U.S. patent application number 13/632895 was filed with the patent office on 2013-04-04 for method of forming a web from fibrous material.
This patent application is currently assigned to Owens Corning Intellectual Capital, LLC. The applicant listed for this patent is Owens Corning Intellectual Capital, LLC. Invention is credited to David J. Gaul, Glenn Haley, Michael T. Pellegrin.
Application Number | 20130084445 13/632895 |
Document ID | / |
Family ID | 47992850 |
Filed Date | 2013-04-04 |
United States Patent
Application |
20130084445 |
Kind Code |
A1 |
Haley; Glenn ; et
al. |
April 4, 2013 |
METHOD OF FORMING A WEB FROM FIBROUS MATERIAL
Abstract
Fibrous material webs and methods of making the fibrous material
webs. Binderless webs can be formed in a continuous process where
fiber material, such as glass is melted and formed into fibers. The
fibers are formed into a web of binderless glass fibers or a web
with a dry binder. The binderless web or the web with dry binder
can be layered and/or the fibers that make up the web can be
mechanically entangled, for example, by needling.
Inventors: |
Haley; Glenn; (Granville,
OH) ; Gaul; David J.; (Granville, OH) ;
Pellegrin; Michael T.; (Newark, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Owens Corning Intellectual Capital, LLC; |
Toledo |
OH |
US |
|
|
Assignee: |
Owens Corning Intellectual Capital,
LLC
Toledo
OH
|
Family ID: |
47992850 |
Appl. No.: |
13/632895 |
Filed: |
October 1, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61541162 |
Sep 30, 2011 |
|
|
|
Current U.S.
Class: |
428/219 ;
442/335; 442/391; 65/469 |
Current CPC
Class: |
D04H 3/08 20130101; C03C
25/1095 20130101; D04H 1/4374 20130101; D04H 1/498 20130101; Y10T
442/67 20150401; D04H 1/46 20130101; D04H 13/008 20130101; Y10T
442/608 20150401; D04H 3/004 20130101; D04H 1/4218 20130101; D04H
1/60 20130101; Y10T 442/609 20150401; D04H 1/724 20130101; D04H
1/488 20130101; Y10T 442/667 20150401; C03B 37/04 20130101 |
Class at
Publication: |
428/219 ;
442/335; 442/391; 65/469 |
International
Class: |
D04H 13/00 20060101
D04H013/00; D04H 3/004 20060101 D04H003/004 |
Claims
1. A continuous method for forming a pack of glass fibers
comprising: melting glass; processing the molten glass to form
glass fibers; forming a binderless web of the glass fibers;
mechanically entangling the fibers of the web to form the pack of
glass fibers.
2. The continuous method of claim 1 wherein the fibers are
entangled by needling.
3. The continuous method of claim 1 wherein the binderless web of
glass fibers has an area weight of about 5 to about 50 grams per
square foot and a thickness of about 0.25 inches to about 4
inches.
4. The continuous method of claim 1 wherein the continuous method
produces between about 750 lbs/hr and 1500 lbs/hr of the pack of
glass fibers.
5. The continuous method of claim 1 wherein the glass fibers have a
diameter range of in a range of from about 9 HT to about 35 HT.
6. The continuous method of claim 5 wherein the glass fibers have a
length range from about 0.25 inches to about 10.0 inches.
7. A binderless web of glass fibers comprising: glass fibers that
are mechanically entangled to form the web; wherein the web has an
area weight of about 5 to about 50 grams per square foot; wherein
the glass fibers have a diameter range of in a range of from about
9 HT to about 35 HT; wherein the glass fibers have a length range
from about 0.25 inches to about 10.0 inches.
8. The binderless web of glass fibers of claim 7 wherein the glass
fibers used to form the have never been compressed for packaging or
shipping.
9. The binderless web of glass fibers of claim 1 wherein the glass
fibers are mechanically entangled by needling.
10. A continuous method for forming a pack of glass fibers
comprising: melting glass; processing the molten glass to form
glass fibers; forming a binderless web of the glass fibers;
layering the binderless web of glass fibers to form the pack.
11. The continuous method of claim 10 further comprising
mechanically entangling the fibers of the layered webs to form the
pack.
12. The continuous method of claim 10 wherein the fibers are
entangled by needling.
13. The continuous method of claim 10 wherein a single layer of the
binderless web of glass fibers has an area weight of about 5 to
about 50 grams per square foot and a thickness of about 0.25 inches
to about 4 inches.
14. The continuous method of claim 10 wherein the continuous method
produces between about 750 lbs/hr and 1500 lbs/hr of the pack of
glass fibers.
15. The continuous method of claim 10 wherein the glass fibers have
a diameter range of in a range of from about 9 HT to about 35
HT.
16. The continuous method of claim 15 wherein the glass fibers have
a length range from about 0.25 inches to about 10.0 inches.
17. A layered binderless web of glass fibers comprising: a first
web of glass fibers; at least one additional web of glass fibers
disposed on the first web of glass fibers; wherein the first web
has an area weight of about 5 to about 50 grams per square foot;
wherein the glass fibers have a diameter range of in a range of
from about 9 HT to about 35 HT; wherein the glass fibers have a
length range from about 0.25 inches to about 10.0 inches.
18. The layered binderless web of glass fibers of claim 17 wherein
the glass fibers of the first web are mechanically entangled with
the glass fibers of the at least one additional web.
19. The binderless web of glass fibers of claim 17 wherein the
glass fibers used to form the have never been compressed for
packaging or shipping.
20. The binderless web of glass fibers of claim 18 wherein the
glass fibers are mechanically entangled by needling.
21. (canceled)
22. (canceled)
23. (canceled)
24. (canceled)
25. (canceled)
26. (canceled)
27. (canceled)
28. (canceled)
29. (canceled)
30. (canceled)
31. (canceled)
32. (canceled)
Description
RELATED APPLICATIONS
[0001] This application claims priority from provisional
application No. 61/541,162 filed on Sep. 30, 2011, titled "Method
of Forming a Pack from Fibrous Materials." Provisional application
No. 61/541,162 is incorporated herein by reference in its
entirety.
BACKGROUND
[0002] Fibrous material can be formed into various products
including webs, packs, batts and blankets. Packs of fibrous
material can be used in many applications, including the
non-limiting examples of insulation and sound-proofing for
buildings and building components, appliances and aircraft. Packs
of fibrous material are typically formed by processes that include
fiberizers, forming hoods, ovens, trimming and packaging machines.
Typical processes also include the use of wet binders, binder
reclaim water and washwater systems.
SUMMARY
[0003] The present application discloses multiple exemplary
embodiments of fibrous material webs and methods of making the
fibrous material webs. Binderless webs or webs with dry binder can
be formed in a continuous process where fiber material, such as
glass is melted and formed into fibers. The fibers are formed into
a web of binderless glass fibers or a web with a dry binder. The
binderless web or the web with dry binder can be layered and/or the
fibers that make up the web can be mechanically entangled, for
example, by needling.
[0004] Other advantages of the webs, batts, and methods of
producing the webs and batts will become apparent to those skilled
in the art from the following detailed description, when read in
view of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1A is a flowchart of an exemplary embodiment of method
for forming a binderless layered web or pack of glass fibers;
[0006] FIG. 1B is a flowchart of an exemplary embodiment of a
method for forming a binderless entangled web of glass fibers;
[0007] FIG. 1C is a flowchart of an exemplary embodiment of a
method for forming a binderless layered and entangled web or pack
of glass fibers;
[0008] FIG. 2A is a flowchart of an exemplary embodiment of method
for forming a layered web or pack of glass fibers with dry
binder;
[0009] FIG. 2B is a flowchart of an exemplary embodiment of a
method for forming a binderless entangled web of glass fibers with
dry binder;
[0010] FIG. 2C is a flowchart of an exemplary embodiment of a
method for forming a binderless layered and entangled web or pack
of glass fibers with dry binder;
[0011] FIG. 2D is a flowchart of an exemplary embodiment of a
method for forming a binderless layered and entangled web or pack
of glass fibers with dry binder;
[0012] FIG. 3A is a schematic illustration of an exemplary
apparatus for forming a binderless layered web or pack of glass
fibers;
[0013] FIG. 3B is a schematic illustration of an exemplary
apparatus for forming a binderless entangled web of glass
fibers;
[0014] FIG. 3C is a schematic illustration of an exemplary
apparatus for forming a binderless layered and entangled web or
pack of glass fibers;
[0015] FIG. 4 is a schematic illustration of a forming apparatus
for forming a web of glass fibers;
[0016] FIG. 5 is a schematic illustration of an exemplary apparatus
for forming a web or pack of glass fibers with a dry binder;
[0017] FIG. 6 is a schematic representation, in elevation of a
process for forming a pack of fibrous materials; and
[0018] FIG. 7 is a schematic representation, in plan view, of a
process for forming a pack from fibrous materials.
DETAILED DESCRIPTION OF THE INVENTION
[0019] The present invention will now be described with occasional
reference to the specific exemplary embodiments of the invention.
This invention may, however, be embodied in different forms and
should not be construed as limited to the embodiments set forth
herein. Rather, these embodiments are provided so that this
disclosure will be thorough and complete, and will fully convey the
scope of the invention to those skilled in the art.
[0020] Unless otherwise defined, all technical and scientific terms
used herein have the same meaning as commonly understood by one of
ordinary skill in the art to which this invention belongs. The
terminology used in the description of the invention herein is for
describing particular embodiments only and is not intended to be
limiting of the invention. As used in the description of the
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.
[0021] Unless otherwise indicated, all numbers expressing
quantities of dimensions such as length, width, height, and so
forth as used in the specification and claims are to be understood
as being modified in all instances by the term "about."
Accordingly, unless otherwise indicated, the numerical properties
set forth in the specification and claims are approximations that
may vary depending on the desired properties sought to be obtained
in embodiments of the present invention. Notwithstanding that the
numerical ranges and parameters setting forth the broad scope of
the invention are approximations, the numerical values set forth in
the specific examples are reported as precisely as possible. Any
numerical values, however, inherently contain certain errors
necessarily resulting from error found in their respective
measurements.
[0022] The description and figures disclose an improved method of
forming a pack from fibrous materials. Generally, the improved
continuous methods replace the traditional methods of applying a
wet binder to fiberized materials with new methods of making a batt
or pack of fibers without any binder (i.e. material that binds
fibers together) and/or new methods of making a batt or pack of
fibers with dry binders.
[0023] The term "fibrous materials", as used herein, is defined to
mean any material formed from drawing or attenuating molten
materials. The term "pack", as used herein, is defined to mean any
product formed by fibrous materials that are joined together by an
adhesive and/or by mechanical entanglement.
[0024] FIGS. 1A and 3A illustrate a first exemplary embodiment of a
continuous process or method 100 of forming a pack 300 (see FIG.
3A) from fibrous materials. The dashed line 101 around the steps of
the method 100 indicates that the method is a continuous method, as
will be described in more detail below. The methods and packs will
be described in terms of glass fibers, but the methods and packs
are applicable as well to the manufacture of fibrous products
formed from other mineral materials, such as the non-limiting
examples of rock, slag and basalt.
[0025] Referring to FIG. 1A, glass is melted 102. For example, FIG.
3A schematically illustrates a melter 314. The melter 314 may
supply molten glass 312 to a forehearth 316. Melters and
forehearths are known in the art and will not be described herein.
The molten glass 312 can be formed from various raw materials
combined in such proportions as to give the desired chemical
composition.
[0026] Referring back to FIG. 1A, the molten glass 312 is processed
to form 104 glass fibers 322. The molten glass 312 can be processed
in a variety of different ways to form the fibers 322. For example,
in the example illustrated by FIG. 3A, the molten glass 312 flows
from the forehearth 316 to one or more rotary fiberizers 318. The
rotary fiberizers 18 receive the molten glass 312 and subsequently
form veils 320 of glass fibers 322. As will be discussed in more
detail below, the glass fibers 322 formed by the rotary fiberizers
318 are long and thin. Accordingly, any desired fiberizer, rotary
or otherwise, sufficient to form long and thin glass fibers 322 can
be used. While the embodiment illustrated in FIG. 3A shows one
rotary fiberizer 318, it should be appreciated that any desired
number of rotary fiberizers 318 can be used.
[0027] The long and thin fibers may take a wide variety of
different forms. In an exemplary embodiment, the long and thin
fibers have a length in a range of from about 0.25 inches to about
10.0 inches and a diameter dimension in a range of from about 9 HT
to about 35 HT. HT stands for hundred thousandths of an inch. In an
exemplary embodiment, the fibers 322 have a length in a range of
from about 1.0 inch to about 5.0 inches and a diameter dimension in
a range of from about 14 HT to about 25 HT. In an exemplary
embodiment, the fibers 322 have a length of about 3 inches and an
average diameter of about 16-17 HT. While not being bound by the
theory, it is believed the use of the relatively long and thin
fibers advantageously provides a pack having better thermal and
acoustic insulative performance, as well as better strength
properties, such as higher tensile strength and/or higher bond
strength, than a similar sized pack having shorter and thicker
fibers.
[0028] In the exemplary embodiments 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 bind the glass fibers together. In an exemplary embodiment, the
lubricant can be a silicone compound, such as siloxane, dimethyl
siloxane and/or silane. The lubricant can also be other materials
or combinations of materials, such as, oil or an oil emulsion. The
oil or oil emulsion may be a mineral oil or mineral oil emulsion
and/or a vegetable oil or vegetable oil emulsion.
[0029] The glass fibers can be coated or partially coated with a
lubricant in a wide variety of different ways. For example, the
lubricant can be sprayed onto the glass fibers 322. In an exemplary
embodiment, the lubricant is configured to prevent damage to the
glass fibers 322 as the glass fibers 322 move through the
manufacturing process and come into contact with various apparatus
as well as other glass fibers. The lubricant can also be useful to
reduce dust in the manufacturing process. The application of the
optional lubricant can be precisely controlled by any desired
structure, mechanism or device.
[0030] Referring to FIG. 1A, a web 321 of fibers without a binder
or other material that binds the fibers together is formed 106. The
web 321 can be formed in a wide variety of different ways. In the
example illustrated by FIG. 3A, the glass fibers 322 are gathered
by an optional gathering member 324. The gathering member 324 is
shaped and sized to receive the glass fibers 322. The gathering
member 324 is configured to divert the glass fibers 322 to a duct
330 for transfer to downstream processing stations, such as for
example forming apparatus 332, which forms the web 321. In other
embodiments, the glass fibers 322 can be gathered on a conveying
mechanism (not shown) to form the web.
[0031] The forming apparatus 332 can be configured to form a
continuous dry web 321 of fibrous material having a desired
thickness. In one exemplary embodiment, the dry webs 321 disclosed
in this application can have a thickness in the range of about 0.25
inches to about 4 inches thick and a density in the range of about
0.2 lb/ft.sup.3 to about 0.6 lb/ft.sup.3. In one exemplary
embodiment, the dry webs 321 disclosed in this application can have
a thickness in the range of about 1 inch to about 3 inches thick
and a density in the range of about 0.3 lb/ft.sup.3 to about 0.5
lb/ft.sup.3. In one exemplary embodiment, the dry webs 321
disclosed in this application can have a thickness of about 1.5
inches and a density of about 0.4 lb/ft.sup.3. The forming
apparatus 332 can take a wide variety of different forms. Any
arrangement for forming a dry web 321 of glass fibers can be
used.
[0032] In one exemplary embodiment, the forming apparatus 332
includes a rotating drum with forming surfaces and areas of higher
or lower pressure. Referring to FIG. 4, the pressure P1 on a side
460 of the forming surface 462 where the fibers 322 are collected
is higher than the pressure P2 on the opposite side 464. This
pressure drop .DELTA.P causes the fibers 322 to collect on the
forming surface 462 to form the dry web 321. In one exemplary
embodiment, the pressure drop .DELTA.P across the forming surface
462 is controlled to be a low pressure and produce a low area
weight web. For example, the pressure drop .DELTA.P can be from
about 0.5 inches of water and 30 inches of water. A velocity V of
the air traveling through the web being formed that results in this
low pressure drop .DELTA.P may be up to 1,000 feet per minute.
[0033] A low area weight web 321 having an area weight of about 5
to about 50 grams per square foot. The low area weight web may have
the density and thickness ranges mentioned above. The low area
weight web may have a thickness in the range of about 0.25 inches
to about 4 inches thick, about 1 inch to about 3 inches thick, or
about 1.5 inches. The low area weight web may have a density in the
range of about 0.2 lb/ft.sup.3 to about 0.6 lb/ft.sup.3, about 0.3
lb/ft.sup.3 to about 0.5 lb/ft.sup.3 or about 0.4 lb/ft.sup.3.
Referring to FIG. 3A, the dry web 321 leaves the forming apparatus
332. In one exemplary embodiment, the low area weight web 321 has a
measured area weight distribution Coefficient of Variation=Sigma
(One Standard Deviation)/Mean (Average).times.100%=of between 0 and
40%. 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 Coefficient of
Variation by measuring multiple small sample area sizes, for
example, 2''.times.2'', of a large sample, for example a 6 ft by 10
ft sample with a light table.
[0034] In the example illustrated by FIG. 1A, the web 321 or
multiple webs are layered 108. For example, a single web 321 may be
lapped in the machine direction or cross-lapped at ninety degrees
to the machine direction to form a layered web 350. In another
embodiment, the web may be cut into portions and the portions are
stacked on top of one another to form the layered web. In yet
another exemplary embodiment, one or more duplicate fiberizers 318
and forming apparatus 332 can be implemented such that two or more
webs are continuously produced in parallel. The parallel webs are
then stacked on top of each other to form the layered web.
[0035] In one exemplary embodiment, the layering mechanism 332 is a
lapping mechanism or a cross-lapping mechanism that functions in
association with a conveyor 336. The conveyor 336 is configured to
move in a machine direction as indicated by the arrow D1. The
lapping or cross-lapping mechanism is configured to receive the
continuous web 321 and deposit alternating layers of the continuous
web on the first conveyer 336 as the first conveyor moves in
machine direction D1. In the deposition process, a lapping
mechanism 334 would form the alternating layers in a machine
direction as indicated by the arrows D1 or the cross-lapping
mechanism 334 would form the alternating layers in a cross-machine
direction. Additional webs 321 may be formed and lapped or
cross-lapped by additional lapping or cross-lapping mechanisms to
increase the number of layers and throughput capacity.
[0036] In one exemplary embodiment, a cross-lapping mechanism is
configured to precisely control the movement of the continuous web
321 and deposit the continuous web on the conveyor 336 such that
the continuous web is not damaged. The cross-lapping mechanism can
include any desired structure and can be configured to operate in
any desired manner. In one exemplary embodiment, the cross-lapping
mechanism includes a head (not shown) configured to move back and
forth at 90 degrees to the machine direction D1. In this
embodiment, the speed of the moving head is coordinated such that
the movement of the head in both cross-machine directions is
substantially the same, thereby providing uniformity of the
resulting layers of the fibrous body. In an exemplary embodiment,
the cross-lapping mechanism comprises vertical conveyors (not
shown) configured to be centered with a centerline of the conveyor
336. The vertical conveyors are further configured to swing from a
pivot mechanism above the conveyor 336 such as to deposit the
continuous web on the conveyor 336. While multiple examples of
cross lapping mechanisms have been described above, it should be
appreciated that the cross-lapping mechanism can be other
structures, mechanisms or devices or combinations thereof.
[0037] The layered web 350 can have any desired thickness. The
thickness of the layered web is a function of several variables.
First, the thickness of the layered web 350 is a function of the
thickness of the continuous web 321 formed by the forming apparatus
332. Second, the thickness of the layered web 350 is a function of
the speed at which the layering mechanism 334 deposits layers of
the continuous web 321 on the conveyer 336. Third, the thickness of
the layered web 334 is a function of the speed of the conveyor 336.
In the illustrated embodiment, the layered web 350 has a thickness
in a range of from about 0.1 inches to about 20.0 inches. In an
exemplary embodiment, a cross lapping mechanism 334 may form a
layered web 350 having from 1 layer to 60 layers. Optionally, a
cross-lapping mechanisms can be adjustable, thereby allowing the
cross-lapping mechanisms 334 and 334 to form a pack having any
desired width. In certain embodiments, the pack can have a general
width in a range of from about 98.0 inches to about 236.0
inches.
[0038] In one exemplary embodiment, the layered web 350 is produced
in a continuous process indicated by dashed box 101 in FIG. 1A. The
fibers produced by the fiberizer 318 are sent directly to the
forming apparatus 332 (i.e. the fibers are not collected and packed
and then unpacked for use at a remote forming apparatus). The web
321 is provided directly to the layering device 352 (i.e. the web
is not formed and rolled up and then unrolled for use at a remote
layering device 352). In an exemplary embodiment of the continuous
process, each of the processes (forming and layering in FIG. 1A)
are connected to the fiberizing process, such that fibers from the
fiberizer are used by the other processes without being stored for
later use.
[0039] In one exemplary embodiment, the web 321 is relatively thick
and has a low area weight, yet the continuous process has a high
throughput. For example, a single layer of the web 321 may have an
area weight of about 5 to about 50 grams per square foot. The low
area weight web may have the density and thickness ranges mentioned
above. The high output continuous process may produce between about
750 lbs/hr and 1500 lbs/hr, such as at least 900 lbs/hr or at least
1250 lbs/hr. The layered web 350 can be used in a wide variety of
different applications.
[0040] FIGS. 1B and 3B illustrate a second exemplary embodiment of
a method 150 of forming a pack 300 (see FIG. 3B) from fibrous
materials without the use of a binder. The dashed line 151 around
the steps of the method 150 indicates that the method is a
continuous method. Referring to FIG. 1B, glass is melted 102. The
glass may be melted as described above with respect to FIG. 3A. The
molten glass 312 is processed to form 104 glass fibers 322. The
molten glass 312 can be processed as described above with respect
to FIG. 3A to form the fibers 322. A web 321 of fibers without a
binder or other material that binds the fibers together is formed
106. The web 321 can be formed as described above with respect to
FIG. 3A.
[0041] 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 entangling mechanism 345, such as a
needling device. The entanglement mechanism 345 is configured to
entangle the individual fibers 322 of the web 321. Entangling the
glass fibers 322 ties the fibers of the web together. The
entanglement causes mechanical properties of the web, such as for
example, tensile strength and shear strength, to be improved. In
the illustrated embodiment, the entanglement mechanism 345 is a
needling mechanism. In other embodiments, the entanglement
mechanism 345 can include other structures, mechanisms or devices
or combinations thereof, including the non-limiting example of
stitching mechanisms.
[0042] 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 apparatus 332 and the
amount of compression of the continuous web 321 by the entanglement
mechanism 345. In an exemplary embodiment, the entangled web 352
has a thickness in a range of from about 0.1 inches to about 2.0
inches. In an exemplary embodiment, the entangled web 352 has a
thickness in a range of from about 0.5 inches to about 1.75 inches.
For example, in one exemplary embodiment, the thickness of the
entangled web is about 1/241 .
[0043] In one exemplary embodiment, the entangled web 352 is
produced in a continuous process 151. The fibers produced by the
fiberizer 318 are sent directly to the forming apparatus 332 (i.e.
the fibers are not collected and packed and then unpacked for use
at a remote forming apparatus). The web 321 is provided directly to
the entangling device 345 (i.e. the web is not formed and rolled up
and then unrolled for use at a remote entangling device 345). The
entangled web 352 can be used in a wide variety of different
applications. In an exemplary embodiment of the continuous process,
each of the processes (forming and entangling in FIG. 1B) are
connected to the fiberizing process, such that fibers from the
fiberizer are used by the other processes without being stored for
later use.
[0044] FIGS. 1C and 3C illustrate a third exemplary embodiment of a
method 170 of forming a pack 370 (see FIG. 3C) from fibrous
materials without the use of a binder. Referring to FIG. 1C, glass
is melted 102. The dashed line 171 around the steps of the method
170 indicates that the method is a continuous method The glass may
be melted as described above with respect to FIG. 3A. Referring
back to FIG. 1C, the molten glass 312 is processed to form 104
glass fibers 322. The molten glass 312 can be processed as
described above with respect to FIG. 3A to form the fibers 322.
Referring to FIG. 1C, a web 321 of fibers without a binder or other
material that binds the fibers together is formed 106. The web 321
can be formed as described above with respect to FIG. 3A. Referring
to FIG. 1C, the web 321 or multiple webs are layered 108. The web
321 or multiple webs can be layered as described above with respect
to FIG. 3A. Referring to FIG. 1C, the fibers 322 of the layered
webs 350 are mechanically entangled 302 to form an entangled pack
370 of layered webs.
[0045] Referring to FIG. 3C, the fibers of the layered webs 350 can
be mechanically entangled by an entangling mechanism 345, such as a
needling device. The entanglement mechanism 345 is configured to
entangle the individual fibers 322 forming the layers of the
layered web. Entangling the glass fibers 322 ties the fibers of the
layered webs 350 together to form the pack. The mechanical
entanglement causes mechanical properties, such as for example,
tensile strength and shear strength, to be improved. In the
illustrated embodiment, the entanglement mechanism 345 is a
needling mechanism. In other embodiments, the entanglement
mechanism 345 can include other structures, mechanisms or devices
or combinations thereof, including the non-limiting example of
stitching mechanisms.
[0046] The entangled pack 370 of layered webs 350 can have any
desired thickness. The thickness of the entangled pack is a
function of several variables. First, the thickness of the
entangled pack is a function of the thickness of the continuous web
321 formed by the forming apparatus 332. Second, the thickness of
the entangled pack 370 is a function of the speed at which the
lapping or cross-lapping mechanism 334 deposits layers of the
continuous web 321 on the conveyer 336. Third, the thickness of the
entangled pack 370 is a function of the speed of the conveyor 336.
Fourth, the thickness of the entangled pack 370 is a function of
the amount of compression of the layered webs 350 by the
entanglement mechanism 345. The entangled pack 370 can have a
thickness in a range of from about 0.1 inches to about 20.0 inches.
In an exemplary embodiment, the entangled pack 370 may having from
1 layer to 60 layers. Each entangled web layer 352 may be from 0.1
to 2 inches thick. For example, each entangled web layer may be
about 0.5 inches thick.
[0047] In one exemplary embodiment, the entangled pack 370 is
produced in a continuous process. The fibers produced by the
fiberizer 318 are sent directly to the forming apparatus 332 (i.e.
the fibers are not collected and packed and then unpacked for use
at a remote forming apparatus). The web 321 is provided directly to
the layering device 352 (i.e. the web is not formed and rolled up
and then unrolled for use at a remote layering device 352). The
layered web 350 is provided directly to the entangling device 345
(i.e. the layered web is not formed and rolled up and then unrolled
for use at a remote entangling device 345). In an exemplary
embodiment of the continuous process, each of the processes
(forming, layering, and entangling in FIG. 1C) are connected to the
fiberizing process, such that fibers from the fiberizer are used by
the other processes without being stored for later use.
[0048] In one exemplary embodiment, the entangled pack 370 of
layered webs is made from a web 321 or webs that is relatively
thick and has a low area weight, yet the continuous process has a
high throughput. For example, a single layer of the web 321 may
have the area weights, thicknesses, and densities mentioned above.
The high output continuous process may produce between about 750
lbs/hr and 1500 lbs/hr, such as at least 900 lbs/hr or at least
1250 lbs/hr. In an exemplary embodiment, the combination of high
web throughput and mechanical entanglement, such as needling, of a
continuous process is facilitated by layering of the web 321, such
as lapping or cross-lapping of the web. By layering the web 321,
the linear speed of the material moving through the layering device
is slower than the speed at which the web is formed. For example,
in a continuous process, a two layer web will travel through the
entangling apparatus 345 at 1/2 the speed at which the web is
formed (3 layers -1/3 the speed, etc.). This reduction in speed
allows for a continuous process where a high throughput, low area
weight web 321 is formed and converted into a multiple layer,
mechanically entangled pack 370. The entangled pack 370 of layered
webs can be used in a wide variety of different applications.
[0049] In an exemplary embodiment, the layering and entangling of
the long, thin fibers results in a strong web 370. For example, the
entanglement of the long, thin glass fibers described in this
application results in a layered, entangled web with a high tensile
strength and a high bond strength. Tensile strength is the strength
of the web 370 when the web is pulled in the direction of the
length or width of the web. Bond strength is the strength of the
web when the web 370 is pulled apart in the direction of the
thickness of the web.
[0050] Tensile strength and bond strength may be tested in a wide
variety of different ways. In one exemplary embodiment, a machine,
such as an Instron machine, pulls the web 370 apart at a fixed
speed (12 inches per second in the examples described below) and
measures the amount of force required to pull the web apart. Forces
required to pull the web apart, including the peak force applied to
the web before the web rips or fails, are recorded.
[0051] In one method of testing tensile strength, the tensile
strength in the length direction is measured by clamping the ends
of the web along the width of the web, pulling the web 370 along
the length of the web with the machine at the fixed speed (12
inches per second in the examples provided below), and recording
the peak force applied in the direction of the length of the web.
The tensile strength in the width direction is measured by clamping
the sides of the web along the width of the web, pulling the web
370 along the width of the web at the fixed speed (12 inches per
second in the examples provided below), and recording the peak
force applied. The tensile strength in the length direction and the
tensile strength in the width direction are averaged to determine
the tensile strength of the sample.
[0052] In one method of testing bond strength, a sample of a
predetermined size (6'' by 6'' in the examples described below) is
provided. Each side of the sample is bonded to a substrate, for
example by gluing. The substrates on the opposite side of the
sample are pulled apart with the machine at the fixed speed (12
inches per second in the examples provided below), and recording
the peak force applied. The peak force applied is divided by the
area of the sample (6'' by 6'' in the examples described below) to
provide the bond strength in terms of force over area.
[0053] The following examples are provided to illustrate the
increased strength of the layered, entangled web 370. In these
examples, no binder is included. That is, no aqueous or dry binder
is included. These examples do not limit the scope of the present
invention, unless expressly recited in the claims. Examples of
layered, entangled webs having 4, 6, and 8 layers are provided.
However, the layered entangled web 370 may be provided with any
number of layers. The layered, entangled web 370 sample length,
width, thickness, number of laps, and weight may vary depending on
the application for the web 370.
[0054] In one exemplary embodiment, a web 370 sample that is 6
inches by 12 inches, has multiple layers, such as two laps (i.e.
four layers), is between 0.5 inches thick and 2.0 inches thick, has
a weight per square foot between 0.1 and 0.3 lbs/sq ft, has a
tensile strength that is greater than 3 lbf, and has a tensile
strength to weight ratio that is greater than 40 lbf/lbm, such as
from about 40 to about 120 lbf/lbm. In an exemplary embodiment, a
bond strength of this sample is greater than 0.1 lbs/sq ft. In an
exemplary embodiment, the tensile strength of the sample described
in this paragraph is greater than 5 lbf. In an exemplary
embodiment, the tensile strength of the sample described in this
paragraph is greater than 7.5 lbf. In an exemplary embodiment, the
tensile strength of the sample described in this paragraph is
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 and 15 lbf. In an exemplary
embodiment, the bond strength of the sample described in this
paragraph is greater than 2 lbs/sq ft. In an exemplary embodiment,
the bond strength of the sample described in this paragraph is
greater than 5 lbs/sq ft. In an exemplary embodiment, the bond
strength of the sample described in this paragraph is greater than
10 lbs/sq ft. In an exemplary embodiment, the bond strength of the
sample described in this paragraph is greater than 15 lbs/sq ft. In
an exemplary embodiment, the bond strength of the sample described
in this paragraph is greater than 20 lbs/sq ft. In an exemplary
embodiment, the tensile strength of the sample described in this
paragraph is greater than 5 lbf and the bond strength is greater
than 2 lbs/sq ft. In an exemplary embodiment, the tensile strength
of the sample described in this paragraph is greater than 7.5 lbf
and the bond strength is greater than 7.5 lbs/sq ft. In an
exemplary embodiment, the tensile strength of the sample described
in this paragraph is greater than 10 lbf and the bond strength is
greater than 10 lbs/sq ft. In an exemplary embodiment, the tensile
strength of the sample described in this paragraph is greater than
12.5 lbf and the bond strength is greater than 15 lbs/sq ft. In an
exemplary embodiment, the tensile strength of the sample described
in this paragraph is greater than 13.75 lbf and the bond strength
is greater than 20 lbs/sq ft. In an exemplary embodiment, the
tensile strength of the sample described in this paragraph is
between 3 and 15 lbf and the bond strength is between 0.3 and 30
lbs/sq ft.
[0055] In one exemplary embodiment, a web 370 sample that is 6
inches by 12 inches, has multiple layers, such as two laps (i.e.
four layers), is between 0.5 inches thick and 1.75 inches thick,
has a weight per square foot between 0.12 and 0.27 lbs/sq ft, has a
tensile strength that is greater than 3 lbf, and has a tensile
strength to weight ratio that is greater than 40 lbf/lbm, such as
from about 40 to about 120 lbf/lbm, and a bond strength that is
greater than 1 lb/sq ft. In an exemplary embodiment, the tensile
strength of the sample described in this paragraph is greater than
5 lbf. In an exemplary embodiment, the tensile strength of the
sample described in this paragraph is greater than 7.5 lbf. In an
exemplary embodiment, the tensile strength of the sample described
in this paragraph is 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 one exemplary embodiment, the tensile
strength of the sample described in this paragraph is between 3 and
15 lbf. In an exemplary embodiment, the bond strength of the sample
described in this paragraph is greater than 2 lbs/sq ft. In an
exemplary embodiment, the bond strength of the sample described in
this paragraph is greater than 5 lbs/sq ft. In an exemplary
embodiment, the bond strength of the sample described in this
paragraph is greater than 10 lbs/sq ft. In an exemplary embodiment,
the bond strength of the sample described in this paragraph is
greater than 15 lbs/sq ft. In an exemplary embodiment, the bond
strength of the sample described in this paragraph is greater than
20 lbs/sq ft. In an exemplary embodiment, the tensile strength of
the sample described in this paragraph is greater than 5 lbf and
the bond strength is greater than 2 lbs/sq ft. In an exemplary
embodiment, the tensile strength of the sample described in this
paragraph is greater than 7.5 lbf and the bond strength is greater
than 7.5 lbs/sq ft. In an exemplary embodiment, the tensile
strength of the sample described in this paragraph is greater than
10 lbf and the bond strength is greater than 10 lbs/sq ft. In an
exemplary embodiment, the tensile strength of the sample described
in this paragraph is greater than 12.5 lbf and the bond strength is
greater than 15 lbs/sq ft. In an exemplary embodiment, the tensile
strength of the sample described in this paragraph is greater than
13.75 lbf and the bond strength is greater than 20 lbs/sq ft. In an
exemplary embodiment, the tensile strength of the sample described
in this paragraph is between 3 and 15 lbf and the bond strength is
between 0.3 and 30 lbs/ sq ft.
[0056] In one exemplary embodiment, a web 370 sample that is 6
inches by 12 inches, has multiple layers, such as two laps (i.e.
four layers), is between 0.5 inches thick and 1.25 inches thick,
has a weight per square foot between 0.2 and 0.3 lbs/sq ft, has a
tensile strength that is greater than 10 lbf, and has a tensile
strength to weight ratio that is greater than 75 lbf/lbm, such as
from about 75 about 120 lbf/lbm. In an exemplary embodiment, the
tensile strength of the sample described in this paragraph is
greater than 12.5 lbf. In an exemplary embodiment, the tensile
strength of the sample described in this paragraph is greater than
13.75 lbf. In one exemplary embodiment, the tensile strength of the
sample described in this paragraph is between 3 and 15 lbf. In one
exemplary embodiment, the bond strength of the sample described in
this paragraph is greater than 3 lb/sq ft. In an exemplary
embodiment, the bond strength of the sample described in this
paragraph is greater than 10 lb/sq ft. In an exemplary embodiment,
the bond strength of the sample described in this paragraph is
greater than 15 lb/sq ft. In one exemplary embodiment, the tensile
strength of the sample described in this paragraph is greater than
10 lbf and the bond strength is greater than 3 lb/sq ft. In an
exemplary embodiment, the tensile strength of the sample described
in this paragraph is greater than 12.5 lbf and the bond strength is
greater than 10 lb/sq ft. In an exemplary embodiment, the tensile
strength of the sample described in this paragraph is greater than
13.75 lbf and the bond strength is greater than 15 lb/sq ft.
[0057] In one exemplary embodiment, a web 370 sample that is 6
inches by 12 inches, has multiple layers, such as three laps (i.e.
six layers), is between 1.0 inches thick and 2.25 inches thick, has
a weight per square foot between 0.15 and 0.4 lbs/sq ft, has a
tensile strength that is greater than 5 lbf, and has a tensile
strength to weight ratio that is greater than 40 lbf/lbm, such as
from about 40 to about 140 lbf/lbm. In an exemplary embodiment, the
bond strength of this sample is greater than 0.1 lbs/sq ft. In an
exemplary embodiment, the tensile strength of the sample described
in this paragraph is greater than 7.5 lbf. In an exemplary
embodiment, the tensile strength of the sample described in this
paragraph is 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 and 20 lbf. In an
exemplary embodiment, the bond strength of the sample described in
this paragraph is greater than 0.5 lbs/sq ft. In an exemplary
embodiment, the bond strength of the sample described in this
paragraph is greater than 1.0 lbs/sq ft. In an exemplary
embodiment, the bond strength of the sample described in this
paragraph is greater than 1.5 lbs/sq ft. In an exemplary
embodiment, the bond strength of the sample described in this
paragraph is greater than 2.0 lbs/sq ft. In an exemplary
embodiment, the bond strength of the sample described in this
paragraph is greater than 2.5 lbs/sq ft. In an exemplary
embodiment, the bond strength of the sample described in this
paragraph is greater than 3.0 lbs/sq ft. In an exemplary
embodiment, the tensile strength of the sample described in this
paragraph is greater than 7.5 lbf and the bond strength is greater
than 0.40 lbs/sq ft. In an exemplary embodiment, the tensile
strength of the sample described in this paragraph is greater than
10 lbf and the bond strength is greater than 0.6 lbs/ sq ft. In an
exemplary embodiment, the tensile strength of the sample described
in this paragraph is greater than 12.5 lbf and the bond strength is
greater than 0.9 lbs/ sq ft. In an exemplary embodiment, the
tensile strength of the sample described in this paragraph is
between 5 and 20 lbf and the bond strength is between 0.1 and 4
lbs/sq ft.
[0058] In one exemplary embodiment, a web 370 sample that is 6
inches by 12 inches, has multiple layers, such as three laps (i.e.
six layers), is between 1.0 inches thick and 1.50 inches thick, and
has a weight per square foot between 0.25 and 0.4 lbs/sq ft, has a
tensile strength that is greater than 9 lbf, and has a tensile
strength to weight ratio that is greater than 50 lbf/lbm, such as
from about 50 to about 140 lbf/lbm. In an exemplary embodiment, the
tensile strength of the sample described in this paragraph is
greater than 12.5 lbf. In an exemplary embodiment, the tensile
strength of the sample described in this paragraph is greater than
13.75 lbf. In one exemplary embodiment, the tensile strength of the
sample described in this paragraph is between 9 and 15 lbf. In an
exemplary embodiment, the bond strength of the sample described in
this paragraph is greater than 0.5 lbs/sq ft. In an exemplary
embodiment, the bond strength of the sample described in this
paragraph is greater than 1.0 lbs/sq ft. In an exemplary
embodiment, the bond strength of the sample described in this
paragraph is greater than 1.5 lbs/sq ft. In an exemplary
embodiment, the bond strength of the sample described in this
paragraph is greater than 2.0 lbs/sq ft. In an exemplary
embodiment, the bond strength of the sample described in this
paragraph is greater than 2.5 lbs/sq ft. In an exemplary
embodiment, the bond strength of the sample described in this
paragraph is greater than 3.0 lbs/sq ft. In an exemplary
embodiment, the tensile strength of the sample described in this
paragraph is greater than 9 lbf and a bond strength that is greater
than 0.5 lbs/sq ft. In an exemplary embodiment, the tensile
strength of the sample described in this paragraph is greater than
12.5 lbf and a bond strength that is greater than 1.0 lbs/sq ft. In
an exemplary embodiment, the tensile strength of the sample
described in this paragraph is greater than 13.75 lbf and a bond
strength that is greater than 2 lbs/sq ft.
[0059] In one exemplary embodiment, a web 370 sample that is 6
inches by 12 inches, has multiple layers, such as four laps (i.e.
eight layers), is between 0.875 inches thick and 2.0 inches thick,
and has a weight per square foot between 0.15 and 0.4 lbs/sq ft,
has a tensile strength that is greater than 3 lbf, and has a
tensile strength to weight ratio that is greater than 40 lbf/lbm,
such as from about 40 to about 130 lbf/lbm. In one exemplary
embodiment, the web has a bond strength that is greater than 0.3
lbs/sq ft. In an exemplary embodiment, the bond strength of this
sample is greater than 0.1 lbs/sq ft. In an exemplary embodiment,
the tensile strength of the sample described in this paragraph is
greater than 7.5 lbf. In an exemplary embodiment, the tensile
strength of the sample described in this paragraph is greater than
10 lbf. In one exemplary embodiment, the tensile strength of the
sample described in this paragraph is between 3 and 15 lbf. In an
exemplary embodiment, the bond strength of the sample described in
this paragraph is greater than 0.5 lbs/sq ft. In an exemplary
embodiment, the bond strength of the sample described in this
paragraph is greater than 1.0 lbs/sq ft. In an exemplary
embodiment, the bond strength of the sample described in this
paragraph is greater than 2 lbs/sq ft. In an exemplary embodiment,
the bond strength of the sample described in this paragraph is
greater than 3 lbs/sq ft. In an exemplary embodiment, the bond
strength of the sample described in this paragraph is greater than
4 lbs/sq ft. In an exemplary embodiment, the bond strength of the
sample described in this paragraph is greater than 5 lbs/sq ft. In
an exemplary embodiment, the bond strength of the sample described
in this paragraph is greater than 10 lbs/sq ft. In an exemplary
embodiment, the tensile strength of the sample described in this
paragraph is greater than 7.5 lbf and the bond strength is greater
than 0.5 lbs/sq ft. In an exemplary embodiment, the tensile
strength of the sample described in this paragraph is greater than
10 lbf and the bond strength is greater than 1.0 lbs/sq ft. In one
exemplary embodiment, the tensile strength of the sample described
in this paragraph is between 3 and 15 lbf and the bond strength is
between 0.3 and 15 lbs/sq ft.
[0060] In one exemplary embodiment, a web 370 sample that is 6
inches by 12 inches, has multiple layers, such as four laps (i.e.
eight layers), is between 1.0 inches thick and 2.0 inches thick,
and has a weight per square foot between 0.1 and 0.3 lbs/sq ft, has
a tensile strength that is greater than 9 lbf, and has a tensile
strength to weight ratio that is greater than 70 lbf/lbm. In an
exemplary embodiment, the tensile strength of the sample described
in this paragraph is greater than 10 lbf. In an exemplary
embodiment, the bond strength of the sample described in this
paragraph is greater than 0.5 lbs/sq ft. In an exemplary
embodiment, the bond strength of the sample described in this
paragraph is greater than 1.0 lbs/sq ft. In an exemplary
embodiment, the bond strength of the sample described in this
paragraph is greater than 2 lbs/sq ft. In an exemplary embodiment,
the bond strength of the sample described in this paragraph is
greater than 3 lbs/sq ft. In an exemplary embodiment, the bond
strength of the sample described in this paragraph is greater than
4 lbs/sq ft. In an exemplary embodiment, the bond strength of the
sample described in this paragraph is greater than 5 lbs/sq ft. In
an exemplary embodiment, the bond strength of the sample described
in this paragraph is greater than 10 lbs/sq ft. In an exemplary
embodiment, the tensile strength of the sample described in this
paragraph is greater than 10 lbf and the bond strength is greater
than 5 lbs/sq ft.
[0061] FIGS. 2A-2C illustrate exemplary embodiments of methods that
are similar to the embodiments of FIGS. 1A-1C, except the web 521
(see FIG. 5) is formed 260 with a dry or non-aqueous binder. 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.
[0062] FIG. 2D illustrates a method 290 that is similar to the
method 270 of FIG. 2C. In FIG. 2D, the steps in boxes with dashed
lines are optional. In the exemplary embodiment illustrated by FIG.
2D, the dry binder can optionally be added to the web step 292
and/or the layered web at step 294, instead of (or in addition to)
before the web is formed. For example, if step 292 is included, the
web may be formed without a dry binder, and then the dry binder is
added to the web before layering and/or during layering. If step
294 is included, the web may be formed and layered without a dry
binder, and then the dry binder is added to the layered web.
[0063] Referring to FIG. 5, the dry binder (indicated by the large
arrows) can be added to the fibers 322 and/or the web 521 at a
variety of different points in the process. Arrow 525 indicates
that the dry binder can be added to the fibers 322 at or above the
collecting member. Arrow 527 indicates that the dry binder can be
added to the fibers 322 in the duct 330. Arrow 529 indicates that
the dry binder can be added to the fibers 322 in the forming
apparatus 332. Arrow 531 indicates that the dry binder can be added
to the web 321 after the web leaves the forming apparatus 332.
Arrow 533 indicates that the dry binder can be added to the web 321
as the web is layered by the layering apparatus 334. Arrow 535
indicates that the dry binder can be added to the web 321 after the
web is layered. Arrow 537 indicates that the dry binder can be
added to the web 321 or layered web in the oven 550. The dry binder
can be added to the fibers 322 or the web 321 to form a web 521
with dry binder in any manner.
[0064] In one exemplary embodiment, the dry binder is applied to
the fibers 322 at a location that is significant distance
downstream from the fiberizer 318. For example, the dry binder may
be applied to the fibers at a location where the temperature of the
fibers and/or a temperature of the air surrounding the fibers is
significantly lower than the temperature of the fibers and the
surrounding air at the fiberizer. In one exemplary embodiment, the
dry binder is applied at a location where a temperature of the
fibers and/or a temperature of air that surrounds the fibers is
below a temperature at which the dry binder melts or a temperature
at which the dry binder fully cures or reacts. For example, a
thermoplastic binder may be applied at a point in the production
line where a temperature of the fibers 322 and/or a temperature of
air that surrounds the fibers are below the melting point of the of
the thermoplastic binder. A thermoset binder may be applied at a
point in the production line where a temperature of the fibers 322
and/or a temperature of air that surrounds the fibers are below a
curing temperature of the thermoset binder. That is, the thermoset
binder may be applied at a point where a temperature of the fibers
322 and/or a temperature of air that surrounds the fibers is below
a point where the thermoset binder fully reacts or full
cross-linking of the thermoset binder occurs. In one exemplary
embodiment, the dry binder is applied at a location in the
production line where the temperature of the fibers 322 and/or a
temperature of air that surrounds the fibers are below 250 degrees
F. In one exemplary embodiment, the temperature of the fibers
and/or a temperature of air that surrounds the fibers at the
locations indicated by arrows 527, 529, 531, 533, and 535 in FIG. 5
is below a temperature at which the dry binder melts or fully
cures.
[0065] In one exemplary embodiment, the binder applicator is a
sprayer configured for dry powders. The sprayer may be configured
such that the force of the spray is adjustable, thereby allowing
more or less penetration of the dry powder into the continuous web
of fibrous material. Alternatively, the binder applicator can be
other structures, mechanisms or devices or combinations thereof,
such as for example a vacuum device, sufficient to draw the dry
binder into the continuous web 321 of glass fibers.
[0066] The optional dry binder can take a wide variety of different
forms. Any non-aqueous medium that holds the fibers 322 together to
form a web 521 can be used. In one exemplary embodiment, the dry
binder, while being initially applied to the fibers, is comprised
of substantially 100% solids. The term "substantially 100% solids",
as used herein, means any binder material having diluents, such as
water, in an amount less than or equal to approximately two
percent, and preferably less than or equal to one percent by weight
of the binder (while the binder is being applied, rather than after
the binder has dried or cured). However, it should be appreciated
that certain embodiments, the binder can include diluents, such as
water, in any amount as desired depending on the specific
application and design requirements. In one exemplary embodiment,
the dry binder is a thermoplastic resin-based material that is not
applied in liquid form and further is not water based. In other
embodiments, the dry binder can be other materials or other
combinations of materials, including the non-limiting example of
polymeric thermoset resins. The dry binder can have any form or
combinations of forms including the non-limiting examples of
powders, particles, fibers and/or hot melt. Examples of hot melt
polymers include, but are not limited to, ethylene-vinyl acetate
copolymer, ethylene-acrylate copolymer, low density polyethylene,
high density polyethylene, atactic polypropylene, polybutene-1,
styrene block copolymer, polyamide, thermoplastic polyurethane,
styrene block copolymer, polyester and the like. In one exemplary
embodiment, sufficient dry binder is applied such that a cured
fibrous pack can be compressed for packaging, storage and shipping,
yet regains its thickness--a process known as "loft recovery"--when
installed.
[0067] In the examples illustrated by FIGS. 2A-2D and 5, the glass
fibers 322 can optionally be coated or partially coated with a
lubricant before or after the dry binder is applied to the glass
fibers. In an exemplary embodiment, the lubricant is applied after
the dry binder to enhance the adhesion of the dry binder to the
glass fibers 322. The lubricant can be any of the lubricants
described above.
[0068] Referring to FIG. 5, the continuous web with unreacted dry
binder 521 is transferred from the forming apparatus 332 to the
optional layering mechanism 334. The layering mechanism may take a
wide variety of different forms. For example, the layering
mechanism may be a lapping mechanism that layers the web 321 in the
machine direction D1 or a cross-lapping mechanism that laps the web
in a direction that is substantially orthogonal to the machine
direction. The cross-lapping device described above for layering
the binderless web 321 can be used to layer the web 521 with
unreacted dry binder.
[0069] In an exemplary embodiment, the dry binder of the continuous
web 521 is configured to be configured to be thermally set in a
curing oven 550. In an exemplary embodiment, the curing oven 550
replaces the entanglement mechanism 345, since the dry binder holds
the fibers 322 together. In another exemplary embodiment, both a
curing oven 550 and an entanglement mechanism 345 are included.
[0070] FIGS. 6 and 7 schematically illustrate another exemplary
embodiment of a method for forming a pack from fibrous materials is
illustrated generally at 610. Referring to FIG. 6, molten glass 612
is supplied from a melter 614 to a forehearth 616. The molten glass
612 can be formed from various raw materials combined in such
proportions as to give the desired chemical composition. The molten
glass 612 flows from the forehearth 616 to a plurality of rotary
fiberizers 618.
[0071] Referring to FIG. 6, the rotary fiberizers 618 receive the
molten glass 612 and subsequently form veils 620 of glass fibers
622 entrained in a flow of hot gases. As will be discussed in more
detail below, the glass fibers 622 formed by the rotary fiberizers
618 are long and thin. Accordingly, any desired fiberizer, rotary
or otherwise, sufficient to form long and thin glass fibers 22 can
be used. While the embodiment illustrated in FIGS. 6 and 7 show a
quantity of two rotary fiberizers 618, it should be appreciated
that any desired number of rotary fiberizers 18 can be used.
[0072] The flow of hot gases can be created by optional blowing
mechanisms, such as the non-limiting examples of annular blowers
(not shown) or annular burners (not shown). Generally, the blowing
mechanisms are configured to direct the veil 620 of glass fibers
622 in a given direction, usually in a downward manner. It should
be understood that the flow of hot gasses can be created by any
desired structure, mechanism or device or any combination
thereof.
[0073] As shown in FIG. 6, optional spraying mechanisms 626 can be
positioned beneath the rotary fiberizers 618 and configured to
spray fine droplets of water or other fluid onto the hot gases in
the veils 620 to help cool the flow of hot gases, protect the
fibers 622 from contact damage and/or enhance the bonding
capability of the fibers 622. The spraying mechanisms 626 can be
any desired structure, mechanism or device sufficient to spray fine
droplets of water onto the hot gases in the veils 620 to help cool
the flow of hot gases, protect the fibers 622 from contact damage
and/or enhance the bonding capability of the fibers 22. While the
embodiment shown in FIG. 6 illustrates the use of the spraying
mechanisms 626, it should be appreciated that the use of the
spraying mechanisms 626 is optional and the method of forming the
pack from fibrous materials 610 can be practiced without the use of
the spraying mechanisms 626.
[0074] 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 positioned around the
veils 620 at a position beneath the rotary fiberizers 618. The
nozzles 628 can be configured to supply a lubricant (not shown) to
the glass fibers 622 from a source of lubricant (not shown).
[0075] The application of the lubricant can be precisely controlled
by any desired structure, mechanism or device, such as the
non-limiting example of a valve (not shown). In certain
embodiments, the lubricant can be a silicone compound, such as
siloxane, dimethyl siloxane, and/or silane. The lubricant can also
be other materials or combinations of materials, such as for
example an oil or an oil emulsion. The oil or oil emulsion may be a
mineral oil or mineral oil emulsion and/or a vegetable oil or
vegetable oil emulsion. In an exemplary embodiment, the lubricant
is applied in an amount of about 1.0 percent oil and/or silicone
compound by weight of the resulting pack of fibrous materials.
However, in other embodiments, the amount of the lubricant can be
more or less than about 1.0 percent oil and/or silicone compound by
weight.
[0076] While the embodiment shown in FIG. 6 illustrates the use of
nozzles 628 to supply a lubricant (not shown) to the glass fibers
622, it should be appreciated that the use of nozzles 628 is
optional and the method of forming the pack from fibrous materials
610 can be practiced without the use of the nozzles 628.
[0077] In the illustrated embodiment, the glass fibers 622,
entrained within the flow of hot gases, can be gathered by an
optional gathering member 624. The gathering member 624 is shaped
and sized to easily receive the glass fibers 622 and the flow of
hot gases. The gathering member 624 is configured to divert the
glass fibers 622 and the flow of hot gases to a duct 630 for
transfer to downstream processing stations, such as for example
forming apparatus 632a and 632b. In other embodiments, the glass
fibers 622 can be gathered on a conveying mechanism (not shown)
such as to form a blanket or batt (not shown). The batt can be
transported by the conveying mechanism to further processing
stations (not shown). The gathering member 624 and the duct 630 can
be any structure having a generally hollow configuration that is
suitable for receiving and conveying the glass fibers 622 and the
flow of hot gases. While the embodiment shown in FIG. 6 illustrates
the use of the gathering member 624, it should be appreciated that
the use of gathering member 624 to divert the glass fibers 622 and
the flow of hot gases to the duct 630 is optional and the method of
forming the pack from fibrous materials 610 can be practiced
without the use of the gathering member 624.
[0078] In the embodiment shown in FIGS. 6 and 7, a single fiberizer
618 is associated with an individual duct 630, such that the glass
fibers 622 and the flow of hot gases from the single fiberizer 618
are the only source of the glass fibers 622 and the flow of hot
gasses entering the duct 630. Alternatively, an individual duct 630
can be adapted to receive the glass fibers 622 and the flow of hot
gases from multiple fiberizers 618 (not shown).
[0079] Referring again to FIG. 6, optionally, a header system (not
shown) can be positioned between the forming apparatus 632a and
632b and the fiberizers 618. The header system can be configured as
a chamber in which glass fibers 622 and gases flowing from the
plurality of fiberizers 618 can be combined while controlling the
characteristics of the resulting combined flow. In certain
embodiments, the header system can include a control system (not
shown) configured to combine the flows of the glass fibers 622 and
gases from the fiberizers 618 and further configured to direct the
resulting combined flows to the forming apparatus 632a and 632b.
Such a header system can allow for maintenance and cleaning of
certain fiberizers 618 without the necessity of shutting down the
remaining fiberizers 618. Optionally, the header system can
incorporate any desired means for controlling and directing the
glass fibers 22 and flows of gases.
[0080] Referring now to FIG. 7, the momentum of the flow of the
gases, having the entrained glass fibers 622, will cause the glass
fibers 622 to continue to flow through the duct 630 to the forming
apparatus 632a and 632b. The forming apparatus 632a and 632b can be
configured for several functions. First, the forming apparatus 632a
and 632b can be configured to separate the entrained glass fibers
622 from the flow of the gases. Second, the forming apparatus 632a
and 632b can be configured to form a continuous thin and dry web of
fibrous material having a desired thickness. Third, the forming
apparatus 632a and 632b can be configured to allow the glass fibers
622 to be separated from the flow of gasses in a manner that allows
the fibers to be oriented within the web with any desired degree of
"randomness". The term "randomness", as used herein, is defined to
mean that the fibers 622, or portions of the fibers 622, can be
nonpreferentially oriented in any of the X, Y or Z dimensions. In
certain instances, it may be desired to have a high degree of
randomness. In other instances, it may be desired to control the
randomness of the fibers 622 such that the fibers 622 are
non-randomly oriented, in other words, the fibers are substantially
coplanar or substantially parallel to each other. Fourth, the
forming apparatus 632a and 632b can be configured to transfer the
continuous web of fibrous material to other downstream
operations.
[0081] In the embodiment illustrated in FIG. 7, each of the forming
apparatus 632a and 632b include a drum (not shown) configured for
rotation. The drum can include any desired quantity of foraminous
surfaces and areas of higher or lower pressure. Alternatively, each
of the forming apparatus 332a and 332b can be formed from other
structures, mechanisms and devices, sufficient to separate the
entrained glass fibers 622 from the flow of the gases, form a
continuous web of fibrous material having a desired thickness and
transfer the continuous web of fibrous material to other downstream
operations. In the illustrated embodiment shown in FIG. 7, each of
the forming apparatus 632a and 632b are the same. However, in other
embodiments, each of the forming apparatus 632a and 632b can be
different from each other.
[0082] Referring again to FIG. 7, the continuous web of fibrous
material is transferred from the forming apparatus 632a and 632b to
an optional binder applicator 646. The binder applicator 646 is
configured to apply a "dry binder" to the continuous web of fibrous
material. The term "dry binder", as used herein, is defined to mean
that the binder is comprised of substantially 100% solids while the
binder is being applied. The term "substantially 100% solids", as
used herein, is defined to mean any binder material having
diluents, such as water, in an amount less than or equal to
approximately two percent, and preferably less than or equal to
approximately one percent by weight of the binder (while the binder
is being applied, rather than after the binder has dried and/or
cured). However, it should be appreciated that certain embodiments,
the binder can include diluents, such as water, in any amount as
desired depending on the specific application and design
requirements. The binder may be configured to thermally set in a
curing oven 650. In this application, the terms "cure" and
"thermally set" refer to a chemical reaction and/or one or more
phase changes that cause the dry binder to bind the fibers of the
web together. For example, a thermoset dry binder (or thermoset
component of the dry binder) cures or thermally sets as a result of
a chemical reaction that occurs as a result of an application of
heat. A thermoplastic dry binder (or thermoplastic component of the
dry binder) cures or thermally sets as a result of being heated to
a softened or melted phase and then cooled to a solid phase.
[0083] In an exemplary embodiment, the dry binder is a
thermoplastic resin-based material that is not applied in liquid
form and further is not water based. In other embodiments, the dry
binder can be other materials or other combinations of materials,
including the non-limiting example of polymeric thermoset resins.
The dry binder can have any form or combinations of forms including
the non-limiting examples of powders, particles, fibers and/or hot
melt. Examples of hot melt polymers include, but are not limited
to, ethylene-vinyl acetate copolymer, ethylene-acrylate copolymer,
low density polyethylene, high density polyethylene, atactic
polypropylene, polybutene-1, styrene block copolymer, polyamide,
thermoplastic polyurethane, styrene block copolymer, polyester and
the like. Sufficient dry binder is applied such that a cured
fibrous pack can be compressed for packaging, storage and shipping,
yet regains its thickness--a process known as "loft recovery"--when
installed. Applying the dry binder to the continuous web of fibrous
material forms a continuous web, optionally with unreacted
binder.
[0084] In the embodiment illustrated by FIGS. 6 and 7, the binder
applicator 646 is a sprayer configured for dry powders. The sprayer
is configured such that the force of the spray is adjustable,
thereby allowing more or less penetration of the dry powder into
the continuous web of fibrous material. Alternatively, the binder
applicator 646 can be other structures, mechanisms or devices or
combinations thereof, such as for example a vacuum device,
sufficient to draw a "dry binder" into the continuous web of
fibrous material.
[0085] While the embodiment illustrated in FIG. 7 shows a binder
applicator 646 configured to apply a dry binder to the continuous
web of fibrous material, it is within the contemplation of this
invention that in certain embodiments no binder will be applied to
the continuous web of fibrous material.
[0086] Referring again to FIG. 7, the continuous web, optionally
with unreacted binder is transferred from the binder applicators
646 to the corresponding cross-lapping mechanism 634a and 634b. As
shown in FIG. 7, forming apparatus 632a is associated with
cross-lapping mechanism 634a and forming apparatus 632b is
associated with cross-lapping mechanism 634b. The cross-lapping
mechanisms 634a and 634b function in association with a first
conveyor 636. The first conveyor 636 is configured to move in a
machine direction as indicated by the arrow D1. The cross-lapping
mechanism 634a is configured to receive the continuous web,
optionally with unreacted binder, from the optional binder
applicators 646 and is further configured to deposit alternating
layers of the continuous web, optionally with unreacted binder, on
the first conveyer 636 as the first conveyor 636 moves in machine
direction D1, thereby forming the initial layers of a fibrous body.
In the deposition process, the cross-lapping mechanism 634a forms
the alternating layers in a cross-machine direction as indicated by
the arrows D2. Accordingly, as the deposited continuous web,
optionally with unreacted binder, from crosslapping mechanism 634a
travels in machine direction D1, additional layers are deposited on
the fibrous body by the downstream cross-lapping mechanism 634b.
The resulting layers of the fibrous body deposited by cross-lapping
mechanisms 634a and 634b form a pack.
[0087] In the illustrated embodiment, the cross-lapping mechanisms
634a and 634b are devices configured to precisely control the
movement of the continuous web with unreacted binder and deposit
the continuous web with unreacted binder on the first conveyor 636
such that the continuous web, optionally with unreacted binder, is
not damaged. The cross-lapping mechanisms 634a and 634b can include
any desired structure and can be configured to operate in any
desired manner. In one example, the cross-lapping mechanisms 634a
and 634b can include a head (not shown) configured to move back and
forth in the cross-machine direction D2. In this embodiment, the
speed of the moving head is coordinated such that the movement of
the head in both cross-machine directions is substantially the
same, thereby providing uniformity of the resulting layers of the
fibrous body. In another example, vertical conveyors (not shown)
configured to be centered with a centerline of the first conveyor
636 can be utilized. The vertical conveyors are further configured
to swing from a pivot mechanism above the first conveyor 636 such
as to deposit the continuous web, optionally with unreacted binder,
on the first conveyor 36. While several examples of cross lapping
mechanisms have been described above, it should be appreciated that
the cross-lapping mechanisms 634a and 634b can be other structures,
mechanisms or devices or combinations thereof
[0088] Referring again to FIG. 7, optionally the positioning of the
continuous web, optionally with unreacted binder, on the first
conveyor 636 can be accomplished by a controller (not shown), such
as to provide improved uniformity of the pack. The controller can
be any desired structure, mechanism or device or combinations
thereof.
[0089] The layered web or pack can have any desired thickness. The
thickness of the pack is a function of several variables. First,
the thickness of the pack is a function of the thickness of the
continuous web, optionally with unreacted binder, formed by each of
the forming apparatus 632a and 632b. Second, the thickness of the
pack is a function of the speed at which the cross-lapping
mechanisms 634a and 634b alternately deposit layers of the
continuous web, optionally with unreacted binder, on the first
conveyer 636. Third, the thickness of the pack is a function of the
speed of the first conveyor 636. In the illustrated embodiment, the
pack has a thickness in a range of from about 0.1 inches to about
20.0 inches. In other embodiments, the pack can have a thickness
less than about 0.1 inches or more than about 20.0 inches.
[0090] As discussed above, the cross lapping mechanisms 634a and
634b are configured to deposit alternating layers of the continuous
web, optionally with unreacted binder, on the first conveyer 636 as
the first conveyor 636 moves in machine direction D1, thereby
forming layers of a fibrous body. In the illustrated embodiment,
the cross lapping mechanism 634a and 634b and the first conveyor
636 are coordinated such as to form a fibrous body having a
quantity of layers in a range of from about 1 layer to about 60
layers. In other embodiments, the cross lapping mechanism 634a and
634b and the first conveyor 636 can be coordinated such as to form
a fibrous body having any desired quantity of layers, including a
fibrous body having in excess of 60 layers.
[0091] Optionally, the cross-lapping mechanisms 634a and 634b can
be adjustable, thereby allowing the cross-lapping mechanisms 634a
and 634b to form a pack having any desired width. In certain
embodiments, the pack can have a general width in a range of from
about 98.0 inches to about 236.0 inches. Alternatively, the pack
can have a general width less than about 98.0 inches or more than
about 236.0 inches.
[0092] While the cross-lapping mechanisms 634a and 634b have been
described above as being jointly involved in the formation of a
fibrous body, it should be appreciated that in other embodiments,
the cross-lapping mechanisms 634a and 634b can operate
independently of each other such as to form discrete lanes of
fibrous bodies.
[0093] Referring to FIGS. 6 and 7, the pack, having the layers
formed by the cross-lapping mechanisms 634a and 634b, is carried by
the first conveyor 636 to an optional trim mechanism 640. The
optional trim mechanism 640 is configured to trim the edges of the
pack, such as to form a desired width of the pack. In an exemplary
embodiment, the pack can have an after-trimmed width in a range of
from about 98.0 inches to about 236.0 inches. Alternatively, the
pack can have an after trimmed width less than about 98.0 inches or
more than about 236.0 inches.
[0094] In the illustrated embodiment, the optional trim mechanism
640 includes a saw system having a plurality of rotating saws (not
shown) positioned on either side of the pack. Alternatively, the
trim mechanism 640 can be other structures, mechanisms or devices
or combinations thereof including the non-limiting examples of
water jets, compression knives.
[0095] In the illustrated embodiment, the trim mechanism 640 is
advantageously positioned upstream from the curing oven 650.
Positioning the trim mechanism 640 upstream from the curing oven
650 allows the pack to be trimmed before the pack is thermally set
in the curing oven 650. Optionally, materials that are trimmed from
the pack by the trim mechanism 640 can be returned to the flow of
gasses and glass fibers in the ducts 630 and recycled in the
forming apparatus 632a and 632b. Recycling of the trim materials
advantageously prevents potential environmental issues connected
with the disposal of the trim materials. As shown in FIG. 6,
ductwork 642 connects the trim mechanism 640 with the ducts 630 and
is configured to facilitate the return of trim materials to the
forming apparatus 632a and 632b. While the embodiment shown in
FIGS. 6 and 7 illustrate the recycling of the trimmed materials, it
should be appreciated that the recycling of the trimmed materials
is optional and the method of forming the pack from fibrous
materials 610 can be practiced without recycling of the trimmed
materials. In another exemplary embodiment, the trim mechanism 640
is positioned downstream from the curing oven 650. This positioning
is particularly useful if the trimmed materials are not recycled.
Trimming the pack forms a trimmed pack.
[0096] The trimmed pack is conveyed by the first conveyor 636 to a
second conveyor 644. As shown in FIG. 6, the second conveyor 644
may be positioned to be "stepped down" from the first conveyor 636.
The term "stepped down", as used herein, is defined to mean the
upper surface of the second conveyor 644 is positioned to be
vertically below the upper surface of the first conveyor 636. The
stepping down of the conveyors will be discussed in more detail
below.
[0097] Referring again to FIGS. 1 and 2, the trimmed pack is
carried by the second conveyor 644 to an optional entanglement
mechanism 645. The entanglement mechanism 645 is configured to
entangle the individual fibers 622 forming the layers of the
trimmed pack. Entangling the glass fibers 622 within the pack ties
the pack together. In the embodiments where dry binder is included,
entangling the glass fibers 622 advantageously allows mechanical
properties, such as for example, tensile strength and shear
strength, to be improved. 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 the non-limiting example of stitching mechanisms. While
the embodiment shown in FIGS. 6 and 7 illustrate the use of the
entanglement mechanism 645, it should be appreciated that the use
of the entanglement mechanism 645 is optional and the method of
forming the pack from fibrous materials 610 can be practiced
without the use of the entanglement mechanism 645. Entangling the
fibers within the pack forms an entangled pack.
[0098] The second conveyor 644 conveys the pack with optional dry
binder, that is optionally trimmed, and/or optionally entangled
(hereafter both the trimmed pack and the entangled pack are simply
referred to as the "pack") to a third conveyor 648. When the pack
includes a dry binder, the third conveyor 648 is configured to
carry the pack to an optional curing oven 650. The curing oven 650
is configured to blow a fluid, such as for example, heated air
through the pack such as to cure the dry binder and rigidly bond
the glass fibers 622 together in a generally random,
three-dimensional structure. Curing the pack in the curing oven 650
forms a cured pack.
[0099] As discussed above, the pack optionally includes a dry
binder. The use of the dry binder, rather than a traditional wet
binder, advantageously allows the curing oven 650 to use less
energy to cure the dry binder within the pack. In the illustrated
embodiment, the use of the dry binder in the curing oven 650
results in an energy savings in a range of from about 30.0% to
about 80.0% compared to the energy used by conventional curing
ovens to cure wet or aqueous binder. In still other embodiments,
the energy savings can be in excess of 80.0%. The curing oven 650
can be any desired curing structure, mechanism or device or
combinations thereof.
[0100] The third conveyor 648 conveys the cured pack to a fourth
conveyor 652. The fourth conveyor 652 is configured to carry the
cured pack to a cutting mechanism 654. Optionally, the cutting
mechanism 654 can be configured for several cutting modes. In a
first optional cutting mode, the cutting mechanism is configured to
cut the cured pack in vertical directions along the machine
direction D1 such as to form lanes. The formed lanes can have any
desired widths. In a second optional cutting mode, the cutting
mechanism is configured to bisect the cured pack in a horizontal
direction such as to form continuous packs having thicknesses. The
resulting bisected packs can have any desired thicknesses. Cutting
the cured pack forms cut pack.
[0101] In the illustrated embodiment, the cutting mechanism 654
includes a system of saws and knives. 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 positioned such as to allow the
capture of dust and other waste materials formed during the cutting
operation. Optionally, dust and other waste materials stemming from
the cutting mechanism can be returned to the flow of gasses and
glass fibers in the ducts 630 and recycled in the forming apparatus
632a and 632b. Recycling of the dust and waste materials
advantageously prevents potential environmental issues connected
with the disposal of the dust and waste materials. As shown in
FIGS. 6 and 7, ductwork 655 connects the cutting mechanism 654 with
the ducts 630 and is configured to facilitate the return of dust
and waste materials to the forming apparatus 632a and 632b. While
the embodiment shown in FIGS. 6 and 7 illustrate the recycling of
the dust and waste materials, it should be appreciated that the
recycling of the dust and waste materials is optional and the
method of forming the pack from fibrous materials 10 can be
practiced without recycling of the dust and waste materials.
[0102] Optionally, prior to the conveyance of the cured pack to the
cutting mechanism 654, the major surfaces of the cured pack can be
faced with facing material or materials by facing mechanisms 662a,
662b as shown in FIG. 6. In the illustrated embodiment, the upper
major surface of the cured pack is faced with facing material 663a
provided by facing mechanism 662a and the lower major surface of
the cured pack is faced with facing material 663b provided by
facing mechanism 662b. The facing materials can be any desired
materials including paper, polymeric materials or non-woven webs.
The facing mechanisms 662a and 662b can be any desired structures,
mechanisms or devices or combinations thereof. In the illustrated
embodiment, the facing materials 663a and 663b are applied to the
cured pack (if the pack includes a binder) by adhesives. In other
embodiments, the facing materials 663a and 663b can be applied to
the cured pack by other methods, including the non-limiting example
of sonic welding. While the embodiment shown in FIG. 6 illustrates
the application of the facing materials 663a and 663b to the major
surfaces of the cured pack, it should be appreciated that the
application of the facing materials 663a and 663b to the major
surfaces of the cured pack is optional and the method of forming
the pack from fibrous materials 610 can be practiced without the
application of the facing materials 663a and 663b to the major
surfaces of the cured pack.
[0103] Referring to FIGS. 6 and 7, the fourth conveyor 652 conveys
the cut pack to an optional chopping mechanism 656. The chopping
mechanism 656 is configured to section the cut pack into desired
lengths across the machine direction D1. In the illustrated
embodiment, the chopping mechanism 656 is configured to section the
cut pack as the cut pack continuously moves in the machine
direction D1. Alternatively, the chopping mechanism 656 can be
configured for batch chopping operation. Sectioning the cut pack
into lengths forms a dimensioned pack. The lengths of the chopped
pack can have any desired dimension.
[0104] Chopping mechanisms are known in the art and will not be
described herein. The chopping mechanism 656 can be any desired
structure, mechanism or device or combinations thereof.
[0105] Optionally, prior to the conveyance of the cut pack to the
chopping mechanism 656, the minor surfaces of the cut pack can be
faced with edging material or materials by edging mechanisms 666a,
666b as shown in FIG. 7. The edging materials can be any desired
materials including paper, polymeric materials or nonwoven webs.
The edging mechanisms 666a and 666b can be any desired structures,
mechanisms or devices or combinations thereof. In the illustrated
embodiment, the edging materials 667a and 667b are applied to the
cut pack by adhesives. In other embodiments, the edging materials
667a and 667b can be applied to the cut pack by other methods,
including the non-limiting example of sonic welding. While the
embodiment shown in FIG. 7 illustrate the application of the edging
materials 667a and 667b to the minor surfaces of the cut pack, it
should be appreciated that the application of the edging materials
667a and 667b to the minor surfaces of the cut pack is optional and
the method of forming the pack from fibrous materials 610 can be
practiced without the application of the edging materials 667a and
667b to the minor surfaces of the cut pack.
[0106] Referring again to FIG. 6, the fourth conveyor 652 conveys
the dimensioned pack to a fifth conveyor 658. The fifth conveyor
658 is configured to convey the dimensioned pack to a packaging
mechanism 660. The packaging mechanism 660 is configured to package
the dimensioned pack for future operations. The term "future
operations," as used herein, is defined to include any activity
following the forming of the dimensioned pack, including the
non-limiting examples of storage, shipping, sales and
installation.
[0107] In the illustrated embodiment, the packaging mechanism 660
is configured to form the dimensioned pack into a package in the
form of a roll. In other embodiments, the packaging mechanism 660
can form packages having other desired shapes, such as the
non-limiting examples of slabs, batts and irregularly shaped or die
cut pieces. The packaging mechanism 660 can be any desired
structure, mechanism or device or combinations thereof.
[0108] Referring again to FIG. 6, the conveyors 636, 644, 648, 652
and 658 are in a "stepped down" relationship in the machine
direction D1. The "stepped down" relationship means that the upper
surface of the successive conveyor is positioned to be vertically
below the upper surface of the preceding conveyor. The "stepped
down" relationship of the conveyors advantageously provides a
self-threading feature to the conveyance of the pack. In the
illustrated embodiment, the vertical offset between adjacent
conveyors is in a range of from about 3.0 inches to about 10.0
inches. In other embodiments, the vertical offset between adjacent
conveyors can be less than about 3.0 inches or more than about 10.0
inches.
[0109] As illustrated in FIGS. 6 and 7, the method for forming a
pack from fibrous materials 610 eliminates the use of a wet binder,
thereby eliminating the traditional needs for washwater and
washwater related structures, such as forming hoods, return pumps
and piping. The elimination of the use of water, with the exception
of cooling water, and the application of lubricant, color and other
optional chemicals, advantageously allows the overall size of the
manufacturing line (or "footprint") to be significantly reduced as
well as reducing the costs of implementation, operating costs and
maintenance and repair costs.
[0110] As further illustrated in FIGS. 6 and 7, the method for
forming a pack from fibrous materials 610 advantageously allows the
uniform and consistent deposition of long and thin fibers on the
forming apparatus 632a and 632b. In the illustrated embodiment, the
fibers 622 have a length in a range of from about 0.25 inches to
about 10.0 inches and a diameter dimension in a range of from about
9 HT to about 35 HT. In other embodiments, the fibers 22 have a
length in a range of from about 1.0 inch to about 5.0 inches and a
diameter dimension in a range of from about 14 HT to about 25 HT.
In still other embodiments, the fibers 22 can have a length less
than about 0.25 inches or more than about 10.0 inches and a
diameter dimension less than about 9 HT or more than about 35 HT.
While not being bound by the theory, it is believed the use of the
relatively long and thin fibers advantageously provides a pack
having better thermal and acoustic insulative performance than a
similar sized pack having shorter and thicker fibers.
[0111] While the embodiment illustrated in FIGS. 6 and 7 have been
generally described above to form packs of fibrous materials, it
should be understood that the same apparatus can be configured to
form "unbonded loosefill insulation". The term "unbonded loosefill
insulation", as used herein, is defined to mean any conditioned
insulation material configured for application in an airstream.
[0112] While exemplary embodiments of packs and methods for forming
a pack from fibrous materials 610 have been described generally
above, it should be appreciated that other embodiments and
variations of the method 610 are available and will be generally
described below.
[0113] Referring to FIG. 7 in another embodiment of the method 610,
the cross lapping mechanisms 634a and 634b are configured to
provide precise deposition of alternating layers of the continuous
web on the first conveyer 36, thereby allowing elimination of
downstream trim mechanism 40.
[0114] 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, is defined to mean that each of
the layers can be configured with different characteristics,
including the non-limiting examples of fiber diameter, fiber
length, fiber orientation, density, thickness and glass
composition. It is contemplated that the associated mechanisms
forming a layer, that is, the associated fiberizer, forming
apparatus and cross lapping mechanism can be configured to provide
a layer having specific and desired characteristics. Accordingly, a
pack can be formed from layers having different
characteristics.
[0115] In another embodiment, the dry binder can include or be
coated with additives to impart desired characteristics to the
pack. One non-limiting example of an additive is a fire retardant
material, such as for example baking soda. Another non-limiting
example of an additive is a material that inhibits the transmission
of ultraviolet light through the pack. Still another non-limiting
example of an additive is a material that inhibits the transmission
of infrared light through the pack.
[0116] Referring to FIG. 6 in another embodiment of the method 610
and as discussed above, a flow of hot gases can be created by
optional blowing mechanisms, such as the non-limiting examples of
annular blowers (not shown) or annular burners (not shown). It is
known in the art to refer to the heat created by the annular
blowers and the annular burners as the "heat of fiberization". It
is contemplated in this embodiment, that the heat of fiberization
is captured and recycled for use in other mechanisms or devices.
The heat of fiberization can be captured at several locations in
the method 610. As shown in FIGS. 6 and 7, duct work 670 is
configured to capture the heat emanating from the fiberizers 618
and convey the heat for use in other mechanisms, such as for
example the optional curing oven 650. Similarly, duct work 672 is
configured to capture the heat emanating from the flow of hot gases
within the duct 30 and duct work 674 is configured to capture the
heat emanating from the forming apparatus 632a and 632b. The
recycled heat can also be used for purposes other than the forming
of fibrous packs, such as for example heating an office
[0117] In certain embodiments, the duct 630 can include heat
capturing devices, such as for example, heat extraction fixtures
configured to capture the heat without significantly interfering
with the momentum of the flow of the hot gasses and entrained glass
fibers 622. In other embodiments, any desired structure, device or
mechanism sufficient to capture the heat of fiberization can be
used.
[0118] Referring to FIG. 6 in another embodiment of the method 610,
fibers or other materials having other desired characteristics can
be mixed with glass fibers 622 entrained in the flow of gasses. In
this embodiment, a source 676 of other materials, such as for
example, synthetic or ceramic fibers, coloring agents and/or
particles can be provided to allow such materials to be introduced
into a duct 678.
[0119] The duct 678 can be connected to the duct 630 such as to
allow mixing with the glass fibers 622 entrained in the flow of
gasses. In this manner, the characteristics of the resulting pack
can be engineered or tailored for desired properties, such as the
nonlimiting examples acoustic, thermal enhancing or UV inhibiting
characteristics.
[0120] In still other embodiments, it is contemplated that other
materials can be positioned between the layers deposited by the
cross-lapping mechanisms 634a and 634b on the first conveyor 636.
The other materials can include sheet materials, such as for
example, facings, vapor barriers or netting, or other non-sheet
materials including the non-limiting examples of powders, particles
or adhesives. The other materials can be positioned between the
layers in any desired manner. In this manner, the characteristics
of the resulting pack can be further engineered or tailored as
desired.
[0121] While the embodiments shown in FIG. 6 illustrates the
application of a dry binder by the binder applicator 646, it should
be appreciated that in other embodiments, the dry binder can be
applied to the glass fibers 622 entrained in the flow of gasses. In
this embodiment, a source 680 of dry binder can be introduced into
a duct 682. The duct 682 can be connected to the duct 630 such as
to allow mixing of the dry binder with the glass fibers 622
entrained in the flow of gasses. The dry binder can be configured
to attach to the glass fibers in any desired manner, including by
electrostatic processes.
[0122] While the embodiment illustrated in FIG. 6 illustrates use
of the continuous web by the cross-lapping mechanisms 634a and
634b, it should be appreciated that in other embodiments, the web
can be removed from the forming apparatus 632a and 632b and stored
for later use.
[0123] As discussed above, optionally the trimmed materials can be
can be returned to the flow of gasses and glass fibers in the ducts
630 and recycled in the forming apparatus 632a and 632b. In an
exemplary embodiment, when an optional binder is included in the
pack, the operating temperature of the forming apparatus 332a and
332b is kept below the softening temperature of the dry binder,
thereby preventing the dry binder from curing prior to the
downstream operation of the curing oven 550. In this embodiment,
the maximum operating temperature of the curing oven 650 is in a
range of from about 165.degree. F. to about 180.degree. F. In other
embodiments, the maximum operating temperature of the curing oven
650 can be less than about 165.degree. F. or more than about
180.degree. F.
[0124] Several exemplary embodiments of mineral fiber webs and
packs and methods of producing mineral fiber webs and packs are
disclosed by this application. Mineral fiber webs and packs and
methods of producing mineral fiber webs and packs in accordance
with the present invention may include any combination or
subcombination of the features disclosed by the present
application.
[0125] In accordance with the provisions of the patent statutes,
the principles and modes of the improved methods of forming a pack
from fibrous materials have been explained and illustrated in its
preferred embodiment. However, it must be understood that the
improved method of forming a pack from fibrous materials may be
practiced otherwise than as specifically explained and illustrated
without departing from its spirit or scope.
* * * * *