U.S. patent application number 16/423893 was filed with the patent office on 2019-09-19 for method for forming a melt-resistant glass fiber product, and associated apparatus.
The applicant listed for this patent is BLH Technologies, Inc.. Invention is credited to Daniel Baroux.
Application Number | 20190284093 16/423893 |
Document ID | / |
Family ID | 48428864 |
Filed Date | 2019-09-19 |
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United States Patent
Application |
20190284093 |
Kind Code |
A1 |
Baroux; Daniel |
September 19, 2019 |
Method for Forming a Melt-Resistant Glass Fiber Product, and
Associated Apparatus
Abstract
A method is provided for forming a melt-resistant glass fiber
product, by applying an insulating material to a glass fiber
product comprised of filiform glass fibers so as to substantially
coat each of the filiform glass fibers therewith, such that the
coated filiform glass fibers render the glass fiber product
resistant to heat. In one aspect, such a method comprises forming a
wetted mixture including filiform glass fibers and insulating
material comprising a fire-retarding solution, wherein the wetted
mixture has a solids content of the fire-retarding solution
substantially uniformly and thoroughly dispersed therethrough. An
associated apparatus is also provided.
Inventors: |
Baroux; Daniel; (Halifax,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
BLH Technologies, Inc. |
Halifax |
|
CA |
|
|
Family ID: |
48428864 |
Appl. No.: |
16/423893 |
Filed: |
May 28, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14278542 |
May 15, 2014 |
10329195 |
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16423893 |
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PCT/CA2011/050706 |
Nov 15, 2011 |
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14278542 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C03C 25/12 20130101;
C03C 25/10 20130101; B32B 2307/3065 20130101; B32B 2262/101
20130101; B32B 5/26 20130101; B32B 17/02 20130101; C03C 25/005
20130101; C03C 25/1095 20130101; B32B 2255/02 20130101; B32B
2307/306 20130101 |
International
Class: |
C03C 25/005 20060101
C03C025/005; B32B 5/26 20060101 B32B005/26; B32B 17/02 20060101
B32B017/02; C03C 25/1095 20060101 C03C025/1095; C03C 25/12 20060101
C03C025/12; C03C 25/10 20060101 C03C025/10 |
Claims
1-20. (canceled)
21. An apparatus for forming a melt-resistant glass fiber product,
said apparatus comprising: a first mixing device arranged to apply
an insulating material to filiform glass fibers, by forming a
wetted mixture including the filiform glass fibers and the
insulating material comprising a fire-retarding solution such that
the fire retarding solution coats each of the filiform glass
fibers, the wetted mixture having a solids content of the
fire-retarding solution dispersed therethrough, and the coating
rendering the coated filiform glass fibers resistant to heat; a
processing device arranged to receive the coated filiform glass
fibers from the first mixing device and to de-liquefy the coated
filiform glass fibers to form dry coated filiform glass fibers
having a moisture content of between 0% and about 3%; a second
mixing device arranged to receive the dry coated filiform glass
fibers from the processing device and to form a cohesive glass
fiber mixture from the dry coated filiform glass fibers and a glass
fiber binding agent; and a forming device arranged to receive a
layer of a cohesive cellulose fiber mixture between two layers of
the cohesive glass fiber mixture from the second mixing device,
such that the layers are adjacent to each other, the forming device
being further arranged to intermix glass and cellulose fibers at
interfaces between the cohesive cellulose fiber mixture layer and
each of the cohesive glass fiber mixture layers to form the
adjacent layers into an integral composite sheet or board
product.
22. An apparatus according to claim 21, wherein the first mixing
device is arranged to apply the insulating material to the glass
fiber product comprised exclusively of filiform glass fibers.
23. An apparatus according to claim 21, wherein the first mixing
device is arranged to form the wetted mixture by saturating the
filiform glass fibers with the fire-retarding solution or forming a
slurry from the filiform glass fibers and the fire-retarding
solution.
24. An apparatus according to claim 21, wherein the first mixing
device is arranged to form the wetted mixture from the filiform
glass fibers and the fire-retarding solution comprising a boron
compound, a phosphorus compound, a chlorine compound, a fluorine
compound, an antimony compound, a borate compound, a halogen
compound, boric acid, an inorganic hydrate, a bromine compound,
aluminum hydroxide, magnesium hydroxide, hydromagnesite, antimony
trioxide, a phosphonium salt, ammonium phosphate, diammonium
phosphate, methyl bromide, methyl iodide,
bromochlorodifluoromethane, dibromotetrafluoroethane,
dibromodifluoromethane, carbon tetrachloride, urea-potassium
bicarbonate, or any combination thereof.
25. An apparatus according to claim 21, wherein the processing
device is arranged to dewater the coated filiform glass fibers; and
to dry the dewatered coated filiform glass fibers to form the dry
coated filiform glass fibers.
26. An apparatus according to claim 21, wherein the processing
device is arranged to heat the coated filiform glass fibers to form
dry coated filiform glass fibers.
27. An apparatus according to claim 21, further comprising a
recovery device configured to recover excess fire-retarding
solution, in one of a liquid and a vapor form, upon de-liquefying
the coated filiform glass fibers to form the dry coated filiform
glass fibers; and to add the recovered excess fire-retarding
solution to the filiform glass fibers to form an additional
quantity of the coated filiform glass fibers.
28. An apparatus according to claim 21, wherein the first mixing
device is configured to form a wetted mixture from the filiform
glass fibers and one of an aqueous fire-retarding solution, a
nontoxic liquid fire-retarding solution, and a neutral pH liquid
fire-retarding solution.
29. An apparatus according to claim 21, wherein the second mixing
device is configured to form the cohesive glass fiber mixture from
the dry coated filiform glass fibers and the glass fiber binding
agent comprising one of a resin material and an adhesive
material.
30. An apparatus according to claim 21, wherein the second mixing
device is arranged to form the cohesive glass fiber mixture having
between about 0.1% by weight and about 50% by weight of the binding
agent.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application of U.S.
application Ser. No. 14/278,542, filed May 15, 2014, which is a
continuation of International Application No. PCT/CA2011/050706,
filed Nov. 15, 2011, which International Application was published
by the International Bureau in English on May 23, 2013, which are
both incorporated herein by reference in their entirety and for all
purposes.
BACKGROUND OF THE DISCLOSURE
Field of the Disclosure
[0002] Aspects of the present disclosure relate to methods for
forming improved glass fiber products, and, more particularly, to a
method for forming a melt-resistant or otherwise
thermally-resistant glass fiber product, and associated
apparatus.
Description of Related Art
[0003] It may sometimes be desirable for particular glass
fiber-based products to exhibit resistance to heat, such as that
resulting from an incidental fire, in addition to fire resistance.
In some instances, such a glass fiber-based insulation product may
have a fire-retardant product applied thereto, post-formation, to
provide some fire resistance capabilities therefor. That is, an
exemplary as-formed filiform glass fiber-based insulation product
may have a surface treatment, for example, a liquid fire retardant,
applied thereto in order for the treated product to exhibit at
least some fire resistance. Because of the nonporous nature of such
filiform glass fibers, such treatments may tend to remain on
exposed surfaces of the glass fibers and do not penetrate or become
absorbed by the glass fibers or the insulation product itself.
However, such glass fiber-based insulation products used, for
example, in building construction, may be comprised of filiform
glass fibers that may tend to melt in the presence of excess heat,
wherein the melted glass fibers may then lose the insulation
properties found in the original insulation product. Thus, while
the treatment of the as-formed glass fiber-based insulation product
may be somewhat effective for fire resistance, particularly with a
liquid fire retardant, it may be difficult or otherwise inefficient
to achieve an even and consistent fire-resistance treatment of that
product, and such treatment may not necessarily render the product
thermal/heat resistant. More particularly, the result of some fire
resistance treatment processes involving application of a liquid
fire-retardant to an as-formed glass fiber-based insulation product
may be an uneven or otherwise inconsistent coverage of the fire
retardant with respect to the product, with insignificant
improvement in thermal/heat resistance characteristics. In those
cases, the glass-fiber product may pose a hazard in the event of a
fire which the product is intended to retard or otherwise provide
some resistance to heat and/or flames. Further, such treatment
processes may not necessarily be efficient in terms of applying the
fire retardant to the glass fiber-based product, may not include
provisions for capturing or recycling excess portions of the fire
retardant product, and may not have the capability for preventing
or restricting losses of the fire retardant due, for instance, to
evaporative processes.
[0004] Thus, there exists a need for a process and associated
apparatus for evenly and consistently applying a coating, for
example a liquid fire retardant coating, to the fibers of a
filiform glass fiber-based product such as, for example, a glass
fiber-based insulation product. In some instances, it may be
desirable to form an integral glass fiber product having enhanced
characteristics and physical properties, compared to an existing
glass fiber product, while also providing an enhanced level of heat
and/or fire resistance (i.e., no or limited melting) and
effectively maintaining its original insulation properties. It may
also be desirable, in some instances, to have a glass fiber-based
product formation process with the capability of capturing excess
fire retardant and recycling the captured excess in subsequent
glass fiber product manufacturing cycles, whether the excess is
captured in a liquid form or in other forms, such as vapors.
BRIEF SUMMARY OF THE DISCLOSURE
[0005] The above and other needs are met by aspects of the present
disclosure, wherein one such aspect relates to a method of forming
a melt-resistant glass fiber product. Such a method comprises
applying an insulating material to a glass fiber product comprised
of filiform glass fibers so as to substantially coat each of the
filiform glass fibers therewith, such that the coated filiform
glass fibers render the glass fiber product resistant to heat. In
one instance, such as method may comprise forming a wetted mixture
including filiform glass fibers and insulating material comprising
a fire-retarding solution, wherein the wetted mixture has a solids
content of the fire-retarding solution substantially uniformly and
thoroughly dispersed therethrough. Forming the wetted mixture may
comprise, in some cases, interacting the filiform glass fibers with
the fire-retarding solution such that the fire retarding solution
substantially coats each of the filiform glass fibers. In
particular instances, applying an insulating material may comprise
applying an insulating material to a glass fiber product comprised
exclusively of filiform glass fibers. In instances where the glass
fiber product comprises an insulation product, the coated filiform
glass fibers may facilitate the insulation product maintaining
original insulation properties or otherwise experiencing minimal
losses with respect thereto (i.e., prevent the filiform glass
fibers from melting into solid glass and losing the insulation
properties of the original insulation product).
[0006] In some instances, such a method may further comprise
forming a cohesive mixture from the coated filiform glass fibers
and a binding agent, and then forming the cohesive mixture into a
formed glass fiber product. The cohesive mixture may, in some
cases, have between about 0.1% by weight and about 50% by weight of
the binding agent. Such a binding agent may comprise, for example,
a binder such as a resin, a glue, a starch, and/or a starch-based
resin or adhesive. In some instances, the insulating material
(i.e., the fire-retarding solution) may be a suitable binding
agent. In other instances, the binding agent may comprise a
thickening agent such as, for example, guar gum or xanthan gum. In
still other instances, the cohesive mixture may be interacted with
a cohesive cellulose fiber mixture to form a composite product. In
further instances, forming a cohesive mixture may be performed
substantially concurrently with forming the coated filiform glass
fibers or a wetted mixture. In yet other instances, such a method
may include de-liquefying the wetted mixture to form dry
melt-resistant filiform glass fibers, such that forming a cohesive
mixture involves forming a cohesive mixture from the dry
melt-resistant filiform glass fibers and a binding agent.
[0007] Another aspect of the present disclosure relates to an
apparatus for forming a melt-resistant glass fiber product. Such an
apparatus comprises a first mixing device configured to apply an
insulating material to a glass fiber product comprised of filiform
glass fibers so as to substantially coat each of the filiform glass
fibers therewith, wherein the coated filiform glass fibers render
the glass fiber product resistant to heat. In particular instances,
the first mixing device may be configured to form a wetted mixture
from filiform glass fibers and insulating material comprising a
fire-retarding solution, wherein the wetted mixture has a solids
content of the fire-retarding solution substantially uniformly and
thoroughly dispersed therethrough. The first mixing device may be,
in some cases, configured to interact the filiform glass fibers
with the fire-retarding solution such that the fire retarding
solution substantially coats each of the filiform glass fibers. In
particular instances, the first mixing device may be configured to
apply an insulating material to a glass fiber product comprised
exclusively of filiform glass fibers. In instances where the glass
fiber product comprises an insulation product, the coated filiform
glass fibers may facilitate the insulation product maintaining
original insulation properties or otherwise experiencing minimal
losses with respect thereto (i.e., prevent the filiform glass
fibers from melting into solid glass and losing the insulation
properties of the original insulation product).
[0008] In some instances, such an apparatus may further comprise a
second mixing device configured to form a cohesive mixture from the
coated filiform glass fibers/the wetted mixture and a binding
agent, wherein the cohesive mixture includes between about 0.1% by
weight and about 50% by weight of the binding agent, and a forming
device configured to form the cohesive mixture into a formed glass
fiber product. A suitable binding agent may comprise, for example,
a binder such as a resin, a glue, a starch, and/or a starch-based
resin or adhesive. In some instances, the insulating material
(i.e., the fire-retarding solution) may be a suitable binding
agent. In other instances, the binding agent may comprise a
thickening agent such as, for example, guar gum or xanthan gum. In
yet other instances, a composite forming device may be configured
to interact the cohesive mixture with a cohesive cellulose fiber
mixture to form a composite product. In further instances, the
first mixing device and the second mixing device are configured to
substantially concurrently form the coated filiform glass
fibers/wetted mixture and form the cohesive mixture. In yet other
instances, a second processing device may be configured to
de-liquefy the wetted mixture to form dry melt-resistant filiform
glass fibers, wherein the second mixing device is configured to
form a cohesive mixture from the dry melt-resistant filiform glass
fibers and a binding agent.
[0009] In some aspects, the fire-retarding solution may be an
aqueous fire-retarding solution. It may be preferred that the
fire-retarding solution be nontoxic and/or have a neutral pH and/or
be hypoallergenic and/or have any number of otherwise desirable
properties. In some aspects, the fire-retarding solution may
comprise any one of a boron compound, a phosphorus compound, a
chlorine compound, a fluorine compound, an antimony compound, a
borate compound, a halogen compound, boric acid, an inorganic
hydrate, a bromine compound, aluminum hydroxide, magnesium
hydroxide, hydromagnesite, antimony trioxide, a phosphonium salt,
ammonium phosphate, diammonium phosphate, methyl bromide, methyl
iodide, bromochlorodifluoromethane, dibromotetrafluoroethane,
dibromodifluoromethane, carbon tetrachloride, urea-potassium
bicarbonate, and combinations thereof.
[0010] In still further aspects, the first mixing device may be
configured, for example, to form the wetted mixture by
substantially saturating the filiform glass fibers with the
fire-retarding solution and/or forming a slurry from the filiform
glass fibers and the fire-retarding solution. In further aspects,
the processing device may be configured to dewater the wetted
mixture and to dry the dewatered wetted mixture to form the dry
melt-resistant filiform glass fibers. In doing so, the wetted
mixture may also be heated to facilitate the formation of the dry
melt-resistant filiform glass fibers.
[0011] In yet other aspects, the apparatus may also comprise a
recovery device configured to recover excess fire-retarding
solution, in one of a liquid and a vapor form, from the processing
device, upon the processing device de-liquefying the wetted mixture
to form the dry melt-resistant filiform glass fibers. Further, the
recovery device may be configured to direct the recovered excess
fire-retarding solution to the first mixing device, to be added to
the filiform glass fibers to form the wetted mixture, for example,
in a closed-loop, fire-retarding solution recycling process.
[0012] Also, in other aspects, the processing device may be
configured to form a cohesive mixture from the coated filiform
glass fibers and a binding agent comprising one of a resin material
and an adhesive material, and the forming device may be configured
to compress the cohesive mixture to form a densified glass fiber
product, extrude the cohesive mixture to form the formed glass
fiber product, or mold the cohesive mixture to form the formed
glass fiber product. In doing so, the cohesive mixture may be
formed into a glass fiber board product.
[0013] Aspects of the present disclosure thus address the
identified needs and provide other advantages as otherwise detailed
herein.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0014] Having thus described the disclosure in general terms,
reference will now be made to the accompanying drawings, which are
not necessarily drawn to scale, and wherein:
[0015] FIG. 1 schematically illustrates an apparatus for forming a
melt-resistant glass fiber product, according to one aspect of the
disclosure; and
[0016] FIG. 2 schematically illustrates a method of forming a
melt-resistant glass fiber product, according to one aspect of the
disclosure.
DETAILED DESCRIPTION OF THE DISCLOSURE
[0017] The present disclosure now will be described more fully
hereinafter with reference to the accompanying drawings, in which
some, but not all aspects of the disclosure are shown. Indeed, the
disclosure may be embodied in many different forms and should not
be construed as limited to the aspects set forth herein; rather,
these aspects are provided so that this disclosure will satisfy
applicable legal requirements. Like numbers refer to like elements
throughout.
[0018] Aspects of the present disclosure are generally directed to
apparatuses and methods for forming a melt-resistant filiform glass
fiber product. As previously discussed, possible limitations in the
treatment of as-formed filiform glass fiber products, such as a
glass fiber-based insulation or board product, for fire resistance,
particularly with a liquid fire retardant, include difficulty in
achieving an even and consistent treatment of that glass fiber
product, as well as difficulty in effecting thermal/heat resistance
in the as-formed product. That is, the result of some fire
resistance surface-treatment processes may be an uneven,
non-uniform, or otherwise inconsistent or incomplete application of
the fire retardant to the glass fiber product. In those cases, such
uneven surface treatment may result in varying levels of fire/heat
resistance of the treated glass fiber product which may, in turn,
become a hazard in the event of a fire which the product is
intended to retard or otherwise provide some resistance. Moreover,
such surface fire-retardant treatments may have little effect on
the overall thermal/heat resistance of the as-formed product.
[0019] As such, one aspect of the present disclosure involves an
apparatus for forming a melt-resistant filiform glass fiber
product, such an apparatus being indicated as element 100 in FIG.
1. Such an apparatus 100 may comprise, for example, a first mixing
device 300 configured to apply an insulating material 250 to a
glass fiber product comprised of filiform glass fibers 225 so as to
substantially coat each of the filiform glass fibers therewith,
wherein the coated filiform glass fibers 275 render the glass fiber
product resistant to heat. Particularly, in some aspects, the first
mixing device 300 may be configured to form a wetted mixture 275
from filiform glass fibers 225 and insulating material comprising a
fire-retarding solution 250, such that the wetted mixture 275 has a
solids content of the fire-retarding solution 250 substantially
uniformly and thoroughly dispersed therethrough. A second mixing
device 400 is configured to form a cohesive mixture 325 from the
coated filiform glass fibers/wetted mixture 275 and a binding agent
260, and a forming device 700 is configured to form the cohesive
mixture 325 into a formed glass fiber product 750.
[0020] The filiform glass fibers may be comprised of, for example,
E-glass (i.e., alumino-borosilicate glass with less than about 1%
w/w alkali oxides), A-glass (i.e., alkali-lime glass with little or
no boron oxide), E-CR-glass (i.e., alumino-lime silicate with less
than 1% w/w alkali oxides), C-glass (i.e., alkali-lime glass with
high boron oxide content), D-glass (i.e., borosilicate glass),
R-glass (i.e., alumino silicate glass without MgO and CaO), and/or
S-glass (i.e., alumino silicate glass without CaO but with high MgO
content). Such filiform glass fibers may be formed, for example,
using a direct melt process or a marble remelt process, wherein
bulk glass material is melted and then extruded through appropriate
bushings or nozzles. In a continuous filament process, a sizing may
be applied to the drawn fibers before the fibers are wound. In a
staple fiber process, the glass material can be blown or blasted
with heat or steam after exiting a formation machine. For example,
in rotary process formation machine, molten glass enters a rotating
spinner, and due to centrifugal force is thrown
horizontally/laterally outward, wherein air jets may push the glass
vertically downward while a binder is applied, and wherein a
resulting fiber mat may be vacuumed to a screen and the binder then
cured in an oven to form a cohesive mat.
[0021] In some instances, the glass fibers implemented to form the
resulting glass fiber product may be exclusively or substantially
exclusively comprised of filiform glass fibers of the type
disclosed herein. One skilled in the art will appreciate from the
disclosure herein, however, that in some aspects, that contaminants
in reasonable levels in the filiform glass fibers will likely have
little if any detrimental effect with respect to the resulting
as-formed glass fiber product. As such, a decontamination
process/apparatus may not necessarily be contemplated (e.g., for
the filiform glass fibers), but could be included, should there be
a need or desire for a contaminant-free glass fiber product.
[0022] Once the filiform glass fibers are procured, the filiform
glass fibers 225 may then be directed to the first mixing device
300 to be mixed with the insulating material comprising, for
example, a fire-retarding solution 250, to form coated filiform
glass fibers/a wetted mixture 275. The first mixing device 300 may
be further configured to mix the filiform glass fibers 225 with the
fire-retarding solution 250 such that the fire-retarding solution
250 is substantially uniformly distributed through the filiform
glass fibers 225. In some instances, the fire-retarding solution
250 may have a particular solids content, and the first mixing
device 300 may be further configured to mix the filiform glass
fibers and the fire-retarding solution 250 such that the wetted
mixture 275 has the solids content of the fire-retarding solution
250 substantially uniformly and thoroughly dispersed therethrough.
In forming the coated filiform glass fibers/wetted mixture 275, the
first mixing device 300 may be configured to substantially saturate
the filiform glass fibers 225 with the fire-retarding solution 250,
wherein the fire-retarding solution 250 has a first concentration
of the particular solids content, and/or the first mixing device
300 may be configured to form a slurry from the filiform glass
fibers 225 and the fire-retarding solution 250. In some instances,
the first mixing device 300 may also be configured to add water
and/or other appropriate liquid or chemical to the filiform glass
fibers 225 and fire-retarding solution 250 to form the slurry. Such
a procedure may be applicable, for example, to as-formed insulation
products comprised of or exclusively comprised of filiform glass
fibers, such as glass fiber insulations batts. For instance, such
insulation batts may be saturated or substantially saturated with
the insulating material comprising, for example, a fire-retarding
solution, and the batt then processed, for instance, through a
Fourdrinier-type arrangement or compression roller arrangement to
remove excess amounts of the insulating
material/fire-retardant.
[0023] In particular aspects, the insulating material may comprise
the fire-retarding solution 250, wherein the fire-retarding
solution may be an aqueous fire-retarding solution. It may be
preferred that the fire-retarding solution be nontoxic and/or have
a neutral pH and/or be hypoallergenic and/or have any number of
otherwise desirable properties affecting human/animal and/or
environmental safety, while maintaining the necessary efficacy, as
implemented and upon exposure of the filiform glass fibers and/or
the glass fiber product to heat and/or flame. In some aspects, the
fire-retarding solution 250 may include a component which, standing
alone, may not necessarily exhibit one or more of the
previously-disclosed preferred or desirable properties. However,
one skilled in the art will appreciate that other different
components of the fire-retarding solution 250 may interact with the
noted component so as to neutralize, minimize, or otherwise
eliminate, chemically or otherwise, the non-preferred or
undesirable properties of the noted component such that the overall
fire-retarding solution 250 exhibits one or more of the preferred
or desirable properties. In some other aspects, the fire-retarding
solution 250 may comprise any one of a boron compound, a borate, an
inorganic hydrate, a bromine compound, aluminum hydroxide,
magnesium hydroxide, hydromagnesite, antimony trioxide, a
phosphonium salt, ammonium phosphate, and diammonium phosphate, or
various combinations thereof. In this regard, one skilled in the
art will appreciate that various fire-retarding or fire resistant
substances, either currently known or later developed or
discovered, may be applicable to the disclosed processes and
apparatuses herein within the scope of the present disclosure.
[0024] One skilled in the art will further appreciate that the
fire-retarding solution 250 may be formed by adding a solid
fire-retardant product to a liquid (i.e., water) or other chemical
mixed with the filiform glass fibers such that the solid
fire-retardant product forms a solution with the liquid or other
chemical comprising a slurry with the filiform glass fibers 225. In
other instances, the solution formed from the solid fire-retardant
product and the liquid or other chemical may be used to form the
wetted mixture 275 with the filiform glass fibers 225. In some
aspects, the first mixing device 300 may be configured to agitate
the slurry or wetted mixture, so as to substantially uniformly
distribute the fire-retarding solution therethrough (i.e., such
that the insulating material coats or substantially coats each of
the filiform glass fibers). In other aspects, the first mixing
device 300 may be configured to manipulate the wetted mixture 275,
such that the solids content of the fire-retarding solution is
substantially uniformly and thoroughly dispersed through the wetted
mixture. The first mixing device 300 may be any machine suitable
for forming the wetted mixture and/or the slurry from the filiform
glass fibers and the fire-retarding solution, in the various
manners discussed.
[0025] In another aspect, the first mixing device 300 may be, in
some cases, configured to interact the filiform glass fibers 225
with the fire-retarding solution 250 such that the fire retarding
solution substantially coats each of the filiform glass fibers. In
yet another aspect, the fire-retarding solution 250 itself may be
configured to substantially coat each of the filiform glass fibers
when interacted therewith. In such instances, the fire-retarding
solution 250 may interact with the filiform glass fibers, for
example, such that the fire-retarding solution or a component
thereof etches the exposed surfaces of the glass fibers so as to
promote and/or facilitate bonding of particular solid components of
the fire-retarding solution with the exposed surfaces of the glass
fibers and/or formation of a coating over the exposed surfaces.
[0026] In some particular aspects, in order to facilitate
interaction between the fire-retarding solution and the glass
fibers, a processing device 500 may be provided to de-liquefy the
wetted mixture 275, and to form dry melt-resistant filiform glass
fibers. The processing device 500, such as a dryer, may thus be
provided, as necessary and as will be appreciated by one skilled in
the art, to process the wetted mixture 275 to form the dry
melt-resistant filiform glass fibers. In one aspect, the processing
device 500 may be configured to apply heat to the wetted mixture
275, for example, via heated air (i.e., air heated with combusted
natural gas or other suitable fuel source), or through any of a
variety of heating/de-liquefying/drying methods, such as, for
example, microwave or infrared drying techniques, as will be
appreciated by one skilled in the art.
[0027] In instances where the first mixing device 300 is configured
to form a slurry from the filiform glass fibers and the
fire-retarding solution, the processing device 500 may be
configured to dewater the slurry, before drying the dewatered
slurry to form the dry melt-resistant filiform glass fibers. Such a
dewatering process may be accomplished, for example, by a suitably
modified Fourdrinier-type machine, compression rollers, or other
appropriate process, as will be appreciated by one skilled in the
art. The slurry may also be dewatered, for instance, using a twin
wire forming section and/or appropriate screening devices. Further,
as previously disclosed, in order to dry the dewatered slurry, the
processing device 500 may be configured to apply heat to the wetted
mixture, for example, via heated air (i.e., air heated with
combusted natural gas or other suitable fuel source), or through
any of a variety of heating/de-liquefying/drying methods, such as,
for example, microwave or infrared drying techniques, as will be
appreciated by one skilled in the art. One skilled in the art will
also appreciate that the processing device 500 may be configured in
many different manners. For example, a suitably-configured screen
device may be configured to receive the slurry, wherein the screen
device may include a number of perforations. Once deposited in the
screen device, the slurry may be engaged by an opposing platen,
which may also be perforated. The perforations may serve to dewater
the slurry, while the platen and/or the screen device may be heated
to provide for drying of the dewatered slurry.
[0028] In some aspects, the apparatus 100 may also comprise a
recovery device 600 configured to recover excess fire-retarding
solution, in one of a liquid and a vapor form, upon the processing
device 500 de-liquefying/drying the wetted mixture 275. In some
instances, the recovery device 600 may also be configured to engage
the first mixing device 300 for accomplishing the recovery of the
excess fire-retarding solution. That is, the recovery device 600
may be configured to direct the recovered excess fire-retarding
solution, removed from the wetted mixture upon de-liquefication
thereof by the processing device 500, to the mixing device 300, for
example, in a closed-loop, fire-retarding solution recycling
process. Upon recovery of the excess portions, including liquids
and vapors, by the recovery device 600, the recovered excess
fire-retarding solution may be strained, filtered, or otherwise
purified, and then reintroduced to the first mixing device 300 to
form subsequent portions of the wetted mixture 275, such that the
fire-retarding solution is substantially or entirely prevented from
leaving the apparatus 100 as a waste product.
[0029] According to some aspects of the present disclosure, the dry
filiform glass fibers may be rendered fire-resistant and/or
melt-resistant by the coating of the glass fibers formed by
particular solid components of the fire-retarding solution
remaining on the glass fibers following the
heating/de-liquefying/drying process and/or the bonding of such
solid components to the exposed surfaces of the glass fibers. In
being so classified, the dry (coated) filiform glass fibers may,
for example, exhibit no loss or otherwise limited loss of volume
upon exposure to heat or flame (i.e., the dry filiform glass fibers
will exhibit limited if any tendency for the fibers to contract
into a solid glass mass or otherwise evaporate in response to the
application of heat or flame). In such instances, the solid coating
may form an insulating barrier capable of diffusing incident heat
(i.e., provide thermal/heat/melt resistance for the glass fibers)
while also resisting ignition by incident flame (i.e., provide
ignition/fire/flame resistance for the glass fibers). On this
basis, according to some aspects, the dry melt-resistant filiform
glass fibers (and/or coated filiform glass fibers) themselves may
be implemented as a glass fiber end product. For example, the dry
melt-resistant filiform glass fibers may be used as blown-in
insulation or insulation sheets in batt or roll form. In instances
where the glass fiber product comprises an insulation product, the
coated filiform glass fibers may facilitate the insulation product
maintaining original insulation properties or otherwise
experiencing minimal losses with respect thereto (i.e., prevents
the filiform glass fibers from melting into solid glass and losing
the insulation properties of the original insulation product).
[0030] In other instances, once the coated filiform glass
fibers/wetted mixture 275 are/is formed by the first mixing device
300, the second mixing device 400 may be configured to receive the
coated filiform glass fibers/wetted mixture 275 and to form the
cohesive mixture 325 from the coated filiform glass fibers/wetted
mixture 275 and a binding agent 260 added thereto. Such a binding
agent 260 may comprise, for example, a resin material or an
adhesive material. In one particular example, the binding agent 260
may comprise methylene dipenyl diisocyanate (MDI). However, one
skilled in the art will appreciate that the binding agent 260 may
vary considerably, as appropriate, and may comprise other suitable
materials such as, for instance, urea formaldehyde (UF) or phenol
formaldehyde (PF). In other examples, such a binding agent may
comprise a binder such as a resin, a glue, a starch, and/or a
starch-based resin or adhesive. In yet other example, the
insulating material (i.e., the fire-retarding solution) may itself
be a suitable binding agent. In still other instances, the binding
agent may comprise a thickening agent such as, for example, guar
gum or xanthan gum. In some aspects, the first mixing device 300
may be configured to form the coated filiform glass fibers/wetted
mixture 275 prior to the second mixing device 400 forming the
cohesive mixture 325. In other instances, the first and second
mixing devices 300, 400 may be configured to form the coated
filiform glass fibers/wetted mixture 275 and the cohesive mixture
325 substantially concurrently (i.e., adding the insulating
material/fire-retarding solution to the filiform glass fibers
substantially concurrently with adding the binding agent).
[0031] In such instances, the processing device 500 may be
configured to de-liquefy/dry the wetted mixture 275 such that the
moisture content is substantially 0%. However, upon exposure to
atmosphere, the now dry melt-resistant filiform glass fibers may
absorb/retain some moisture from atmospheric humidity. As such, the
dry melt-resistant filiform glass fibers may typically exhibit some
moisture content (i.e., about 1% to about 3%). In further aspects
of the disclosure, the second mixing device 400 may be configured
to form a cohesive mixture 325 from the dry melt-resistant filiform
glass fibers and a binding agent 260. In this regard, some binding
agents, such as MDI, may require a particular amount of moisture
present to actuate or otherwise enhance the binding properties
thereof. Accordingly, prior to the second mixing device 400 forming
the cohesive mixture, the second mixing device 400 and/or the
processing device 500 may be configured to add moisture to the dry
fire-retarding fiber mixture. Sufficient moisture may thus be added
to the dry melt-resistant filiform glass fibers, as necessary or
desired, to achieve the desired binding properties of the binding
agent.
[0032] Once the cohesive mixture 325 is formed, a forming device
700 may be implemented to form the cohesive mixture into a formed
glass fiber product 750. For example, the forming device 700 may be
configured to form the cohesive mixture 325 into the formed glass
fiber product 750 by compressing the cohesive mixture to form a
densified glass fiber product, extruding the cohesive mixture to
form the formed glass fiber product, and/or molding the cohesive
mixture to form the formed glass fiber product. The formed glass
fiber product 750 may, in some instances, be characterized as, for
example, a glass fiber board product (i.e., in the manner of a
medium density fiber (MDF) board). However, one skilled in the art
will appreciate, from the disclosure herein, that the cohesive
mixture 325, and the glass fiber product formed therefrom, are
distinguished from fiberglass (also called glass-reinforced plastic
(GRP), glass fiber-reinforced plastic (GFRP), or fiber-reinforced
plastic (FRP)). That is, "fiberglass" is generally characterized as
a fiber reinforced polymer made of a plastic or polymeric matrix
reinforced by fine fibers of glass, wherein the plastic/polymer
matrix may be, for example, an epoxy, a thermosetting plastic
(i.e., polyester or vinylester), or a thermoplastic. In contrast,
aspects of the present disclosure implement a cohesive mixture that
includes between about 0.1% by weight and about 50% by weight of
the binding agent and, as such, the resulting glass fiber product
may be characterized, for instance, as a filiform glass fiber
network, wherein the glass fibers treated with the fire-retarding
solution are held together in a cohesive manner by the binding
agent (i.e., a glass fiber matrix held together by a binding
agent). Such a binding agent may comprise, for example, a binder
such as a resin, a glue, a starch, and/or a starch-based resin or
adhesive. In some instances, the insulating material (i.e., the
fire-retarding solution) may be a suitable binding agent. In other
instances, the binding agent may comprise a thickening agent such
as, for example, guar gum or xanthan gum.
[0033] One skilled in the art will also appreciate that, according
to some aspects of the present disclosure, the cohesive mixture 325
may itself be melt-resistant due to the melt-resistant
characteristics of the glass fibers, wherein such melt-resistance
may be facilitated, in some instances, through heat and/or fire
resistance characteristics of the selected binding agent (i.e., the
cohesive mixture may in and of itself provide thermal/heat/melt
resistance protective characteristics). The cohesive mixture may
also be capable of resisting ignition by incident flame (i.e.,
provide ignition/fire/flame resistance characteristics). On this
basis, according to some aspects, the cohesive mixture itself may
be implemented as all of part of a glass fiber end product. For
example, the cohesive mixture may be applied, whether via the
forming device 700, or independently thereof, to various as-formed
products as a "coating" formed upon suitable application of the
cohesive mixture to the product and actuation of the binding agent
(or application of a separate suitable adhesive material). In one
case, for instance, the cohesive mixture may be applied to various
products to form a protective "coating" therefor. For example, the
cohesive mixture may be applied to various components of a
building, such as a floor, interior or exterior walls, or even
individual support beams, whether wood-based or metal, or otherwise
applied as an encasement element (in any instance, upon suitable
actuation of the binding agent or application of a separate
suitable adhesive material).
[0034] One skilled in the art will further appreciate that, in some
instances, the cohesive mixture 325 may be manipulated in different
manners using variants of the forming device 700 to achieve
different end products. For example, in some instances, the
cohesive mixture 325, including the filiform glass fibers
interacted with the fire-retarding solution, may form one or more
layers of the resulting product, which may be in a composite or
pseudo-laminate form. More particularly, in some instances, two
layers of the cohesive mixture 325, including the filiform glass
fibers interacted with the fire-retarding solution, may be
introduced into the forming device 700, with a suitable cohesive
mixture of cellulose fibers (i.e., as disclosed in International
Patent Application Serial No. PCT/CA2011/050013, filed Jan. 13,
2001, and entitled "Method for Forming a Fire-Resistant Cellulose
Product, and Associated Apparatus"--see, e.g., element 800 in FIG.
1) disposed between the two layers. Upon processing by the forming
device 700, the resulting end product may be characterized as
having a glass fiber--cellulose--glass fiber composite or
pseudo-laminate form in a sheet or board configuration. In some
particular instances, the glass fiber layers may comprise
exclusively or substantially exclusively glass fibers, while the
cellulose layer may comprise exclusively or substantially
exclusively cellulose fibers. In such particular instances, as will
be appreciated by one skilled in the art, there may be some
intermixing of the glass and cellulose fibers at the interfaces
between the respective layers, but the resulting end product (due,
for example, to interaction between the binding agents associated
with each of the glass fiber and cellulose layers) would appear as
in integral sheet or board.
[0035] In some aspects, the glass fiber product 750 may be formed
as a sheet or board having a desired length, width, and thickness,
or as a continuous sheet that is later subdivided into segments of
a desired length. In some instances, the forming device 700 may be
configured to engage the cohesive mixture with one of a negative
die and a positive die, so as to form a glass fiber product having
a surface defining a negative impression of the one of the negative
die and the positive die. That is, for example, various platen may
be appropriately patterned with a raised and/or depressed pattern
such that the formed glass fiber product will have a corresponding
surface defining a negative impression of the pattern. One skilled
in the art will also appreciate that the capability of manipulating
the cohesive mixture in this manner indicates that the final form
of the glass fiber product need not necessarily be in planar form,
but may take many different shapes, contours, and sizes in addition
to that disclosed herein.
[0036] Further, in some instances, the glass fiber product formed
in accordance with aspects of the present disclosure, particularly
through treatment of the filiform glass fibers with the
fire-retarding solution, may provide a more uniform and thorough
dispersion and distribution of the fire-retarding solution within
the formed glass fiber product, thus enhancing fire resistance
(flame spread), as well as thermal barrier (thermal
resistance/insulation) and/or other characteristics.
[0037] Many modifications and other aspects of the disclosures set
forth herein will come to mind to one skilled in the art to which
these disclosures pertain having the benefit of the teachings
presented in the foregoing descriptions and the associated
drawings. For example, one skilled in the art that the apparatuses
disclosed herein readily lead to associated processes and methods
for forming a melt-resistant glass fiber product, as shown, for
example, in FIG. 2. More particularly, such methods may comprise
applying an insulating material to a glass fiber product comprised
of filiform glass fibers so as to substantially coat each of the
filiform glass fibers therewith, wherein the coated filiform glass
fibers rendering the glass fiber product resistant to heat (block
1200). In one particular instance, such a method may comprise
forming a wetted mixture from filiform glass fibers and an
insulating material comprising, for example, a fire-retarding
solution, wherein the wetted mixture has the fire-retarding
solution substantially uniformly distributed therethrough (block
1250--indicated in dashed lines as being optional or exemplary). A
cohesive mixture is then formed from the coated filiform glass
fibers/wetted mixture and a binding agent (block 1300), and then
the cohesive mixture formed into a glass fiber product (block
1400).
[0038] In addition, in some instances, the first mixing device 300
may be configured to add and/or receive other appropriate
substances/materials/chemicals for addition to the filiform glass
fibers. For example, the first mixing device 300 may be configured
to receive a mold inhibitor; a water repellant, waterproofing,
and/or otherwise water resistant substance. In any instance, it may
be preferable that any additional substances received into the
filiform glass fibers be suitably processed by the first mixing
device 300 so as to be substantially uniformly and thoroughly
distributed and dispersed within the filiform glass fibers.
[0039] Further, one skilled in the art will appreciate that, in
some aspects, the cohesive mixture may be generally prepared, and
can then be formed, molded, or otherwise manipulated into various
end products such as, for example, boards, compounded roofing
shingles, compounded roofing shakes, compounded sidewall shingles,
compounded Spanish style "red clay" type roof tiles, electrical
outlet encasements, doors, interior wall planking, exterior
sheathing, cabinetry cores, cupboards, compounded cabinet door
faces, flooring, laminated flooring, veneered compounded flooring,
or the like. However, the exemplary end products presented herein
are not intended to be limiting in any manner with respect to the
wide variety of contemplated end products. Thus, the general
cohesive material concept may be extend to instances where the end
product may be produced in many different manners such as, for
example, by molding, extrusion, pressing, stamping, or by any other
suitable production method.
[0040] Moreover, the general cohesive material/mixture may be
provided as a component or other portion of a further end assembly,
in such previous examples as laminated flooring and cored
cabinetry. One skilled in the art will thus appreciate that formed
glass fiber products in accordance with aspects of the present
disclosure may be produced such that the insulating
material/fire-retarding solution is dispersed at least partially,
if not consistently and uniformly, throughout. As such, the
components of the end assembly comprising the thermal/heat and fire
resistant glass fiber product may likely be wholly resistant to
fire and/or unable to ignite and/or thermal/heat resistant, on a
more permanent basis (i.e., since the fire-retarding solution is
effectively integrated into the glass fiber product), as compared
to simple surface treatments that may be easily removed, washed
away, or subject to degradation over time.
[0041] In other aspects, other filiform fibers, whether natural or
synthetic/man-made, may be implemented with respect to the methods
and apparatuses disclosed herein. For example, such synthetic or
man-made fibers may generally be derived from synthetic materials
such as petrochemicals, though some types of synthetic fibers may
be manufactured from natural cellulose, including but not limited
to rayon, modal, and Lyocell.TM.. Cellulose-based fibers may be of
two types, regenerated or pure cellulose such as from the
cupro-ammonium process, and modified cellulose such as the
cellulose acetates. Fiber classification in reinforced plastics may
fall into two classes: (i) short fibers, also known as
discontinuous fibers, with a general aspect ratio (defined as the
ratio of fiber length to diameter) between 20 to 60, and (ii) long
fibers, also known as continuous fibers, the general aspect ratio
is between 200 to 500.
[0042] Mineral fibers may be implemented, in some instances, such
as purified natural quartz fibers, silica fiber made from sodium
silicate (water glass), and basalt fiber made from melted basalt.
Metallic fibers can be drawn from ductile metals such as copper,
gold or silver and extruded or deposited from more brittle metals,
such as nickel, aluminum or iron. Stainless steel fibers may also
be implemented. Carbon fibers may be based on oxidized and, via
pyrolysis, carbonized polymers like PAN, though the end product may
be almost pure carbon. Silicon carbide fibers can be implemented,
where the basic polymers are polymers and not hydrocarbons, and
where about 50% of the carbon atoms are replaced by silicon atoms
(i.e., poly-carbo-silanes). Polymer fibers based on synthetic
chemicals may be made from, but are not limited to: polyamide
nylon, PET or PBT polyester, phenol-formaldehyde (PF), polyvinyl
alcohol fiber (PVA) vinylon, polyvinyl chloride fiber (PVC)
vinylon, polyolefins (PP and PE) olefin fiber, acrylic polyesters,
pure polyester PAN fibers used to make carbon fiber, acrylic fiber,
aromatic polyamids (aramids) such as Twaron.TM., Kevlar.TM., and
Nomex.TM., and elastomers such as Spandex.TM. or urethane fibers.
The disclosed filiform glass fibers may also comprise, in some
aspects, microfibers (i.e., sub-denier fiber such as polyester
drawn to 0.5 dn (Denier)). Generally, microfibers may be ultra-fine
fibers (i.e., glass or meltblown thermoplastics) that may be
formed, for example, by extruding fiber that is then split into
multiple finer fibers.
[0043] Therefore, it is to be understood that the disclosures are
not to be limited to the specific aspects disclosed and that
modifications and other aspects are intended to be included within
the scope of the appended claims. Although specific terms are
employed herein, they are used in a generic and descriptive sense
only and not for purposes of limitation.
* * * * *