism. Different. The compression mechanism 375 compresses the web 321 as indicated by arrow 377 before the web 321 is sent to the entanglement mechanism 345 and / or the web 321 is compressed at the inlet of the compression mechanism. The entangled web 352 that is formed has a high density. The compression mechanism can take a variety of different forms. Examples of the compression mechanism 345 include, but are not limited to, a roller, a belt, a rotating tacker, an additional needling mechanism, and a perforated belt that applies negative pressure to the side of the belt opposite the entanglement web 352 (see FIG. 4), any mechanism that includes any combination of the listed compression mechanisms, any mechanism that includes any combination of any of the listed compression mechanisms, and the like. Any configuration for compressing the web can be used. When the entanglement mechanism 345 includes a compression mechanism, the compression mechanism 375 can be omitted in the embodiment of the single layer high density pack 300 shown in FIG. 3D. The compression performed by compression mechanism 375 and / or entanglement mechanism 345 can be any combination of compression and / or needling, which compresses the pack in addition to entanglement of the fibers. Examples of compression and needling arrangements for producing high density packs include, but are not limited to, roller compression and subsequent needling, two-time needling, roller compression and two-time needling. 3 times needling, preliminary needling-needling from above-needling from below, preliminary needling-needling from below-needling from above, compression by rollers-needling from above-below And needling from the bottom-needling from below-needling from above.

The high density entangled web 352 of FIG. 3D can have any desired thickness. The thickness of the entangled web is a function of the thickness of the continuous web 321 formed by the forming device 332 and the amount of compression of the continuous web 321 by the compression mechanism 375 and the entanglement mechanism 345. In the exemplary embodiment, the dense entangled web 352 of FIG. 3D has a thickness in the range of about 0.1 inches to about 5 inches. In the exemplary embodiment, the high density entangled web 352 has a thickness ranging from about 0.250 inches to about 3.0 inches. In an exemplary embodiment, the high density entangled web has a density in the range of 0.4 lb / ft ³ to about 12 lb / ft ³ . In one exemplary embodiment, the dense entangled web 352 of FIG. 3D is manufactured in a continuous process in the same manner as described with respect to FIG. 3B.

  1C and 3C illustrate another exemplary embodiment of a method 170 for forming a pack 370 (see FIG. 3C) from a fibrous material without the use of a binder. Referring to FIG. 1C, the glass is melted (102). Dashed line 171 surrounding the steps of method 170 indicates that this method is a continuous method. The glass can be melted as described above with respect to FIG. 3A. Referring again to FIG. 1C, the molten glass 312 is processed to form glass fibers 322 (104). Molten glass 312 can be processed as described above with respect to FIG. 3A to form fibers 322. Referring to FIG. 1C, a web of fibers 321 is formed that is free of binders or other materials that bind the fibers together (106). Web 321 may be formed as described above with respect to FIG. 3A. Referring to FIG. 1C, a web 321 or multiple webs are laminated (108). The webs 321 or multiple webs can be laminated as described above with respect to FIG. 3A. Referring to FIG. 1C, the fibers 322 of the laminated web 350 are mechanically intertwined (302) to form an intertwined pack 370 of the laminated web.

  Referring to FIG. 3C, the fibers of the laminated web 350 can be mechanically entangled by an entanglement mechanism 345 such as a needling device. The entanglement mechanism 345 is configured to entangle the individual fibers 322 that form the layers of the laminated web. By intertwining the glass fibers 322, the fibers of the laminated web 350 are bound to each other to form a pack. Mechanical entanglement improves mechanical properties such as tensile strength and shear strength. 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, including, as a non-limiting example, a stitching mechanism.

  The intertwined pack 370 of the laminated web 350 can have any desired thickness. The thickness of the entangled pack is a function of several variables. First, the thickness of the entangled pack is a function of the thickness of the continuous web 321 formed by the forming device 332. Second, the thickness of the intertwined pack 370 is a function of the speed at which the fold or cross fold mechanism 334 deposits a layer of continuous web 321 on the conveyor 336. Third, the thickness of the intertwined pack 370 is a function of the speed of the conveyor 336. Fourth, the thickness of the entanglement pack 370 is a function of the amount of compression of the laminated web 350 by the entanglement mechanism 345. Entanglement pack 370 can have a thickness ranging from about 0.1 inches to about 20.0 inches. In an exemplary embodiment, the entanglement pack 370 can have from 1 layer to 60 layers. Each entangled web layer 352 can be 0.1 to 2 inches thick. For example, each entangled web layer can be about 0.5 inches thick.

  In one exemplary embodiment, the intertwined pack 370 is manufactured in a continuous process. The fibers produced by the spinning machine 318 are sent directly to the forming device 332 (ie, the fibers are not collected and packaged and then unpacked for use with a remote forming device). . The web 321 is fed directly to the laminator 352 (i.e., the web is formed and rolled up and then not unwound for use in the remote laminator 352). The laminated web 350 is fed directly to the entanglement device 345 (i.e., the laminated web is formed and rolled up and then not unwound for use in the remote entanglement device 345). In an exemplary embodiment of a continuous process, each process (forming, laminating and entanglement in FIG. 1C) is connected to a spinning process so that the fibers from the spinning machine are stored for later use. Without being used by other processes. In another exemplary embodiment of a continuous process, the one or more spinning machines 318 may have greater throughput than is required by the forming device 332, the laminating device 352, and / or the entanglement device. . Thus, the fibers need not be continuously fed to the forming device 332 by the spinning machine 318 in order to continue the process. For example, the spinning machine 318 can produce a batch of fibers that are accumulated in the same factory in a continuous process and fed to the forming device 332, which are compressed, shipped, and resumed in a continuous process. It will not be packaged. As another example of a continuous process, the fibers produced by the spinning machine 318 can be alternately distributed to the forming device 332 and to another forming device, or for some other use or product. In another example of a continuous process, a portion of the fiber produced by the spinning machine 318 is continuously diverted to the forming device 332 and the remaining portion of the fiber is directed to another forming device or to some other use or product. It is turned around for.

  In an exemplary embodiment, the laminated web entanglement pack 370 is made from a web 321 or multiple webs that are relatively thick and have a low weight per area, yet a continuous process has a high throughput. All fibers produced by the spinning machine are used to make entangled packs. For example, a single layer of web 321 can have the weight, thickness, and density per area described above. High production rate continuous processes can produce between about 750 lbs / hr and 1500 lbs / hr, for example at least 900 lbs / hr or at least 1250 lbs / hr. In the exemplary embodiment, a combination of high web throughput in a continuous process and mechanical entanglement such as needling is facilitated by lamination of webs 321 such as web folds or cross folds. By laminating the web 321, the linear velocity of the material moving through the laminator is slower than the rate at which the web is formed. For example, in a continuous process, a two-layer web will move through the entanglement device 345 at a speed that is half the speed at which the web is formed (1/3 for a three-layer, etc.). This reduction in speed allows a continuous process in which a high throughput and low weight per area web 321 is formed and converted into a multi-layer mechanically entangled pack 370. The laminated web entanglement pack 370 can be used for a variety of different applications.

  In the exemplary embodiment, the lamination and entanglement of long and thin fibers results in a strong web 370. For example, the entanglement of long and thin glass fibers described in this application results in a laminated entangled web having high tensile strength and high adhesive strength. The tensile strength is the strength of the web 370 when the web 370 is pulled in the direction of the length or width of the web. The adhesive strength is the strength of the web when the web 370 is pulled away in the thickness direction of the web.

  Tensile strength and adhesive strength can be tested in a variety of different ways. In one exemplary embodiment, a machine such as an Instron machine pulls the web 370 at a constant speed (12 inches per second in the examples described below) and measures the amount of force required to pull the web apart. To do. The force required to pull the web apart is recorded, including the peak force applied to the web before the web is torn or damaged.

  In one method of testing the tensile strength, the longitudinal tensile strength is determined by fixing the edge of the web along the width of the web and the web 370 by a machine along the length of the web at a constant speed (shown below). The example is measured by pulling at 12 inches per second) and recording the peak force applied along the length of the web. The tensile strength in the width direction is determined by fixing the sides of the web along the width of the web, pulling the web 370 along the width of the web at a constant speed (12 inches per second in the example shown below) It is measured by recording. An average of the tensile strength in the length direction and the tensile strength in the width direction is taken to determine the tensile strength of the sample.

  In one method of testing bond strength, a sample of a predetermined size (6 ″ × 6 ″ in the example shown below) is prepared. Each side surface of the sample is adhered to the substrate by, for example, gluing. The substrates on both sides of the sample are pulled apart by a machine at a constant speed (12 inches per second in the example shown below), and the applied peak force is recorded. Dividing the applied peak force by the area of the sample (6 ″ × 6 ″ in the example shown below) gives the bond strength in units of force / area.

  The following example is presented to show the increase in strength of the layered entangled web 370. In these examples, no binder is included. That is, neither an aqueous binder nor a dry binder is included. These examples do not limit the scope of the invention unless explicitly stated in the claims. Examples of layered entangled webs with 4, 6 and 8 layers are presented. However, the layered entangled web 370 can be provided with any number of layers. The length, width, thickness, number of folds, and weight of the layered entangled web 370 sample can vary depending on the application of the web 370. In the dense single layer embodiment shown in FIG. 3D, the single layer high density pack 300 has a weight per square foot that is higher, eg, twice or more, than the same thickness example in the following six paragraphs. Can have.

  In one exemplary embodiment, a 6 inch by 12 inch sample of web 370 has multiple layers, eg, two folds (ie, 4 layers), 0.5 inch thick and 2.0 inch thick. Having a weight per square foot between 0.1 lbs / sqft and 0.3 lbs / sqft, having a tensile strength greater than 3 lbf and greater than 40 lbf / lbm, for example from about 40 to about 120 lbf / Has a tensile strength to weight ratio of lbm. In an exemplary embodiment, the adhesion strength of this sample is greater than 0.1 lbs / square ft. In an exemplary embodiment, the tensile strength of the samples described in this paragraph is greater than 5 lbf. 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 samples described 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 exemplary embodiment, the tensile strength of the sample described in this paragraph is between 3 lbf and 15 lbf. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 2 lbs / sqft. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 5 lbs / sqft. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 10 lbs / sqft. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 15 lbs / sqft. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 20 lbs / sqft. In an exemplary embodiment, the sample described in this paragraph has a tensile strength greater than 5 lbf and an adhesive strength greater than 2 lbs / sqft. In an exemplary embodiment, the sample described in this paragraph has a tensile strength greater than 7.5 lbf and an adhesive strength greater than 7.5 lbs / sqft. In an exemplary embodiment, the tensile strength of the samples described in this paragraph is greater than 10 lbf and the bond strength is greater than 10 lbs / sqft. In an exemplary embodiment, the sample described in this paragraph has a tensile strength greater than 12.5 lbf and an adhesive strength greater than 15 lbs / sqft. In an exemplary embodiment, the tensile strength of the samples described in this paragraph is greater than 13.75 lbf and the bond strength is greater than 20 lbs / sqft. In an exemplary embodiment, the tensile strength of the sample described in this paragraph is between 3 lbf and 15 lbf, and the bond strength is between 0.3 lbs / sqft and 30 lbs / sqft.

  In one exemplary embodiment, a 6 inch by 12 inch sample of web 370 has multiple layers, eg, two folds (ie, 4 layers), 0.5 inch thick and 1.75 inch thick. Having a weight per square foot between 0.12 lbs / sqft and 0.27 lbs / sqft, having a tensile strength greater than 3 lbf and greater than 40 lbf / lbm, for example from about 40 to about 120 lbf / lbm Has a tensile strength to weight ratio of as well as an adhesive strength greater than 1 lb / sqft. In an exemplary embodiment, the tensile strength of the samples described in this paragraph is greater than 5 lbf. 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 samples described 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 exemplary embodiment, the tensile strength of the sample described in this paragraph is between 3 lbf and 15 lbf. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 2 lbs / sqft. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 5 lbs / sqft. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 10 lbs / sqft. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 15 lbs / sqft. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 20 lbs / sqft. In an exemplary embodiment, the sample described in this paragraph has a tensile strength greater than 5 lbf and an adhesive strength greater than 2 lbs / sqft. In an exemplary embodiment, the sample described in this paragraph has a tensile strength greater than 7.5 lbf and an adhesive strength greater than 7.5 lbs / sqft. In an exemplary embodiment, the tensile strength of the samples described in this paragraph is greater than 10 lbf and the bond strength is greater than 10 lbs / sqft. In an exemplary embodiment, the sample described in this paragraph has a tensile strength greater than 12.5 lbf and an adhesive strength greater than 15 lbs / sqft. In an exemplary embodiment, the tensile strength of the samples described in this paragraph is greater than 13.75 lbf and the bond strength is greater than 20 lbs / sqft. In an exemplary embodiment, the tensile strength of the samples described in this paragraph is between 3 lbf and 15 lbf, and the bond strength is between 0.3 lbs / sqft and 30 lbs / sqft.

  In one exemplary embodiment, a 6 inch by 12 inch sample of web 370 has multiple layers, eg, two folds (ie, 4 layers), 0.5 inch thick and 1.25 inch thick. With a weight per square foot between 0.2 lbs / sqft and 0.3 lbs / sqft, with a tensile strength greater than 10 lbf, greater than 75 lbf / lbm, for example from about 75 to about 120 lbf / lbm Having a ratio of tensile strength to weight. 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 exemplary embodiment, the tensile strength of the sample described in this paragraph is between 3 lbf and 15 lbf. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 3 lbs / sqft. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 10 lbs / sqft. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 15 lbs / sqft. In an exemplary embodiment, the sample described in this paragraph has a tensile strength greater than 10 lbf and an adhesive strength greater than 3 lbs / sqft. In an exemplary embodiment, the tensile strength of the samples described in this paragraph is greater than 12.5 lbf and the bond strength is greater than 10 lbs / sqft. In an exemplary embodiment, the tensile strength of the samples described in this paragraph is greater than 13.75 lbf and the bond strength is greater than 15 lbs / sqft.

  In an exemplary embodiment, a 6 inch × 12 inch sample of web 370 has multiple layers, eg, 3 folds (ie, 6 layers), between 1.0 inch thickness and 2.25 inch thickness. Yes, having a weight per square foot between 0.15 lbs / sqft and 0.4 lbs / sqft, having a tensile strength greater than 5 lbf, greater than 40 lbf / lbm, for example, a tensile strength of about 40 to about 140 lbf / lbm Has a weight to weight ratio. In an exemplary embodiment, the adhesion strength of this sample is greater than 0.1 lbs / sqft. 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 samples described 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 exemplary embodiment, the tensile strength of the sample described in this paragraph is between 5 lbf and 20 lbf. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 0.5 lbs / sqft. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 1.0 lbs / sqft. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 1.5 lbs / sqft. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 2.0 lbs / sqft. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 2.5 lbs / sqft. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 3.0 lbs / sqft. In an exemplary embodiment, the sample described in this paragraph has a tensile strength greater than 7.5 lbf and an adhesive strength greater than 0.40 lbs / sqft. In an exemplary embodiment, the sample described in this paragraph has a tensile strength greater than 10 lbf and an adhesive strength greater than 0.6 lbs / sqft. In an exemplary embodiment, the sample described in this paragraph has a tensile strength greater than 12.5 lbf and an adhesive strength greater than 0.9 lbs / sqft. In an exemplary embodiment, the tensile strength of the sample described in this paragraph is between 5 lbf and 20 lbf, and the bond strength is between 0.1 lbs / sqft and 4 lbs / sqft.

  In one exemplary embodiment, a 6 inch by 12 inch sample of web 370 has multiple layers, eg, 3 folds (ie, 6 layers), 1.0 inch thickness and 1.50 inch thickness. Having a weight per square foot between 0.25 lbs / sqft and 0.4 lbs / sqft, having a tensile strength greater than 9 lbf and greater than 50 lbf / lbm, for example from about 50 to about 140 lbf / lbm Having a ratio of tensile strength to weight. 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 exemplary embodiment, the tensile strength of the sample described in this paragraph is between 9 lbf and 15 lbf. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 0.5 lbs / sqft. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 1.0 lbs / sqft. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 1.5 lbs / sqft. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 2.0 lbs / sqft. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 2.5 lbs / sqft. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 3.0 lbs / sqft. In an exemplary embodiment, the sample described in this paragraph has a tensile strength greater than 9 lbf and an adhesive strength greater than 0.5 lbs / sqft. In an exemplary embodiment, the sample described in this paragraph has a tensile strength greater than 12.5 lbf and an adhesive strength greater than 1.0 lbs / sqft. In an exemplary embodiment, the sample described in this paragraph has a tensile strength greater than 13.75 lbf and an adhesive strength greater than 2 lbs / sqft.

  In one exemplary embodiment, a 6 inch by 12 inch sample of web 370 has multiple layers, eg, 4 folds (ie, 8 layers), 0.875 inch thickness and 2.0 inch thickness. Having a weight per square foot between 0.15 lbs / sqft and 0.4 lbs / sqft, having a tensile strength greater than 3 lbf and greater than 40 lbf / lbm, for example from about 40 to about 130 lbf / lbm Having a ratio of tensile strength to weight. In an exemplary embodiment, the web has an adhesive strength greater than 0.3 lbs / sqft. In an exemplary embodiment, the adhesion strength of this sample is greater than 0.1 lbs / sqft. 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 samples described in this paragraph is greater than 10 lbf. In an exemplary embodiment, the tensile strength of the sample described in this paragraph is between 3 lbf and 15 lbf. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 0.5 lbs / sqft. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 1.0 lbs / sqft. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 2 lbs / sqft. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 3 lbs / sqft. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 4 lbs / sqft. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 5 lbs / sqft. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 10 lbs / sqft. In an exemplary embodiment, the tensile strength of the samples described in this paragraph is greater than 7.5 lbf and the bond strength is. Greater than 5 lbs / sqft. In an exemplary embodiment, the sample described in this paragraph has a tensile strength greater than 10 lbf and an adhesive strength greater than 1.0 lbs / sqft. In one exemplary embodiment, the sample described in this paragraph has a tensile strength between 3 lbf and 15 lbf and an adhesive strength between 0.3 lbs / sqft and 15 lbs / sqft.

  In an exemplary embodiment, a 6 inch by 12 inch sample of web 370 has multiple layers, eg, 4 folds (ie, 8 layers), between 1.0 and 2.0 inches thick. Having a weight per square foot between 0.1 lbs / sqft and 0.3 lbs / sqft, having a tensile strength greater than 9 lbf and a tensile strength to weight ratio greater than 70 lbf / lbm. In an exemplary embodiment, the tensile strength of the samples described in this paragraph is greater than 10 lbf. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 0.5 lbs / sqft. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 1.0 lbs / sqft. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 2 lbs / sqft. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 3 lbs / sqft. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 4 lbs / sqft. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 5 lbs / sqft. In an exemplary embodiment, the adhesion strength of the samples described in this paragraph is greater than 10 lbs / sqft. In an exemplary embodiment, the sample described in this paragraph has a tensile strength greater than 10 lbf and an adhesive strength greater than 5 lbs / sqft.

  In an exemplary embodiment, the entangled web produced by FIGS. 1A-1C and 3A-3C has combined physical properties in the ranges shown in Table 1 below.

  Patent Document 1, and / or Patent Document 2, Patent Document 3, Patent Document 4, and Patent Document 5 are incorporated herein by reference in their entirety. In one exemplary embodiment, the fiber diameter and fiber length identified in this application are those provided by a spinning machine or other spinning machine, but have not been otherwise processed after fiber formation. Relevant to the majority of fibers in a group of fibers. In another exemplary embodiment, the fiber diameters and lengths identified in this application are those provided by a spinning machine or other spinning machine, but have not been otherwise processed after fiber formation. It relates to a group of fibers, where a small number or any number of fibers have their fiber diameter and / or fiber length.

  2A-2C are similar to the embodiment of FIGS. 1A-1C, except that the web 521 (see FIG. 5) is formed using a dry or non-aqueous binder (260). Indicates. The method 200 of FIG. 2A generally corresponds to the method 100 of FIG. 1A. The method 250 of FIG. 2B generally corresponds to the method 150 of FIG. 1B. The method 270 of FIG. 2C generally corresponds to the method 170 of FIG. 1C.

  FIG. 2D shows a method 290 similar to the method 270 of FIG. 2C. In FIG. 2D, the steps in the dashed box are optional. In the exemplary embodiment shown in FIG. 2D, a dry binder is optionally added to the web at step 292 and / or to the laminated web at step 294 instead of (or in addition to) before the web is formed. can do. For example, if step 292 is included, the web can be formed without a dry binder, and then the dry binder is added to the web before and / or during lamination. If step 294 is included, the web can be formed and laminated without a dry binder, and then the dry binder is added to the laminated web.

  Referring to FIG. 5, a dry binder (indicated by large arrows) can be added to the fibers 322 and / or the web 521 at various different points in the process. Arrow 525 indicates that a dry binder can be added to the fibers 322 at or above the collection member. Arrow 527 indicates that a dry binder can be added to fiber 322 in duct 330. Arrow 529 indicates that a dry binder can be added to the fibers 322 in the forming device 332. Arrow 531 indicates that a dry binder can be added to the web after the web 321 exits the forming device 332. Arrow 533 indicates that a dry binder can be added to the web as the web 321 is laminated by the laminator 334. Arrow 535 indicates that a dry binder can be added to the web after the web 321 has been laminated. Arrow 537 indicates that a dry binder can be added to web 321 or laminated web in furnace 550. Referring to FIG. 8, arrow 827 indicates that a dry binder can be added to fiber 322 in duct 330 at a location near the spinning machine. Arrow 829 indicates that a dry binder can be added to the fibers 322 in the elbow of the duct within the duct 330. Arrow 831 indicates that a dry binder can be added to the fiber in duct 330 at the outlet end of the duct. Arrow 833 indicates that a dry binder can be added to the fibers 322 in a molding apparatus 332 having a drum-shaped molding surface. A dry binder can be added to the fibers 322 or the web 321 by any method to form the web 521 having a dry binder.

  FIG. 5A is similar to the embodiment of FIG. 5 except that fibers 322 are collected by accumulator 590. Arrow 592 indicates that the fiber 322 is supplied by the accumulator 590 to the forming device 332 in a controlled manner. The fibers 322 can stay in the accumulator 590 for a predetermined time to cool the fibers before being fed to the forming device 332. In one exemplary embodiment, the fibers 322 are fed to the forming device 322 by the accumulator 590 at the same rate that the fibers 322 are fed to the accumulator 590. Therefore, in this exemplary embodiment, the amount of time that the fibers stay and cool in the accumulator is determined by the amount of fibers 322 in the accumulator. In this example, the residence time is a value obtained by dividing the amount of fibers in the accumulator by the speed at which the fibers are supplied to the forming device 332 by the accumulator. In another exemplary embodiment, accumulator 390 can selectively start and stop fiber feeding and / or adjust the rate of fiber feeding. The dry binder can be added to the fiber 322 at any position shown in FIG. Further, the dry binder may be applied to the fibers 322 in the accumulator as indicated by arrow 594 and / or as the fibers are transferred from the accumulator 590 to the forming device 332 as indicated by arrow 596. it can.

  FIG. 5B is similar to the embodiment of FIG. 5 except that the fibers 322 are selectively selected by the diverter 598 between the forming device 332 and the second forming device and / or for some other use. It is embodiment which can be distributed to. In one exemplary embodiment, the embodiment shown in FIG. 5 can have both an accumulator 590 and a diversion mechanism 598. The dry binder can be applied to the fiber 322 at any position shown in FIG. Further, the dry binder is applied to the fibers 322 in the flow dividing mechanism as indicated by the arrow 595 and / or when the fibers are transferred from the flow dividing mechanism 598 to the forming device 332 as indicated by the arrow 597. Can do.

  In the exemplary embodiment, a dry binder is applied to the fibers 322 at a location far away from the spinning machine 318. For example, the dry binder can be applied to the fiber at a location where the temperature of the fiber and / or the temperature of the air around the fiber is significantly lower than the temperature of the fiber and the ambient air in the spinning machine. In one exemplary embodiment, the dry binder is at a location where the temperature of the fiber and / or the temperature of the air surrounding the fiber is lower than the temperature at which the dry binder melts or the temperature at which the dry binder fully cures or reacts, Is granted. For example, the thermoplastic binder can be applied at a point in the production line where the temperature of the fiber 322 and / or the temperature of the air surrounding the fiber is lower than the melting point of the thermoplastic binder. The thermosetting binder can be applied at a point in the production line where the temperature of the fiber 322 and / or the temperature of the air surrounding the fiber is lower than the curing temperature of the thermosetting binder. That is, the thermosetting binder is such that the temperature of the fiber 322 and / or the temperature of the air surrounding the fiber is lower than the temperature at which the thermosetting binder reacts sufficiently or complete crosslinking of the thermosetting binder occurs. Can be granted at a point. In one exemplary embodiment, the dry binder can be applied at a point in the production line where the temperature of the fibers 322 and / or the temperature of the air surrounding the fibers is below 300 ° F. In one exemplary embodiment, the dry binder can be applied at a point in the production line where the temperature of the fiber 322 and / or the temperature of the air surrounding the fiber is below 250 ° F. In one exemplary embodiment, the temperature of the fiber and / or the temperature of the air around the fiber at the positions indicated by arrows 527, 529, 531, 533, and 535 in FIG. 5 is such that the dry binder melts or Below the full cure temperature.

  In one exemplary embodiment, the binder applicator is a nebulizer configured for dry powder. The sprayer is configured such that the spray force 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 a vacuum device sufficient to draw the dry binder into the continuous web 321 of glass fiber. . For example, a dry binder can include binder fibers supplied in a bale form. The binder applicator includes a bale opener and a blower that opens the bale pack, separates the binder fibers from each other, and blows the binder fibers into the duct where the binder is mixed with the fiberglass fibers. The dry binder can include a powder. The binder applicator can include a screw dispenser that delivers the binder powder to an air nozzle, which delivers the binder powder into a duct where the binder powder is mixed with the fibers. The dry binder can include a non-aqueous liquid. The binder applicator can include a nozzle that delivers a liquid binder into the duct, where the binder is mixed with the fibers.

  9, 9A and 9B illustrate an exemplary embodiment in which a binder 900, such as a fiber or powder form, a fiber form, or a non-aqueous liquid form, is provided by a modified air wrapper 902. FIG. Air wrappers are well known in the art. Examples of air wrappers are disclosed in U.S. Patent Nos. 6,099,086, 5,637, and 5,086, the entirety of which are hereby incorporated by reference. Any feature of the air wrapper disclosed in Patent Literature 6, Patent Literature 7, Patent Literature 8 and Patent Literature 9 can be used in the air wrapper 902 schematically shown in this patent application. One existing type of air wrapper is air-full. • Air Full Veil Wrapper (AFVL). The air wrapper 902 shown in FIGS. 9, 9A and 9B differs from a conventional air wrapper in that the air wrapper is configured to apply a binder 900.

  FIG. 8 shows a rotary spinning machine 318, an optional collection member 324, a duct 330, and a forming device 332. The apparatus shown in FIG. 8 typically also includes a melting apparatus 314 and a forehouse 316 shown in FIG. The melter 314, fore Haas, and other components shown in FIG. 5 are omitted in FIG. 8 for the sake of simplicity.

  Referring to FIG. 8, the forming device 332 can be configured to form a continuous web 321 of fibrous material having a desired thickness. The forming device 332 can take a variety of different forms. Any configuration for forming the glass fiber web 321 can be used. In the exemplary embodiment shown in FIG. 8, the molding apparatus 332 includes a rotating drum 910 having a molding surface 462 and a higher or lower pressure zone. The collection of fibers using the pressure drop ΔP across the surface 462 is as described with respect to FIG.

  Referring to FIGS. 9A and 9B, the air wrapper 902 includes a first blower 920 and a second blower 922. The air wrapper operates by blowing air, for example, by alternately blowing air by the first and second blowers 920 and 922. The blower 920 provides an air flow against the fibers moving in the duct toward the molding surface 462, while the blower 922 does not provide an air flow (see FIGS. 9A and 9B). After a controlled time, the blower 922 provides an air flow against the fibers moving in the duct toward the forming surface 462, while the blower 920 does not provide an air flow. This alternating motion by the first and second blowers 920, 922 results in a uniform distribution of the fibers 322 collected on the forming surface 462.

  The air wrapper 902 shown in FIGS. 9, 9A and 9B differs from a conventional air wrapper in that each of the blowers 920, 922 includes one or more binder introduction devices 904. The binder introduction device 904 can take a variety of different forms. For example, the binder introduction device 904 can supply the binder 900 to the interior 930 of the housing 932 of the blowers 920, 922 as shown, or the binder introduction device can be in the airflow of the blowers 920, 922. 900 can be arranged to be introduced. For example, the nozzle of the binder introduction device can supply the binder into the air flow of the blowers 920 and 922. Examples of binder introduction devices include, but are not limited to, nozzles and blowers that provide less airflow than blowers 920,922. In one exemplary embodiment, the binder introduction device 904 injects the binder 900 into the interior 930 of the housing 932 when the blowers 920, 922 are not blowing. Next, when the blowers 920, 922 are turned on, the interior 930 is pressurized and the binder 900 is carried from the interior 930 into the fiber air stream. Within the air stream, the air from the air wrapper moves the fibers, creating a forming effect on the distribution of the fibers on the forming surface 462, and the air also injects a binder to mix with the fibers in the air stream.

  Referring to FIGS. 9A and 9B, the air wrapper 902 mixes the binder 900 into the fibers 332 that collect on the forming surface 462 to form the web 321. In one exemplary embodiment, the binder introduction device 904 introduces the binder 900 into the blower 920 when the blower 920 provides an air flow 921 against the fibers moving in the duct toward the molding surface 462. The air flow 921 provided by 920 causes the binder to mix with the fibers 322 (shown in FIGS. 9A and 9B). Similarly, in this embodiment, when the blower 922 provides an air flow 921 against the fibers moving in the duct toward the molding surface 462, the binder introduction device 904 introduces the binder 900 into the blower 922 and the blower 922. The air flow 921 provided by the air causes the binder to mix with the fibers 322 (the air flow provided by the blower 922 is not shown, but is the same as the air flow provided by the blower 920). As a result, the binder 900 is uniformly mixed with the fibers 322.

  Dry binders can take a variety of different forms. Any non-aqueous medium that holds the fibers 322 together to form the web 521 can be used. In one exemplary embodiment, the dry binder consists essentially of 100% solids when initially applied to the fiber. The term “substantially 100% solids” as used herein refers to a diluent, such as water, equal to or less than about 2%, preferably less than or equal to 1% by weight of the binder. Is meant any binder material that includes (when the binder is applied, not after the binder has dried or cured). However, it should be appreciated that in certain embodiments, the binder can include any desired amount of diluent, such as water, depending on the specific application and design requirements. In one exemplary embodiment, the dry binder is a thermoplastic based material that is not applied in liquid form and is not water based. In other embodiments, the dry binder can be other materials or mixtures of other materials, including non-limiting examples of polymeric thermosetting resins. The dry binder can have any form or combination of forms, including, but not limited to, powders, particles, fibers and / or hot melts. Examples of hot melt polymers include, but are not limited to, ethylene-vinyl acetate copolymers, ethylene-acrylate copolymers, low density polyethylene, high density polyethylene, atactic polypropylene, polybutene-1, styrene block copolymers. , Polyamide, thermoplastic polyurethane, styrene block copolymer, polyester and the like. In one exemplary embodiment, the dry binder is a formaldehyde-free dry binder, which means that the dry binder does not contain formaldehyde. However, formaldehyde may form when a dry binder that does not contain formaldehyde burns. In one exemplary embodiment, a pack of cured fibers can be compressed for packaging, storage and shipping, but nevertheless its thickness is restored when installed ("bulkyness" (A process known as (loft) recovery), sufficient dry binder is applied.

  In the example shown in FIGS. 2A-2D and FIG. 5, the glass fiber 322 can optionally be coated or partially coated with a lubricant before or after the dry binder is applied to the glass fiber. In the 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 aforementioned lubricants.

  Referring to FIG. 5, a continuous web 521 containing unreacted dry binder is transferred from a forming device 332 to an optional laminating mechanism 334. The stacking mechanism can take a variety of different forms. For example, the lamination mechanism can be a folding mechanism that laminates the web 321 in the machine direction D1 or a cross-folding mechanism that folds the web in a direction substantially perpendicular to the machine direction. The web 521 containing an unreacted dry binder can be laminated using the cross-folding apparatus described above for laminating the binderless web 321.

  In the exemplary embodiment, the dry binder of continuous web 521 is configured to thermally cure in curing oven 550. In the exemplary embodiment, the curing oven 550 replaces the entanglement mechanism 345 because the dry binder holds the fibers 322 together. In another exemplary embodiment, both a curing furnace 550 and an entanglement mechanism 345 are included.

  FIGS. 6 and 7 schematically illustrate another exemplary embodiment of a method for forming a pack from a fibrous material, generally indicated at 610. Referring to FIG. 6, molten glass 612 is supplied from the melting device 614 to the foreground 616. Molten glass 612 can be formed from a variety of raw materials combined in proportions to provide the desired chemical composition. Molten glass 612 flows from fore Haas 616 to a plurality of rotary spinning machines 618.

  Referring to FIG. 6, a rotary spinning machine 618 receives molten glass 612 and then forms a veil 620 of glass fibers 622 that is entrained in the flow of hot gas. As will be described in more detail later, the glass fibers 622 formed by the rotary spinning machine 618 are long and thin. Thus, any desired spinning machine, rotating or otherwise, sufficient to form long thin glass fibers 22 can be used. Although the embodiments shown in FIGS. 6 and 7 show two rotary spinning machines 618, it should be appreciated that any desired number of rotary spinning machines 18 can be used.

  The hot gas flow can be generated by an optional blower mechanism such as a non-limiting example of an annular blower (not shown) or an annular burner (not shown). Generally, the blower mechanism is configured to direct the veil 620 of the glass fiber 622 in a given direction, usually downward. It should be understood that the hot gas flow can be generated by any desired structure, mechanism or device or any combination thereof.

  As shown in FIG. 6, an optional spray mechanism 626 can be positioned below the rotary spinning machine 618 to spray fine droplets of water or other fluid onto the hot gas in the veil 620 to provide a high temperature. It can be configured to assist in cooling the gas flow, protecting the fibers 622 from contact damage, and / or increasing the bonding capability of the fibers 622. The spray mechanism 626 sprays fine droplets of water onto the hot gas in the veil 620 to cool the hot gas stream, protect the fibers 622 from contact damage, and / or increase the bonding ability of the fibers 22. It can be any desired structure, mechanism or device sufficient to help. Although the embodiment shown in FIG. 6 illustrates the use of a spray mechanism 626, the use of the spray mechanism 626 is optional, and the method 610 of forming a pack from fibrous material can be performed without the use of the spray mechanism 626. Recognize that you can.

  Optionally, the glass fibers 622 can be coated with a lubricant after the glass fibers are formed. In the illustrated embodiment, a plurality of nozzles 628 can be disposed around the veil 620 at a position below the rotary spinning machine 618. The nozzle 628 can be configured to supply lubricant (not shown) to the glass fibers 622 from a lubricant source (not shown).

  The application of lubricant can be accurately controlled by any desired structure, mechanism or device, such as a non-limiting example valve (not shown). In certain embodiments, the lubricant can be a silicone compound such as siloxane, dimethylsiloxane and / or silane. The lubricant can also be other materials or mixtures of materials such as, for example, oils or oil emulsions. The oil or oil emulsion can 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 oil and / or silicone compound of about 1.0 percent by weight of the resulting fibrous material pack. However, in other embodiments, the amount of lubricant can be greater or less than about 1.0 weight percent oil and / or silicone compound.

  Although the embodiment shown in FIG. 6 illustrates the use of nozzle 628 to supply lubricant (not shown) to glass fiber 622, the use of nozzle 628 is optional and without using nozzle 628, the fiber It should be appreciated that a method 610 of forming a pack from a material can be performed.

  In the illustrated embodiment, the glass fibers 622 entrained in the hot gas stream can be collected by an optional collection member 624. The collection member 624 is shaped and sized to easily receive the glass fibers 622 and the hot gas flow. The collection member 624 is configured to distribute the glass fibers 622 and the hot gas stream to a duct 630 for transferring to downstream processing stations, such as molding devices 632a and 632b, for example. In other embodiments, the glass fibers 622 can be collected on a transport mechanism (not shown), for example, to form a blanket or bat (not shown). The bat can be transported to a further processing station (not shown) by a transport mechanism. The collection member 624 and the duct 630 can be any structure having a generally hollow configuration suitable for receiving and transporting the glass fibers 622 and the hot gas stream. Although the embodiment shown in FIG. 6 illustrates the use of a collection member 624, it is optional to use the collection member 624 to distribute the glass fibers 622 and the hot gas stream to the duct 630, without using the collection member 624. It should be appreciated that the method 610 of forming a pack from a fibrous material can be performed.

  In the embodiment shown in FIGS. 6 and 7, a single spinning machine 618 is associated with each duct 630, and the glass fibers 622 and the hot gas stream from the single spinning machine 618 enter the glass into the duct 630. It is the only source of fiber 622 and hot gas flow. Alternatively, individual ducts 630 can be adapted to receive glass fibers 622 and hot gas streams from multiple spinning machines 618 (not shown).

  Referring again to FIG. 6, optionally, a header system (not shown) can be placed between the forming devices 632a and 632b and the spinning machine 618. The header system can be configured as a chamber in which glass fibers 622 and gases flowing from multiple spinning machines 618 can be combined while controlling the characteristics of the resulting mixed flow. In certain embodiments, the header system is configured to combine the glass fibers 622 and gas flow from the spinning machine 618 and further configured to direct the resulting mixed flow to the forming devices 632a and 632b. A control system (not shown) can be included. Such a header system can allow maintenance and cleaning of a particular spinning machine 618 without having to stop the remaining spinning machines 618. Optionally, the header system can incorporate any desired means for controlling and directing the glass fibers 22 and gas flow.

  Referring now to FIG. 7, the momentum of the gas flow with entrained glass fibers 622 will cause the glass fibers 622 to continue to flow through the duct 630 to the forming devices 632a and 632b. Molding devices 632a and 632b can be configured for several functions. First, the forming devices 632a and 632b can be configured to separate the entrained glass fibers 622 from the gas stream. Second, the forming devices 632a and 632b can be configured to form a continuous thin dry web of fibrous material having a desired thickness. Third, the forming devices 632a and 632b allow the glass fibers 622 to separate from the gas stream in a manner that allows the fibers to be oriented with any desired degree of “randomness” within the web. Can be configured. The term “randomness” as used herein means that the fibers 622 or portions of the fibers 622 can be non-preferentially oriented in any of the X, Y, or Z dimensions. Defined. In certain cases, it may be desirable to have a high degree of randomness. In other cases, the randomness of the fibers may be controlled so that the fibers are non-randomly oriented, in other words, the fibers are substantially coplanar or substantially parallel to each other. It may be desirable. Fourth, the forming devices 632a and 632b can be configured to transfer a continuous web of fibrous material to other downstream operations.

  In the embodiment shown in FIG. 7, each of the forming devices 632a and 632b includes a drum (not shown) configured to rotate. The drum can include a surface with any desired number of small holes and higher or lower pressure areas. Alternatively, each of the forming devices 632a and 632b separates the entrained glass fibers 622 from the gas stream to form a continuous web of fibrous material having a desired thickness, and another continuous web of fibrous material downstream. It can be formed from other structures, mechanisms and devices sufficient to transfer to operation. In the illustrative embodiment shown in FIG. 7, each of the forming devices 632a and 632b is the same. However, in other embodiments, each of the forming devices 632a and 632b may be different from each other.

  Referring again to FIG. 7, a continuous web of fibrous material is transferred from the forming devices 632a and 632b to an optional binder applicator 646. The binder applicator 646 is configured to apply a “dry binder” to a continuous web of fibrous material. The term “dry binder” as used herein is defined to mean that the binder consists essentially of 100% solids when the binder is applied. The term “substantially 100% solids” as used herein is a diluent equal to or less than about 2% by weight of the binder, preferably less than or equal to about 1%, For example, it is defined to mean any binder material with water (when the binder is applied, not after the binder has dried and / or cured). However, it should be appreciated that in certain embodiments, the binder can include any desired amount of diluent, such as water, depending on the specific application and design requirements. The binder can be configured to thermally cure in a curing oven 650. In this application, the terms “cure” and “thermally set” refer to chemical reactions and / or one or more phase changes that cause the dry binder to bind the fibers of the web together. Point to. For example, a thermosetting dry binder (or a thermosetting component of a dry binder) cures or thermosets as a result of a chemical reaction resulting from the application of heat. The thermoplastic dry binder (or the thermoplastic component of the dry binder) cures or thermosets as a result of being heated to a softened or molten phase and then cooled to a solid phase.

  In an exemplary embodiment, the dry binder is a thermoplastic resin-based material that is not applied in liquid form and is not water-based. In other embodiments, the dry binder can be other materials or mixtures of other materials, including non-limiting examples of polymeric thermosetting resins. The dry binder can have any form or combination of forms including, but not limited to, powders, particles, fibers, and / or hot melts. Examples of hot melt polymers include, but are not limited to, ethylene-vinyl acetate copolymers, ethylene-acrylate copolymers, low density polyethylene, high density polyethylene, atactic polypropylene, polybutene-1, styrene block copolymers. , Polyamide, thermoplastic polyurethane, styrene block copolymer, polyester and the like. A pack of cured fibers can be compressed for packaging, storage and shipping, but still enough to return to its original thickness when installed (a process known as “bulk recovery”) A dry binder is applied. Applying a dry binder to the continuous web of fibers forms a continuous web, optionally with an unreacted binder.

  In the embodiment shown in FIGS. 6 and 7, the binder applicator 646 is a sprayer configured for dry powder. The sprayer is configured such that the spray force is adjustable, thereby allowing more or less penetration of the dry powder into the continuous web of fibrous material. Alternatively, the binder applicator 646 is another structure, mechanism or device, or a combination thereof, such as a vacuum device sufficient to draw the “dry binder” into a continuous web of fibrous material, for example. be able to.

  The embodiment shown in FIG. 7 shows a binder applicator 646 configured to apply a dry binder to a continuous web of fibrous material, but in certain embodiments, the dry binder is applied to a continuous web of fibrous material. It is also within the scope of the present invention not to be granted.

  Referring again to FIG. 7, a continuous web, optionally containing unreacted binder, is transferred from the binder applicator 646 to the corresponding cross fold mechanisms 634a and 634b. As shown in FIG. 7, the forming device 632a is associated with the cross fold mechanism 634a, and the forming device 632b is associated with the cross fold mechanism 634b. The cross fold mechanisms 634a and 634b function in conjunction with the first conveyor 636. The first conveyor 636 is configured to move in the machine direction indicated by arrow D1. The cross fold mechanism 634a is configured to receive a continuous web, optionally containing unreacted binder, from an optional binder applicator 646, and further, as the first conveyor 636 moves in the machine direction D1, the first On conveyor 636 is configured to deposit alternating layers of a continuous web, optionally including unreacted binder, thereby forming an initial layer of fibrous material. In this deposition process, the cross fold mechanism 634a forms alternating layers in the cross-machine direction indicated by arrow D2. Thus, as the continuous web with optionally deposited unreacted binder moves from the cross fold mechanism 634a in the machine direction D1, an additional layer is deposited on the fibrous body by the downstream cross fold mechanism 634b. . The layers of fibrous bodies obtained by being deposited by the cross-folding mechanisms 634a and 634b form a pack.

  In the illustrated embodiment, the cross fold mechanisms 634a and 634b include unreacted binder, with precise control of movement of the continuous web including unreacted binder, optionally so as not to damage the continuous web including unreacted binder. An apparatus configured to deposit a continuous web on a first conveyor 636. The cross fold mechanisms 634a and 634b can include any desired structure and can be configured to operate in any desired manner. In one example, the cross fold mechanisms 634a and 634b can include a head (not shown) configured to move back and forth in the cross machine direction D2. In this embodiment, the speed of the movable head is adjusted so that the head movement in both cross machine directions is substantially the same, thereby providing uniformity of the resulting fibrous layer. ing. In another example, a vertical conveyor (not shown) configured to be centered on the centerline of the first conveyor 636 can be used. This vertical conveyor is further configured to swing above the first conveyor 636 by a pivot mechanism to optionally deposit a continuous web containing unreacted binder on the first conveyor 36. Although several examples of cross fold mechanisms have been described above, it should be appreciated that the cross fold mechanisms 634a and 634b may be other structures, mechanisms or devices, or combinations thereof.

  Referring again to FIG. 7, optionally, a controller (not shown) positions a continuous web, optionally containing unreacted binder, on the first conveyor 636 to provide improved pack uniformity. Can be. The controller can be any desired structure, mechanism or device, or a combination thereof.

  The laminated web or pack can have any desired thickness. The pack thickness is a function of several variables. First, the pack thickness is a function of the thickness of the continuous web, optionally including unreacted binder, formed by each of the forming devices 632a and 632b. Second, the pack thickness is a function of the rate at which the cross-folding mechanisms 634a and 634b alternately deposit a layer of continuous web, optionally containing unreacted binder, on the first conveyor 636. Third, the pack thickness is a function of the speed of the first conveyor 636. In the illustrated embodiment, the pack has a thickness in the range of about 0.1 inches to about 20.0 inches. In other embodiments, the pack can have a thickness of less than about 0.1 or greater than about 20.0 inches.

  As described above, the cross fold mechanisms 634a and 634b optionally deposit alternating layers of continuous web, including unreacted binder, on the first conveyor 636 as the first conveyor 636 moves in the machine direction D1. , Thereby forming a layer of fibrous body. In the illustrated embodiment, the cross fold mechanisms 634a and 634b and the first conveyor 636 are adjusted to form a fibrous body having a number of layers ranging from about 1 layer to about 60 layers. In other embodiments, the cross fold mechanisms 634a and 634b and the first conveyor 636 can be adjusted to form a fibrous body having any number of layers, including fibrous bodies having more than 60 layers. .

  Optionally, the cross fold features 634a and 634b can be adjustable, thereby allowing the cross fold features 634a and 634b to form a pack having any desired width. In certain embodiments, the pack can have an overall width ranging from about 98.0 inches to about 236.0 inches. Alternatively, the pack can have an overall width of less than about 98.0 inches or greater than about 236.0 inches.

  Although the cross fold mechanisms 634a and 634b have been described above as jointly involved in the formation of the fibrous body, in other embodiments, the cross fold mechanisms 634a and 634b are configured to form separate lanes of the fibrous body. It should be appreciated that they can operate independently of each other.

  With reference to FIGS. 6 and 7, the pack having the layers formed by the cross-folding mechanisms 634 a and 634 b is conveyed by the first conveyor 636 to the optional trimming mechanism 640. Optional trimming mechanism 640 is configured to trim the edge of the pack to form the desired pack width. In an exemplary embodiment, the pack can have a trimmed width in the range of about 980 inches to about 236.0 inches. Alternatively, the pack may have a post-trim width less than about 98.0 inches or greater than about 236.0 inches.

  In the illustrated embodiment, optional trimming mechanism 640 includes a saw system having a plurality of rotary saws (not shown) positioned on opposite sides of the pack. Alternatively, the trimming mechanism 640 can be other structures, mechanisms or devices, or combinations thereof, including non-limiting examples of water jets, compression knives.

  In the illustrated embodiment, the trimming mechanism 640 is advantageously positioned upstream from the curing furnace 650. By arranging the trimming mechanism 640 upstream of the curing furnace 650, it is possible to trim the pack before the pack is thermally cured in the curing furnace 650. Optionally, the material cut from the pack by the trimming mechanism 640 can be returned to the flow of gas and glass fibers in the duct 630 and reused in the forming devices 632a and 632b. Reuse of chopped material advantageously prevents potential environmental problems associated with disposal of chopped material. As shown in FIG. 6, the conduit 642 connects the trimming mechanism 640 to the duct 630 and is configured to facilitate the return of the cut material to the forming devices 632a and 632b. The embodiment shown in FIGS. 6 and 7 shows reuse of the cut material, but reuse of the cut material is optional and packs from the fibrous material without reusing the cut material. It should be appreciated that method 610 of forming can be implemented. In another exemplary embodiment, trimming mechanism 640 is disposed downstream from curing furnace 650. This arrangement is particularly useful when the chopped material is not reused. When the pack is trimmed, a trimmed pack is formed.

  The trimmed pack is conveyed by the first conveyor 636 to the second conveyor 644. As shown in FIG. 6, the second conveyor 644 can be arranged to “step down” from the first conveyor 636. The term “step down” as used herein is defined to mean that the upper surface of the second conveyor 644 is located vertically below the upper surface of the first conveyor 636. The step down of the conveyor will be described later in more detail.

  Referring again to FIGS. 1 and 2, the trimmed pack is conveyed by the second conveyor 644 to an optional entanglement mechanism 645. The entanglement mechanism 645 is configured to entangle individual fibers 622 that form a layer of trimmed packs. Entanglement of the glass fibers 622 within the pack binds the pack together. In embodiments where a dry binder is included, entanglement of the glass fibers 622 can advantageously improve mechanical properties such as, for example, tensile strength and shear strength. In the illustrated embodiment, the entanglement mechanism 645 is a needling mechanism. In other embodiments, the entanglement mechanism 645 can include other structures, mechanisms or devices, or combinations thereof, including a non-limiting example stitching mechanism. The embodiment shown in FIGS. 6 and 7 illustrates the use of an entanglement mechanism 645, but the use of the entanglement mechanism 645 is optional and forms a pack from fibrous material without the use of the entanglement mechanism 645. It should be appreciated that method 610 can be performed. When the fibers in the pack are entangled, an entangled pack is formed.

  The second conveyor 644 is optionally trimmed and / or optionally entangled, optionally including a dry binder pack (hereinafter both trimmed and entangled packs are simply referred to as “packs”. ) To the third conveyor 648. If the pack includes a dry binder, the third conveyor 648 is configured to carry the pack to an optional curing furnace 650. The curing oven 650 is configured to blow a fluid, such as heated air, through the pack, thereby curing the dry binder and rigidly bonding the glass fibers 622 together to a generally random three-dimensional structure. When the pack is cured in the curing oven 650, a cured pack is formed.

  As mentioned above, the pack optionally includes a dry binder. Using a dry binder rather than a traditional wet binder advantageously allows the curing furnace 650 to use less energy to cure the dry binder in the pack. In the illustrated embodiment, the use of a dry binder in the curing furnace 650 is about 30.0% to about 80.0 compared to the energy used by a conventional curing furnace to cure a wet or aqueous binder. Brings energy savings in the range of up to%. In yet other embodiments, energy savings may exceed 80.0%. Curing furnace 650 can be any desired curing structure, mechanism or device, or a combination thereof.

  The third conveyor 648 conveys the cured pack to the fourth conveyor 652. The fourth conveyor 652 is configured to carry the cured pack to the cutting mechanism 654. Optionally, the cutting mechanism 654 can be configured in several cutting modes. In the first optional cutting mode, the cutting mechanism is configured to cut the cured pack in a vertical direction along the machine direction D1 to form a lane. The formed lanes can have any desired width. In the second optional cutting mode, the cutting mechanism is configured to divide the cured pack into two equal parts in the horizontal direction to form a continuous pack having a thickness. The resulting bisected pack can have any desired thickness. When the cured pack is cut, a cut pack is formed.

  In the illustrated embodiment, the cutting mechanism 654 includes a saw and knife system. Alternatively, the cutting mechanism 654 can be other structures, mechanisms or devices or combinations thereof. Referring again to FIGS. 6 and 7, the cutting mechanism 654 is advantageously arranged so that dust and other waste material formed during the cutting operation can be obtained. Optionally, dust and other waste material resulting from the cutting mechanism can be returned to the gas and glass fiber flow in duct 630 and reused in molding apparatus 632a and 632b. The reuse of dust and waste materials advantageously prevents potential environmental problems associated with the disposal of dust and waste materials. As shown in FIGS. 6 and 7, the conduit 655 connects the cutting mechanism 654 to the duct 630 and is configured to facilitate the return of dust and waste material to the forming devices 632a and 632b. Although the embodiments shown in FIGS. 6 and 7 illustrate the reuse of dust and waste material, the reuse of dust and waste material is optional and the pack can be removed from the fibrous material without reusing the dust and waste material. It should be appreciated that the forming method 10 can be implemented.

  Optionally, prior to transporting the cured pack to the cutting mechanism 654, the major surface of the cured pack may be overlaid with one or more overlays by the overstripping mechanisms 662a, 662b, as shown in FIG. it can. In the illustrated embodiment, the upper main surface of the cured pack is overlaid with an upper material 663a provided by an upper mechanism 662a, and the lower main surface of the cured pack is formed with an upper material 663b provided by an upper mechanism 662b. It is overlaid. The upholstery material can be any desired material including paper, polymeric material, or nonwoven web. The upholstery mechanisms 662a and 662b can be any desired structure, mechanism or device, or a combination thereof. In the illustrated embodiment, the overlays 663a and 663b are affixed to the cured pack (when the pack includes a binder) with an adhesive. In other embodiments, the overlays 663a and 663b are affixed to the cured pack by other methods including, but not limited to, ultrasonic welding. The embodiment shown in FIG. 6 shows the application of the outer materials 663a and 663b to the main surface of the cured pack, but the application of the outer materials 663a and 663b to the main surface of the cured pack is optional and the It should be appreciated that the method 610 of forming a pack from a fibrous material can be performed without affixing the outer materials 663a and 663b to the main surface.

  With reference to FIGS. 6 and 7, the fourth conveyor 652 carries the cut pack to an optional chopping mechanism 656. The chopping mechanism 656 is configured to cut the cut pack to a desired length across the machine direction D1. In the illustrated embodiment, the chopping mechanism 656 is configured to cut the cutting pack as the cutting pack moves continuously in the machine direction D1. Alternatively, the chopping mechanism 656 can be configured for a batch chopping operation. When the cut pack is cut into a predetermined length, a predetermined dimension pack is formed. The length of the chopped pack can have any desired dimensions.

  Chopping mechanisms are known in the art and will not be described herein. Chopping mechanism 656 can be any desired structure, mechanism or device, or a combination thereof.

  Optionally, prior to transporting the cut pack to the chopping mechanism 656, the secondary surface of the cut pack can be overlaid with one or more borders by the border mechanisms 666a, 666b, as shown in FIG. The border material can be any desired material including paper, polymeric material, or nonwoven web. The edging mechanisms 666a and 666b can be any desired structure, mechanism or device, or a combination thereof. In the illustrated embodiment, the borders 667a and 667b are affixed to the cutting pack with an adhesive. In other embodiments, the borders 667a and 667b can be affixed to the cutting pack by other methods including, but not limited to, ultrasonic welding. The embodiment shown in FIG. 7 shows the application of the borders 667a and 667b to the secondary surface of the cutting pack, but the application of the borders 667a and 667b to the secondary surface of the cutting pack is optional and the secondary surface of the cutting pack It should be appreciated that the method 610 of forming a pack from fibrous material can be performed without applying the fringes 667a and 667b.

  Referring again to FIG. 6, the fourth conveyor 652 carries the predetermined size pack to the fifth conveyor 658. The fifth conveyor 658 is configured to carry the predetermined size pack to the packaging mechanism 660. The packaging mechanism 660 is configured to package the predetermined size pack for future operations. The term “future operation” as used herein is defined to include any activity, including, but not limited to, storage, shipping, and installation, following the formation of a pack of predetermined dimensions. The

  In the illustrated embodiment, the packaging mechanism 660 is configured to form a predetermined size 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 non-limiting examples of slabs, bats, and irregularly shaped or stamped pieces. The packaging mechanism 660 can be any desired structure, mechanism or device, or a combination thereof.

  Referring again to FIG. 6, the conveyors 636, 644, 648, 652 and 658 are in a “step down” relationship in the machine direction D1. A “step down” relationship means that the upper surface of the next conveyor is positioned vertically below the upper surface of the previous conveyor. The “step-down” relationship of the conveyor advantageously provides a self-threading feature for pack transport. In the illustrated embodiment, the vertical offset between adjacent conveyors ranges 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 greater than about 10.0 inches.

  As shown in FIGS. 6 and 7, the method 610 of forming a pack from a fibrous material eliminates the use of a wet binder, thereby providing wash water and wash water related structures such as molding hoods, return pumps and piping. Eliminate the traditional need for Eliminating the use of water other than the application of cooling water and lubricants, colorants and other optional chemicals significantly reduces the overall size (or “installation area”) of the production line, as well as implementation costs, operation It advantageously makes it possible to reduce costs and maintenance and repair costs.

  As further shown in FIGS. 6 and 7, the method 610 of forming a pack from fibrous material advantageously allows for uniform and even deposition of long and thin fibers on the forming devices 632a and 632b. In the illustrated embodiment, the fibers 622 have a length ranging from about 0.25 inches to about 10.0 inches and a diameter dimension ranging from about 9 HT to about 35 HT. In other embodiments, the fibers 22 have a length ranging from about 1.0 inch to about 5.0 inches and a diameter dimension ranging from about 14 HT to about 25 HT. In still other embodiments, the fibers 22 can have a length of less than about 0.25 inches or greater than about 10.0 inches and a diameter dimension of less than about 9 HT or greater than about 35 HT. Without being bound by theory, it is believed that the use of relatively long and thin fibers advantageously provides a pack with better thermal insulation and sound insulation performance than similarly sized packs having shorter and thicker fibers. It is done.

  Although the embodiment shown in FIGS. 6 and 7 has been generally described above to form a pack of fibrous material, the same apparatus is configured to form an “unbonded loosely filled insulation” Please understand that you can. The term “unbonded loosely filled insulation” as used herein means any conditioned insulation material configured for use in an air stream. Is defined.

  While exemplary embodiments of the pack and method 610 of forming a pack from fibrous material have been generally described above, it should be appreciated that other embodiments and variations of the method 610 can be used. This is generally described below.

  Referring to FIG. 7, in another embodiment of the method 610, the cross fold mechanisms 634a and 634b are configured to provide accurate deposition of alternating layers of continuous web on the first conveyor 36, thereby The downstream trimming mechanism 40 can be eliminated.

  Referring again to FIG. 7, in another embodiment of the method 610, the various layers of the pack can be “stratified”. The term “stratified” as used herein refers to each of the layers and / or portions of the layers as non-limiting examples of fiber diameter, fiber length, fiber orientation, density, thickness and Defined as meaning that it can be configured to have different properties, including glass composition. The associated mechanisms that form the layers, i.e., associated spinning machines, forming devices, and cross-folding mechanisms, can be configured to provide layers and / or portions of layers that have certain desired properties. Is contemplated. Thus, a pack can be formed from layers and / or portions of layers having different properties.

  10A-10C illustrate an exemplary embodiment of an insulation product 1000 that includes one or more thick low density cores 1002 and one or more thin high density tensile layers 1004. FIG. The thick low density core 1002 can take a variety of different forms. For example, the low density core 1002 can be made from any of the aforementioned low weight per area packs. In one exemplary embodiment, the low density core 1002 is made from needled and / or laminated glass fibers. In one exemplary embodiment, the low density core 1002 is binderless. In another exemplary embodiment, the low density core fibers 322 are bonded together by a binder.

  The thin high density tensile layer 1004 can take a variety of different forms. In one exemplary embodiment, the thin dense tensile layer 1004 is made from fiberglass fibers that are needled together. However, the dense tensile 1000 fibers can be processed using other processes and / or products that achieve adequate tensile strength. In one exemplary embodiment, the high density tensile layer 1004 is made from the high density pack 300 of the embodiment of FIG. 3D.

  In the exemplary embodiment, high density tensile layer 1004 is attached to low density core 1002. The high density tensile layer 1004 can be attached to the low density core 1002 in a variety of different ways. For example, the layers 1002, 1004 can be attached to each other by adhesives, additional needling steps, thermal bonding (when one or both of the layers 1002, 1004 includes a binder), and the like. Any method of attaching the layers to each other can be used. In the exemplary embodiment, layers 1002, 1004 provide separate characteristics to insulation product 1000.

  In the exemplary embodiment, the thick low density layer 1002 provides a high thermal resistance value R but low tensile strength, and the thin high density tensile layer 1004 provides a low thermal resistance value R but high tensile strength. Have. The combination of the two layers gives the insulation product 1000 both a high tensile strength and a high R value.

  10D-10F illustrate an exemplary embodiment of an insulation product 1000 that includes one or more thick low density cores 1002 and one or more thin outer layers 1004. FIG. The thick low density core 1002 can take a variety of different forms, as described with respect to the embodiment shown in FIGS. 10A-10C. The outer layer 1004 can take a variety of different forms. The material of the outer layer 1004 can be selected to give the insulating product a variety of different properties. For example, the lining material can be selected to provide the insulation product with the desired amount of strength, reflectivity, acoustic performance, water impermeability, and / or vapor impermeability. The outer layer can be made from a variety of different materials including, but not limited to, plastic, metal foil, scrim, paper, combinations of these materials, and the like. Any known outer layer can be used.

  In the exemplary embodiment, the outer layer 1004 is attached to the low density core 1002. The outer layer 1004 can be attached to the low density core 1002 in a variety of different ways. For example, the layers 1002, 1004 can be attached to each other by adhesive, thermal bonding, or the like. Any method of attaching the layers to each other can be used. In the exemplary embodiment, layers 1002, 1004 provide distinct properties to insulation product 1000. In the exemplary embodiment, the thick low density layer 1002 provides a high thermal resistance value R but low tensile strength, and the outer layer 1004 provides tensile strength and other properties.

  The examples shown in FIGS. 10G-10I are described with respect to strata having different densities. However, hierarchies can have different characteristics, which may or may not include different densities. These varying properties can be achieved by changing fiber density, fiber length, fiber diameter, and / or fiber type throughout the thickness of the pack. FIGS. 10G-10I illustrate an exemplary embodiment of a layered bat or pack 1050 that includes one or more low density tiers 1052 and one or more high density tiers 1054. However, the transition between the low density hierarchy 1052 and the high density hierarchy 1054 can be gradual. In the example shown in FIGS. 10A-10F, the insulation product 1000 is formed from separated layers. In the exemplary embodiment shown in FIGS. 10G-10I, the layered bat or pack 1050 is formed with properties that vary through the thickness of the bat or pack. The low density hierarchy 1052 can take a variety of different forms. For example, the low density layer 1052 can be made in the same manner as any of the low weight per area packs described above. In one exemplary embodiment, the low density layer 1052 is made from fiberglass fibers. In one exemplary embodiment, the low density hierarchy 1052 is binderless. In another exemplary embodiment, the fibers 322 of the low density layer 1052 are bonded together by a binder.

  The thin high density hierarchy 1054 can take a variety of different forms. In one exemplary embodiment, the high density layer 1054 is made from fiberglass fibers that are needled together. However, the fibers of the dense tier 1054 can be processed using other processes and / or products that achieve adequate tensile strength. In one exemplary embodiment, the high density hierarchy 1054 is made in the same way that the high density pack 300 of the embodiment of FIG. 3D is made.

  In the exemplary embodiment, the fibers of the high density tier 1054 are attached and / or entangled with the fibers of the low density tier 1052. The fibers of the high density layer 1054 can be attached to the fibers of the low density layer 1052 in a variety of different ways. For example, the fibers of the tiers 1002, 1004 can be attached to each other by an adhesive such as a binder applied to the pack and / or by needling performed when making the pack 1050. Any method of attaching or intertwining the fibers of the tiers 1052, 1054 can be used. In the exemplary embodiment, tiers 1052, 1054 impart different characteristics to insulation product 1000.

  The insulating bats, packs and products of the embodiment of FIGS. 10A-10I can be combined with each other. For example, any layer of the insulation product shown in FIGS. 10A-10F can be layered, and the layered bat or pack of FIGS. 10G-10I can be layered with one or more outer layers or separate high density. Layers and the like can be provided. A variety of different insulating structures can be constructed from the embodiments shown in FIGS. 10A-10I.

  In the exemplary embodiment, a thick low density layer 1052 provides a high thermal resistance value R but has a low tensile strength, and a thin high density tensile layer 1004 provides a low thermal resistance value R but a high tensile strength. Have The combination of the two tiers gives the bat or pack 1050 both high tensile strength and high R value. The hierarchy can be configured to give the bat or pack various different characteristics. For example, alternating thin high density layers and thick low density layers provide bats or packs with superior acoustic properties.

  In one exemplary embodiment, the dry binder can include or be coated with an additive to impart desired properties to the pack. A non-limiting example of an additive is a flame retardant such as sodium bicarbonate. Another non-limiting example of an additive is a material that prevents the transmission of ultraviolet light through the pack. Yet another non-limiting example of an additive is a material that prevents infrared transmission through the pack.

  Referring to FIG. 6, in another embodiment of the method 610, as described above, the flow of hot gas is such as a non-limiting example of an annular blower (not shown) or an annular burner (not shown). It can be generated by an optional blower mechanism. It is known in the art that the heat generated by an annular blower or an annular burner is referred to as “heat of fibrosis”. In this embodiment, it is contemplated that the heat of spinning is obtained and reused for use in other mechanisms or devices. Spinning heat can be obtained at a number of locations in method 610. As shown in FIGS. 6 and 7, the conduit 670 is configured to acquire heat emanating from the spinning machine 618 and carry this heat for use in other mechanisms, such as an optional curing furnace 650. Similarly, the piping 672 is configured to acquire heat generated from the hot gas flow in the duct 30 and the piping 674 is configured to acquire heat generated from the forming devices 632a and 632b. Reuse heat can also be used for purposes other than the formation of fibrous packs, for example for office heating.

  In certain embodiments, the duct 630 is a heat extraction fixture, eg, a heat extraction fixture configured to acquire heat without significantly affecting the momentum of the flow of hot gas and entrained glass fiber 622. fixture) or the like. In other embodiments, any desired structure, device or mechanism sufficient to obtain spinning heat can be used.

  Referring to FIG. 6, in another embodiment of method 610, fibers or other materials having other desired properties can be mixed with glass fibers 622 entrained in the gas stream. In this embodiment, a source 676 of other materials such as, for example, synthetic or ceramic fibers, colorants and / or particles can be provided to allow such materials to be introduced into the duct 678. .

  Duct 678 can be connected to duct 630 to allow mixing with glass fibers 622 entrained in the gas stream. In this way, the properties of the resulting pack can be designed or adjusted to the desired properties, including non-limiting examples of acoustic properties, thermal enhancement properties, or UV deterrent properties.

  In still other embodiments, it is contemplated that other materials can be placed between the layers deposited on the first conveyor 636 by the cross fold mechanisms 634a and 634b. Other materials can include, for example, a sheet material such as a lining material, a moisture barrier layer, or a net product, or other non-sheet material, including non-limiting examples of powders, particles, or adhesives. Other materials can be placed between the layers in any desired manner. In this way, the properties of the resulting pack can be further designed or adjusted as desired.

  Although the embodiment shown in FIG. 6 shows the application of a dry binder with the binder applicator 646, in other embodiments it is recognized that the dry binder can be applied to the glass fibers 622 entrained in the gas stream. I want to be. In this embodiment, a dry binder source 680 can be introduced into the duct 682. Duct 682 is connected to duct 630 to allow mixing of glass fiber 622 and dry binder entrained in the gas stream. The dry binder can be configured to adhere to the glass fiber in any desired manner including an electrostatic process.

  The embodiment shown in FIG. 6 illustrates the use of a continuous web with cross fold mechanisms 634a and 634b, but in other embodiments, the web is removed from the forming devices 632a and 632b and stored for later use. Please be aware that you can.

  As previously described, optionally, the chopped material can be returned to the gas and glass fiber flow in duct 630 and reused in molding apparatus 632a and 632b. In an exemplary embodiment, when the optional binder is included in the pack, the operating temperature of the molding equipment 332a and 332b is kept below the softening temperature of the dry binder, thereby prior to operation of the downstream curing furnace 550. Curing of the binder is prevented. In this embodiment, the maximum operating temperature of the curing furnace 650 is in the range of about 165 ° F to about 180 ° F. In other embodiments, the maximum operating temperature of the curing furnace 650 can be lower than about 165 ° F or higher than about 180 ° F.

  In the exemplary embodiment, the long thin fibers 322 described herein are used for other applications different from those described above. For example, FIG. 11 shows that the long thin fibers 322 are not formed into a web and / or pack, but are air laminated, carded, or otherwise treated for use in a variety of different applications. To be provided as staple fibers. In one application, unbonded staple fibers are blended with aramid fibers such as Kevlar and Konex, and / or heat bonded fibers such as Celbond. These blended fibers can be used to form staple yarns and / or dry nonwoven materials.

  In the embodiment of FIG. 11, the melting device 314 supplies molten glass 312 to the foreground 316. Glass fiber 322 is formed by processing molten glass 312. Molten glass 312 can be processed in a variety of different ways to form fibers 322. For example, the rotary spinning machine 318 receives molten glass 312 and then forms a veil 320 of glass fibers 322. Any desired spinning machine, rotating or otherwise, sufficient to form long thin glass fibers 322 can be used.

  Referring to FIG. 11, an applicator 1100 applies a lubricant, also called a sizing agent, to unbonded glass fibers. In the illustrated embodiment, the sizing agent is applied to the glass fiber below the spinning machine. However, in other embodiments, the sizing agent is applied to the glass fiber at other locations, such as within the duct 330. The sizing agent reinforces the fiber and / or imparts lubricity to the fiber, which aids in fiber processing such as fiber needling or carding. Unadhered staple fibers 322 are provided at the exit of duct 330 as indicated by arrow 1102, where the fibers are collected in a container 1103 and vary in various ways either by themselves or in combination with other fibers such as aramid fibers. It has come to be used for applications.

  The sizing agent can take a variety of different forms. For example, the sizing agent can include silicone and / or silane. However, any sizing agent can be used depending on the application. The sizing agent can be adjusted based on the application for which the glass fiber is used.

  The small fiber diameter and long fiber length allow the sized fiber to be used in applications where the fiber could not be used previously because the fiber is too broken. In one exemplary embodiment, the thinner the fibers are, the easier they are to bend without breaking, so a fiber 322 having a diameter of approximately 4 microns has a superior flexural modulus and resulting strength over conventional fibers. And have. This improved fiber flexural modulus and strength helps the fiber withstand processes such as the destructive carding and air lamination processes that are typically for conventional fibers. Furthermore, the fine diameter of the glass fibers improves both thermal and acoustic performance.

  Glass webs, packs, and staple fibers can be used in a variety of different applications. Examples of applications include, but are not limited to, heating appliances such as ovens, ranges and water heaters, heating, ventilation and air conditioning (HVAC) components such as HVAC ducts, soundproof panels for buildings and / or vehicles, etc. Soundproof panels and materials, molded fiberglass components such as compression molded or vacuum formed fiberglass components. In one exemplary embodiment, heating appliances such as ovens, ranges and water heaters, heating HVAC components such as HVAC ducts, soundproofing panels and materials such as building and / or vehicle soundproofing panels, and / or compression. Molded fiberglass components, such as molded or vacuum-formed fiberglass components, use or are manufactured from binderless fiberglass packs made according to one or more embodiments disclosed by this patent application. . In an exemplary embodiment, since the fiberglass pack is binderless, there is no formaldehyde in the fiberglass pack. In one exemplary embodiment, heating appliances such as ovens, ranges and water heaters, heating HVAC components such as HVAC ducts, soundproofing panels and materials such as building and / or vehicle soundproofing panels, and / or compression. Molded fiberglass components, such as molded or vacuum-formed fiberglass components, use or are manufactured from dry binder fiberglass packs made according to one or more embodiments disclosed by this patent application. . In this exemplary embodiment, the dry binder can be either formaldehyde-free or formaldehyde-free dry binder. When no formaldehyde binder is added, the binder itself does not have formaldehyde, but formaldehyde may become a by-product when the binder burns.

  The fiberglass insulation pack described in this patent application can be used in a variety of different cooking ranges, and can be used in a variety of different configurations within any given cooking range. Patent document 10 is disclosing the example of the heat insulation system used in a range. U.S. Patent No. 6,057,034 is incorporated herein by reference in its entirety. The fiberglass pack described in this specification can be used for any of the heat insulating structures of the heating appliance described in Patent Document 10, including configurations classified as prior art. 12 to 14 correspond to FIGS. 1 to 3 of Patent Document 10. FIG.

  Referring to FIG. 12, a thermal oven 1210 includes a substantially flat upper cooking surface 1212. As shown in FIGS. 12-14, the thermal oven 1210 includes a pair of opposed side panels 1252 and 1254, a back panel 1224, a bottom panel 1225, and a front panel 1232. Opposing side panels 1252 and 1254, back panel 1224, bottom panel 1225, front panel 1232, and cooking surface 1212 are configured to form an outer oven cabinet 1233. The front panel 1232 includes an insulated oven door 1218 that is pivotally connected to the front panel 1232. The oven door 1218 is hinged to the lower end of the front panel 1232 so that the oven door can pivot away from the front panel 1232 and the oven cavity 1216. In the example shown in FIG. 12, oven door 1218 includes a window. In the example shown in FIG. 12A, the oven door 1218 does not include a window, and a heat insulating material is applied to the entire interior of the door.

  As shown in FIGS. 13 and 14, the outer oven cabinet 1233 supports an inner oven liner 1215. Inner oven liner 1215 includes opposing liner sides 1215a and 1215b, liner top 1215c, liner bottom 1215d and liner back 1215e. Opposing liner sides 1215a and 1215b, liner top 1215c, liner bottom 1215d, liner back 1215e, and oven door 1218 are configured to define an oven cavity 1216.

  As further shown in FIGS. 13 and 14, the outside of the oven liner 1215 is covered with a thermal insulation material 1238 that can be made according to any of the embodiments disclosed in this application. The oven door 1238 can also be filled with a thermal insulation material 1238 that can be made according to any of the embodiments disclosed in this application. Insulation material 1238 is placed in contact with the outer surface of oven liner 1215. Insulating material 1238 is used for a number of purposes, including holding heat within oven cavity 1216 and limiting the amount of heat transferred to outer oven cabinet 1233 by conduction, convection and radiation.

  As shown in the example shown in FIGS. 13 and 14, an air gap 1236 is formed between the insulating material 1238 and the outer oven cabinet 1233. The air gap 1236 is used as an additional insulation to limit conductive heat transfer between the oven liner 1215 and the outer oven cabinet 1233. Use of the air gap 1236 complements the insulating material 1238 to minimize the surface temperature of the outer surface of the outer oven cabinet 1233. As shown in the example shown in FIGS. 13A and 14A, the insulating material 1238 can be sized such that no air gap is formed between the insulating material 1238 and the outer oven cabinet 1233. That is, in the embodiment of FIGS. 13A and 14A, the thermal insulation layer 1238 completely fills the space between the oven liner 1215 and the outer oven cabinet 1233. In one exemplary embodiment, the thermal insulation material used in the configuration shown in FIGS. 13, 13A, 14, 14A, and any other configuration disclosed by US Pat. Made from a binderless fiberglass pack made according to one or more disclosed embodiments. In the exemplary embodiment, since the fiberglass pack is binderless, no formaldehyde is present in the thermal insulation layer 1238 of the embodiment of FIGS. 13, 13A, 14, and 14A.

  The fiberglass pack described in this patent application can be used in a variety of different heating, ventilation, and air conditioning (HVAC) systems, such as ducts for HVAC systems. Further, the thermal insulation pack described in this patent application can be provided in a variety of different configurations within any given HVAC duct. US Patent Application No. 13 / 764,920, filed February 12, 2013, all assigned to the assignee of the present application, describes the fibers used in HVAC ducts. An example of a glass insulation system is disclosed. U.S. Patent Nos. 6,028,058 and pending U.S. Patent Application No. 13 / 764,920 are hereby incorporated by reference in their entirety. The fiberglass pack described herein can be used in any of the HVAC duct configurations described in US Pat. Nos. 6,077,086 and pending US patent application Ser. No. 13 / 764,920.

  In one exemplary embodiment, the thermal insulation material used in the HVAC duct disclosed in US Pat. Nos. 6,099,066 and pending US patent application Ser. No. 13 / 764,920 is disclosed in this patent application. Can be constructed from a dry binder fiberglass pack made according to one or more embodiments described. In this exemplary embodiment, the dry binder can be a formaldehyde-free dry binder or a formaldehyde-free dry binder. In the formaldehyde-free binder, the binder itself does not contain formaldehyde, but formaldehyde may become a by-product when the binder burns.

  In an exemplary embodiment, the thermal insulation material used in the HVAC duct disclosed in US Pat. Nos. 6,099,066 and pending US patent application Ser. No. 13 / 764,920 is disclosed in this patent application. It can be constructed from a binderless fiberglass pack made according to one or more embodiments. In the exemplary embodiment, since the fiberglass pack is binderless, no formaldehyde is present in the insulation material.

  The fiberglass insulation pack described in this patent application can be used for a variety of different acoustic applications and can have a variety of different configurations for each application. Examples of soundproof batts include Owens Corning Sound Attenuation Batt and Owens Corning Sonobats insulation, which can be placed behind various panels of the building, such as ceiling tiles or walls. Patent Literature 13 and Patent Literature 14 describe examples of soundproofing applications, which are incorporated herein by reference in their entirety. The fiberglass pack described herein can be used in place of the soundproofing materials of Owens Corning Sound Attenuation Batt and Owens Corning Sonobatts and used for any of the applications disclosed in US Pat. be able to. Additional acoustic applications of the fiberglass soundproof pack described in this patent application include, but are not limited to, duct liners, duct wraps, ceiling panels, wall panels, and the like.

In one exemplary embodiment, soundproofing made according to one or more embodiments of the binderless pack or dry binder pack disclosed in this patent application and tested according to ASTM C522 within 1,500 feet above sea level. The pack has an average ventilation resistivity of 3,000-150,000 (mks Rayls / m). In one exemplary embodiment, soundproofing made according to one or more embodiments of the binderless pack or dry binder pack disclosed in this patent application and tested according to ASTM C423 within 1,500 feet above sea level. The pack has a Sound Absorption Average (SAA) ranging from 0.25 to 1.25. In one exemplary embodiment, soundproofing made according to one or more embodiments of the binderless pack or dry binder pack disclosed in this patent application and tested within 1,500 feet above sea level according to ISO 354 The pack has a sound absorption coefficient α _w in the range of 0.25 to 1.25.

  In one exemplary embodiment, soundproofing used in place of the soundproofing material of Owens Corning Sound Attention Batt and Owens Corning Sonobats and / or used for any of the applications disclosed in US Pat. The material is constructed from a dry binder fiberglass pack made according to one or more embodiments disclosed in this patent application. In this exemplary embodiment, the dry binder can be a formaldehyde-free dry binder or a formaldehyde-free dry binder. In the dry binder without formaldehyde, the binder itself does not contain formaldehyde, but when the binder burns, formaldehyde may become a by-product.

  In an exemplary embodiment, the soundproofing material used in place of the soundproofing material of Owens Corning Sound Attenuation Batt and Owens Corning Sonobats and / or used for any of the applications disclosed in US Pat. Constructed from a binderless fiberglass pack made according to one or more embodiments disclosed in this patent application. In this exemplary embodiment, no formaldehyde is present in the soundproofing material because the fiberglass pack is binderless.

  The fiberglass insulation pack described in this patent application can be used in a variety of shaped fiberglass products. For example, referring to FIGS. 15A-15C, in one embodiment, compression molded fiberglass products can be made using the binderless and / or dry binder fiberglass packs described in this application. Referring to FIG. 15A, a binderless and / or dry binder fiberglass pack 1522 made in accordance with any exemplary embodiment described in this application is between a first and second mold half 1502. Be placed. In the exemplary embodiment, only a binderless or dry binder fiberglass pack 1522 is placed between the mold halves. That is, for example, additional materials such as plastic sheets or plastic resins are not molded with the fiberglass pack.

  Referring to FIG. 15B, the mold halves compress the fiberglass pack 1522 as indicated by arrow 1504. Heat is optionally applied to the mold halves and / or fiberglass packs as indicated by arrows 1506. For example, if the pack 1522 is a binderless fiberglass pack, the mold halves and / or fiberglass packs are heated to a high temperature, for example, above 700 ° F, for example between 700 ° F and 1100 ° F and 1 In one exemplary embodiment, it can be heated to about 900 ° F. If the pack 1522 is a dry binder fiberglass pack, the mold half and / or fiberglass pack can be heated to a lower temperature, for example, the melting point of the dry binder of the pack.

  Referring to FIG. 15C, the mold halves are then moved away as indicated by arrow 1508 and the compression molded fiberglass part 1510 is removed. In one exemplary embodiment, the compression molded fiberglass part 1510 consists solely of or consists essentially of the material of the pack 1522.

  In the example shown in FIGS. 15A-15C, the compression-molded fiberglass part is shaped. However, in other exemplary embodiments, the compression molded fiberglass part can be substantially flat. In one exemplary embodiment, the binderless or dry binder compression molded fiberglass component 1610 has a density that is substantially higher than the density of the initially prepared fiberglass pack 1522, eg, of the initially prepared fiberglass pack 1522. It has a density 4 times or more than the density.

  With reference to FIGS. 16A-16C, in one exemplary embodiment, a vacuum formed fiberglass product can be made using the binderless or dry binder fiberglass pack described in this application. Referring to FIG. 16A, a binderless and / or dry binder fiberglass pack 1522 made according to any exemplary embodiment described in this application is placed on a vacuum mold component 1602. In one exemplary embodiment, only a binderless or dry binder fiberglass pack 1522 is placed on the mold component 1602. That is, for example, additional materials such as plastic sheets or plastic resins are not molded with the fiberglass pack.

  Referring to FIG. 16B, the mold component applies a vacuum to the fiberglass pack 1522 as indicated by arrow 1604. Heat is optionally applied to the mold component 1602 and / or the fiberglass pack as indicated by arrow 1606. For example, if the pack 1522 is a binderless fiberglass pack, the vacuum mold component 1602 and / or the fiberglass pack 1522 may be heated to a high temperature, eg, above 700 ° F, eg, between 700 ° F and 1100 ° F. , And in one exemplary embodiment, can be heated to about 900 degrees Fahrenheit. If the pack 1522 is a dry binder fiberglass pack, the mold half and / or fiberglass pack can be heated to a lower temperature, for example, the melting point of the dry binder of the pack.

  Referring to FIG. 15C, the vacuum mold component 1602 stops applying vacuum and the vacuum formed fiberglass part 1610 is removed. In one exemplary embodiment, the compression molded fiberglass part 1610 consists solely of or consists essentially of the material of the pack 1522.

  In the example shown in FIGS. 16A-16C, the vacuum formed fiberglass component is shaped. However, in other exemplary embodiments, the vacuum formed fiberglass part can be substantially flat. In one exemplary embodiment, the binderless or dry binder vacuum formed fiberglass component 1610 has a density substantially higher than the density of the initially prepared fiberglass pack 1522, for example, the density of the initially prepared fiberglass pack 1522. Has a density of 4 times or more.

  In one exemplary embodiment, the insulating material formed by the embodiment shown in FIGS. 15A-15C or the embodiment shown in FIGS. 16A-16C is one or more embodiments disclosed in this patent application. Made from a binderless fiber glass pack made by In the exemplary embodiment, since the fiberglass pack is binderless, there is no formaldehyde in the compression molded part 1510 or vacuum molded part of the embodiment shown in FIGS. 15A-15C and 16A-16C.

  In an exemplary embodiment, the insulation formed by the embodiment shown in FIGS. 15A-15C or the embodiment shown in FIGS. 16A-16C is made according to one or more embodiments disclosed in this patent application. Made from a dry binder fiberglass pack. In this exemplary embodiment, the dry binder can be a formaldehyde-free dry binder or a formaldehyde-free dry binder. In a formaldehyde-free binder, the binder itself does not have formaldehyde, but formaldehyde may become a by-product when the binder burns.

  Several exemplary embodiments of mineral fiber webs, packs, and staple fibers and methods of making mineral fiber webs, packs, and staple fibers are disclosed by this application. Mineral fiber webs and packs and methods of making mineral fiber webs and packs according to the present invention can include any combination or sub-combination of features disclosed by the present application.

  In accordance with the provisions of the patent law, the principles and aspects of an improved method of forming a pack from a fibrous material have been described and illustrated in its preferred embodiments. However, it should be understood that the improved method of forming a pack from a fibrous material can be practiced otherwise than as specifically described and illustrated without departing from its spirit or scope. .

300: Pack 312, 612: Molten glass 314, 614: Melting apparatus 316, 616: Fore Haas 318, 618: Rotary spinning machine 320, 620: Glass fiber veil 321, 521: Web 322, 622: Glass fiber 324, 624 : Collecting members 330, 630, 678, 680, 682: Ducts 332, 332 ′, 632a, 632b: Molding devices 334, 634a, 634b: Stacking mechanism (folding mechanism)
345, 645: entanglement mechanism 336, 636, 644, 648, 652, 658: conveyor 350: laminated web 352: entanglement web 370: entanglement pack 375: compression mechanism 390, 590: accumulator 525, 527, 529, 531, 533, 535, 537, 594, 595, 596, 597, 827, 829, 831, 833: dry binder addition 398, 598: flow dividing mechanism 550, 650: curing furnace 610: a method of forming a pack from a fibrous material 640: trimming mechanism 646: binder applicator 654: cutting mechanism 656: chopping mechanism 660: packaging mechanism 900: binder 902: air wrapper 910: rotating drum 1000: insulation product 1002: thick low density core (low density layer)
1004: Thin high-density tensile layer (outer layer)
1050: Tiered bat or pack 1052: Low density tier 1054: High density tier 1210: Thermal oven 1215: Inner oven liner 1216: Oven cavity 1233: Outer oven cabinet 1236: Air gap 1238: Insulation material 1502: Mold half 1510 : Compression molded fiber glass component 1522: Binderless or dry binder fiber glass pack 1602: Vacuum mold component 1610: Vacuum molded fiber glass component

Claims (10)

A continuous process for forming a glass fiber pack,
Melting the glass;
Processing the molten glass to form glass fibers;
Accumulating the glass fibers and cooling the glass fibers;
Forming a binderless web from the cooled glass fibers;
Folding and laminating the glass fiber binderless web;
Mechanically interlacing the fibers of the web to form the glass fiber pack;
Including
The glass fibers have a diameter range from 9 HT (2.3 μm) to 35 HT (8.9 μm), and the glass fibers are 0.25 inches (0.64 cm) to 10.0 inches (25. Continuous process characterized in that it has a length range up to 4 cm).   The continuous method according to claim 1, wherein the fibers are entangled by needling. The glass fiber binderless web has a weight per area of 0.10 to 0.38 pounds per square foot (0.5 to 1.9 kg / m ² ) and 0.45 inches (1.14 cm) to 1 The continuous method of claim 1, wherein the method has a thickness of 375 inches (3.5 cm).   The glass fiber pack comprises 99% to 100% glass, or 99% to 100% glass and an inert component that does not bond the glass fibers together. Continuous method. A continuous process for forming a glass fiber pack,
Melting the glass;
Processing the molten glass to form glass fibers;
Accumulating the glass fibers and cooling the glass fibers;
Forming the glass fiber binderless web;
Folding and laminating the glass fiber binderless web to form the pack;
A continuous method characterized by comprising: 6. A continuous method according to claim 5 , characterized in that the fibers are entangled by needling. The glass fiber binderless web has a weight per area of 0.10 to 0.38 pounds per square foot (0.5 to 1.9 kg / m ² ), and 0.45 inches (1.14 cm) to 1. 6. A continuous process according to claim 5 , characterized in that it has a thickness of 375 inches (3.5 cm). 6. A continuous process according to claim 5 , characterized in that the glass fibers have a diameter range ranging from 15HT (3.8 [mu] m) to 19HT (4.85 [mu] m). 9. The continuous method of claim 8 , wherein the glass fibers have a length range from 0.25 inches (0.64 cm) to 10.0 inches (25.4 cm). 6. The glass fiber pack according to claim 5 , characterized in that it comprises 99% to 100% glass, or 99% to 100% glass and an inert component that does not bond the glass fibers together. Continuous method.

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