ES2963838T3 - Method of forming a fabric from fibrous materials - Google Patents

Abstract

Fibrous material webs and methods for manufacturing fibrous material webs. Binderless webs can be formed in a continuous process in which fiber material, such as glass, is melted and formed into fibers. The fibers are formed in a network of glass fibers without a binder or a network with a dry binder. The binderless web or the dry binder web may be laminated and/or the fibers forming the web may be mechanically entangled, for example by needling. (Automatic translation with Google Translate, without legal value)

Description

DESCRIPTION

Method of forming a fabric from fibrous materials

BACKGROUND OF THE INVENTION

The fibrous material can be transformed into various products, including fabrics, packages, wadding and blankets. Fibrous material bundles can be used in many applications, including non-limiting examples of insulation and soundproofing for buildings and building components, appliances and aircraft. Bundles of fibrous material are typically formed by processes that include fiberizers, forming hoods, ovens, slitting machines, and packaging machines. Typical processes also include the use of wet binders, binder recovery water and wash water systems.

WO 2013/049835 A2 describes fabrics of fibrous material and methods for manufacturing the fabrics of fibrous material. Binderless fabrics can be formed in a continuous process where fibrous material, such as glass, is melted and transformed into fibers. The fibers are formed in a fiberglass fabric without a binder or a fabric with a dry binder. The binderless fabric or the dry binder fabric may be laminated and/or the fibers forming the fabric may be entangled mechanically, for example by needling. WO 2013/049835 A2 can be cited as prior art under Article 54(3) of the EPC. Document EP 1669485 A2 describes a molded glass wool product comprising a laminated body of glass wool. The laminated body does not contain any binder, is punched in a direction (Y) orthogonal to a longitudinal direction (X) of its yarns and is integrally formed. The wools have an average diameter of 3 to 7 |jm, and each of the wools has a length of between 10 and 200 mm. US 2003/208891 A1 describes insulating fabrics that include a plurality of fabric layers. Each of the fabric layers comprises single-staple fibers having a length between approximately 1.27 and 5.08 cm (0.5 and 2 inches). The plurality of fabric layers are placed in an overlapping relationship and interconnected with each other (often by needling). WO 96/09427 A1 provides an irregularly shaped glass fiber and the processing of wool bundles having said irregularly shaped fibers directly by needling to form a nonwoven material without intermediate steps such as carding or blending of accompanying fibers. to conventional fiberglass processing operations. Also described is a nonwoven material that includes irregularly shaped fibers in a generally continuous wool bundle, which is produced by "unwinding" a bundle of fiberglass wool collected by a direct forming method.

BRIEF DESCRIPTION OF THE INVENTION

The present application describes multiple examples of fibrous material fabrics and methods for manufacturing the fibrous material fabrics. The continuous method of the present invention is defined in claim 1. Binderless fabrics are formed in a continuous process where the fiber material, specifically glass, is melted and transformed into fibers. The fibers are formed in a fiberglass fabric without binders. The binderless fabric is laminated and the fibers comprising the fabric are mechanically intertwined, for example by needling, where the glass fibers have a diameter range of from 2.3 micrometers (9 HT) to 8.9 micrometers ( 35HT); and wherein the glass fibers have a length range of about 0.64 cm (0.25 inches) to about 25.4 cm (10.0 inches).

The present invention also provides the use defined in claim 7 of a bundle of mechanically intertwined and laminated glass fibers for insulating a heated apparatus, wherein the bundle of mechanically intertwined and laminated glass fibers comprises:

a first fabric of glass fibers without binder;

at least one additional binderless glass fiber web superimposed on the first binderless glass fiber web;

wherein the first binderless fabric has an area weight of 0.24 kg/m2 (0.05 pounds per square foot) to 0.98 kg/m2 (0.2 pounds per square foot);

wherein the glass fibers have a diameter range of about 2.3 micrometers (9 HT) to about 8.9 micrometers (35 HT); and

wherein the glass fibers have a length range of about 0.64 cm (0.25 inches) to about 25.4 cm (10.0 inches).

Other advantages of the fabrics, battings and methods of producing the fabrics and battings will be 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

Figure 1A is a flow chart of an exemplary embodiment of a method for forming a binderless laminated fabric or a bundle of glass fibers;

Figure 1B is a flow chart of an exemplary method for forming a binderless interlaced fabric of glass fibers;

Figure 1C is a flow chart of an exemplary embodiment of a method for forming a binderless laminated interlaced fabric or bundle of glass fibers;

Figure 2A is a flow chart of a method for forming a fabric or laminated bundle of glass fibers with dry binder (not covered by the present invention);

Figure 2B is a flow chart of a method for forming a binderless interlaced fabric of glass fibers with dry binder (not encompassed by the present invention);

Figure 2C is a flow chart of a method for forming a binderless laminated interlaced fabric or bundle of glass fibers with dry binder (not encompassed by the present invention);

Figure 2D is a flow chart of a method for forming a binderless laminated interlaced fabric or bundle of glass fibers with dry binder (not encompassed by the present invention);

Figure 3A is a schematic illustration of an exemplary apparatus for forming a binderless laminated fabric or bundle of glass fibers;

Figure 3B is a schematic illustration of an exemplary apparatus for forming a binderless interlaced fabric of glass fibers;

Figure 3C is a schematic illustration of an exemplary apparatus for forming a binderless laminated interlaced fabric or bundle of glass fibers;

Figure 3D is a schematic illustration of an exemplary apparatus for forming a binderless laminated interlaced fabric or bundle of glass fibers;

Figure 3E is a schematic illustration of an exemplary accumulation arrangement;

Figure 3F is a schematic illustration of an exemplary diverter arrangement;

Figure 4 is a schematic illustration of a forming apparatus for forming a glass fiber fabric; Figure 5 is a schematic illustration of an apparatus for forming a fabric or bundle of glass fibers with a dry binder (not covered by the present invention);

Figure 5A is a schematic illustration of an apparatus for forming a fabric or bundle of glass fibers with a dry binder (not covered by the present invention);

Figure 5B is a schematic illustration of an apparatus for forming a fabric or bundle of glass fibers with a dry binder (not covered by the present invention);

Figure 6 is a schematic representation, in elevation, of a process for forming a package of fibrous materials;

Figure 7 is a schematic representation, in plan view, of a process for forming a package from fibrous materials.

Figure 8 is a schematic illustration of an exemplary apparatus for forming a fabric or bundle of glass fibers with a dry binder (not covered by the present invention);

Figure 9A is a sectional illustration taken along lines 9A-9A of Figure 8;

Figure 9B is a sectional illustration taken along lines 9A-9A of Figure 8;

Figure 10A is a schematic illustration of an exemplary embodiment of an insulating product;

Figure 10B is a schematic illustration of an exemplary embodiment of an insulating product;

Figure 10C is a schematic illustration of an exemplary embodiment of an insulating product;

Figure 10D is a schematic illustration of an exemplary embodiment of an insulating product;

Figure 10E is a schematic illustration of an exemplary embodiment of an insulating product;

Figure 10F is a schematic illustration of an exemplary embodiment of an insulating product;

Figure 10G is a schematic illustration of an exemplary embodiment of an insulating batt or package; Figure 10H is a schematic illustration of an exemplary embodiment of an insulating batt or package; Figure 10I is a schematic illustration of an exemplary embodiment of an insulating batt or package;

Figure 11 is a schematic illustration of an arrangement for producing staple fibers;

Figure 12 is a perspective view of a cooking range;

Figure 12A is a perspective view of a cooking range;

Figure 13 is a front sectional view illustrating an exemplary embodiment of fiberglass insulation

in a range;

Figure 13A is a front sectional view illustrating an exemplary embodiment of fiberglass insulation

in a range;

Figure 14 is a side sectional view illustrating an exemplary embodiment of fiberglass insulation

in a range;

Figure 14A is a side sectional view illustrating an exemplary embodiment of fiberglass insulation

in a range;

Figures 15A-15C illustrate an exemplary embodiment of a method for manufacturing a compression molded fiberglass product from a fiberglass batt without binder or with dry binder; and

Figures 16A-16C illustrate an exemplary embodiment of a method for manufacturing a vacuum molded fiberglass product from a fiberglass batt without binder or with dry binder.

DETAILED DESCRIPTION OF THE INVENTION

The present invention will now be described with occasional reference to specific exemplary embodiments of the invention. However, this invention can be carried out in different ways and should not be considered limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure is thorough and complete, and fully conveys the scope of the invention to those skilled in the art.

Unless otherwise defined, all technical and scientific terms used in this document have

the same meaning commonly understood by one skilled in the art to which this invention belongs. The terminology used in the description of the invention herein is to describe 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", "the" and "the" are intended to also include the plural forms, unless the context clearly indicates otherwise.

Unless otherwise indicated, all numbers expressing dimensional quantities such as length, width, height, etc., as used in the specification and claims, are to be understood as modified in all cases by the term " approximately". 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 establishing the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as accurately as possible. However, any numerical value inherently contains certain errors that necessarily result from errors found in their respective measurements.

The description and figures describe an improved method of forming a package from fibrous materials.

Generally, improved continuous methods replace traditional methods of applying a wet binder

to fibrous materials with new methods of making a batt or fiber bundle without any binder (i.e., material that binds the fibers together) and/or new methods of making a batt or fiber bundle with dry binders.

The term "fibrous materials", as used herein, is defined as any material formed from drawing or attenuating molten materials. The term "package", as used herein, is defined as any product formed from fibrous materials that are bonded together by an adhesive and/or by mechanical interlocking.

Figures 1A and 3A illustrate a first exemplary embodiment of a continuous process or method 100 for forming a package 300 (see Figure 3A) from fibrous materials. The dashed line 101 around the method steps 100 indicates that the method is a continuous method, as will be described in more detail below. The methods and packages will be described in terms of glass fibers, but the methods and packages are also applicable to the manufacture of fibrous products formed from other mineral materials, such as the non-limiting examples of rock, slag and basalt.

Referring to Figure 1A, glass melts 102. For example, Figure 3A schematically illustrates a hot extruder 314. The hot extruder 314 can supply molten glass 312 to a forehearth 316. Hot extruders and forehearths are known in the art and will not be described herein. Molten glass 312 can be formed from various raw materials combined in such proportions as to provide the desired chemical composition.

Returning to Figure 1A, the molten glass 312 is processed to form 104 glass fibers 322. The molten glass 312 can be processed in several different ways to form the fibers 322. For example, in the example illustrated in Figure 3A, the Molten glass 312 flows from the forehearth 316 to one or more rotating fiberizers 318. The rotating fiberizers 18 receive the molten glass 312 and subsequently form webs 320 of glass fibers 322. As will be explained in more detail below, the glass fibers 322 formed by the rotating fiberizers 318 are long and thin. Accordingly, any desired fiberizer, rotary or otherwise, sufficient to form long, thin glass fibers 322 can be used. Although the embodiment illustrated in Figure 3A shows a rotating fiberizer 318, it should be appreciated that any desired number of rotating fiberizers 318 can be used. In another exemplary embodiment, fibers 322 are formed by flame attenuation.

Long, thin fibers can take a wide variety of different shapes. In the present invention, the long thin fibers have a length in a range of about 0.64 cm to 25.4 cm (about 0.25 inches to about 10.0 inches) and a diameter dimension in a range of about 2.3 micrometers to 8.9 micrometers (about 9 HT to approximately 35 HT, where HT means one hundred thousandths of an inch). In an exemplary embodiment, the fibers 322 have a length in a range of about 2.54 cm to about 12.7 cm (about 1.0 inch to about 5.0 inches) and a diameter dimension in a range of about 3.5 micrometers to about 6.3 micrometers (about 14 HT to approximately 25 HT). In an exemplary embodiment, the fibers 322 have a length of about 7.62 cm (about 3 inches) and an average diameter of about 4.1-4.3 micrometers (about 16-17 HT). While not limited by theory, it is believed that the use of relatively long and thin fibers advantageously provides a package that has better thermal and acoustic insulating performance, as well as better strength properties, such as higher tensile strength and/or or higher bond strength, than a similar sized package with shorter, thicker fibers.

In the present invention, where the fibers are glass fibers, the term binderless means that the material, fabric and/or fibrous package comprises 99% or 100% glass only or 99% or 100% glass plus inert content. Inert content is any material that does not bind glass fibers. For example, in exemplary binderless embodiments described herein, the glass fibers 322 may optionally be coated or partially coated with a lubricant after the glass fibers are formed. For example, the glass fibers 322 can be coated with any lubricating material that does not bond the glass fibers together. In an exemplary embodiment, the lubricant may be a silicone compound, such as siloxane, dimethylsiloxane and/or silane. The lubricant may 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 a mineral oil emulsion and/or a vegetable oil or a vegetable oil emulsion.

Glass fibers can be coated or partially coated with a lubricant in many different ways. For example, the lubricant may 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 They come into contact with various devices as well as with other glass fibers. Lubricant can also be useful in reducing dust in the manufacturing process. Application of the optional lubricant can be precisely controlled by any desired structure, mechanism or device.

Referring to Figure 1A, a fabric 321 of fibers without a binder or other material that binds the fibers together is failed 106. The fabric 321 can be formed in a wide variety of different shapes. In the example illustrated in Figure 3A, the glass fibers 322 are gathered by an optional gathering member 324. The gathering member 324 is shaped and sized to receive the glass fibers 322. The gathering member 324 is configured to deflect glass fibers 322 to a conduit 330 for transfer to downstream processing stations, such as forming apparatus 332, which forms fabric 321. In other embodiments, glass fibers 322 may be collected on a conveyor mechanism ( not shown) to form the fabric.

The forming apparatus 332 may be configured to form a continuous dry web 321 of fibrous material having a desired thickness. In an exemplary embodiment, the dry fabrics 321 disclosed in this application may have a thickness in the range of about 0.64 cm to about 10.16 cm (about 0.25 inches to about 4 inches) thick and a density in the range of about 3.20 kg/kg. m3 to approximately 9.61 kg/m3 (approximately 0.2 lb/ft3 to approximately 0.6 lb/ft3). In an exemplary embodiment, the dry fabrics 321 disclosed in this application may have a thickness in the range of about 2.54 cm to about 7.62 cm (about 1 inch to about 3 inches) thick and a density in the range of about 4.81 kg/ m3 to 8.01 kg/m3 (approximately 0.3 lb/ft3 to approximately 0.5 lb/ft3). In an exemplary embodiment, the dry fabrics 321 disclosed in this application may have a thickness of about 3.81 cm (about 1.5 inches) and a density of about 6.41 kg/m3 (about 0.4 lb/ft3). The training apparatus 332 can take a wide variety of different forms. Any arrangement can be used to form a dry fabric 321 of glass fibers.

In an exemplary embodiment, the forming apparatus 332 includes a rotating drum with forming surfaces and areas of greater or lesser pressure. Referring to Figure 4, the pressure P1 on one side 460 of the forming surface 462 where the fibers 322 collect is greater than the pressure P2 on the opposite side 464. This pressure drop AP causes the fibers 322 to collect on the forming surface 462 to form the dry fabric 321. In an exemplary embodiment, the pressure drop AP across the forming surface 462 is controlled to be a low pressure and produce a low surface weight fabric. For example, the pressure drop AP may be approximately 1.27 cm (approximately 0.5 inches) of water and 76.2 cm (30 inches) of water. A velocity V of the air traveling through the forming tissue resulting in this low pressure drop AP can be up to 5.08 meters per second (1,000 feet per minute).

A low area weight fabric 321 having a surface weight of about 53.82 to about 538.2 grams per square meter (about 5 to about 50 grams per square foot). The low surface weight fabric may have the density and thickness ranges mentioned above. The low surface weight fabric may have a thickness in the range of about 0.64 cm to about 10.16 cm (about 0.25 inches to about 4 inches) thick, about 2.54 cm to about 7.62 cm (about 1 inch to about 3 inches) thick. thickness, or about 3.81 cm (about 1.5 inches). The low surface weight fabric may have a density in the range of about 3.2 kg/m3 to about 9.61 kg/m3, (about 0.2 lb/ft3 to about 0.5 lb/ft3), about 4.81 kg/m3 to about 8.01 kg/m3. m3 (approximately 0.3 lb/ft3 to approximately 0.5 lb/ft3) or approximately 6.41 kg/m3 (approximately 0.4 lb/ft3). Referring to Figure 3A, the dry fabric 321 exits the forming apparatus 332. In an exemplary embodiment, the low surface weight fabric 321 has a measured surface weight distribution coefficient of variation = Sigma (one standard deviation) / mean (average) x 100% = 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 an exemplary embodiment, the weight distribution coefficient of variation is between 25% and 30%, such as about 28%. In an exemplary embodiment, the coefficient of variation of the weight distribution is approximately 28%. The weight distribution coefficient of variation is obtained by measuring multiple sizes of small sample areas, for example, 5.08 cm x 5.08 cm (2" x 2"), from a large sample, for example, a 1.83 m by 3.05 m sample. m (6 feet by 10 feet) with a light table.

In the example illustrated in Figure 1A, the fabric 321 or multiple fabrics are laminated 108. For example, a single fabric 321 can be overlapped in the machine direction or overlapped transversely at ninety degrees with respect to the machine direction to form a laminated fabric 350. In another embodiment, the fabric may be cut into portions and the portions are stacked on top of each other to form the laminated fabric. In yet another exemplary embodiment, one or more duplicate fiberizers 318 and a forming apparatus 332 may be implemented so that two or more tissues are continuously produced in parallel. The parallel fabrics are then stacked on top of each other to form the layered fabric.

In an exemplary embodiment, the layering mechanism 332 is a racking mechanism or a cross racking mechanism that operates in association with a conveyor 336. The conveyor 336 is configured to move in the machine direction as indicated by arrow D1. The racking or cross racking mechanism is configured to receive the continuous fabric 321 and deposit alternating layers of the continuous fabric on the first conveyor 336 as the first conveyor moves in the machine direction D1. In the deposition process, a laying mechanism 334 would form the alternating layers in the machine direction as indicated by arrows D1 or the transverse laying mechanism 334 would form the alternating layers in the cross-machine direction. Additional fabrics 321 may be formed and perched or transversely perched by additional perching or transverse perching mechanisms to increase the number of layers and performance capacity.

In an exemplary embodiment, a cross-hanging mechanism is configured to precisely control the movement of the continuous fabric 321 and deposit the continuous fabric on the conveyor 336 such that the continuous fabric is not damaged. The transverse racking mechanism may include any desired structure and may be configured to operate in any desired manner. In an exemplary embodiment, the transverse racking mechanism includes a head (not shown) configured to move forward and backward at 90 degrees with respect to the machine direction D1. In this embodiment, the speed of the moving head is coordinated so that the movement of the head in both directions transverse to the machine is substantially the same, thus providing uniformity of the resulting layers of the fibrous body. In an exemplary embodiment, the transverse racking mechanism comprises vertical conveyors (not shown) configured to be centered with a center line of the conveyor 336. The vertical conveyors are further configured to swing from a pivot mechanism above the conveyor 336 to deposit the fabric. continuous on conveyor 336. While multiple examples of cross-racking mechanisms have been described above, it should be appreciated that the cross-racking mechanism may be other structures, mechanisms or devices or combinations thereof.

The laminated fabric 350 can have any desired thickness. The thickness of the stratified tissue is a function of several variables. First, the thickness of the laminated fabric 350 is a function of the thickness of the continuous fabric 321 formed by the forming apparatus 332. Second, the thickness of the laminated fabric 350 is a function of the speed at which the lamination mechanism 334 deposits layers of the continuous fabric 321 on the conveyor 336. Third, the thickness of the laminated fabric 334 is a function of the speed of the conveyor 336. In the illustrated embodiment, the laminated fabric 350 has a thickness in a range of approximately 0.25 cm to approximately 50.8 cm (approximately 0.1 inch to approximately 20.0 inches). In an exemplary embodiment, a cross-hanging mechanism 334 can form a laminated fabric 350 having from 1 layer to 60 layers. Optionally, a cross-racking mechanism may be adjustable, thereby allowing the cross-racking mechanisms 334 to form a package having any desired width. In certain embodiments, the package may have an overall width in a range of about 2.48 m to about 5.99 m (about 98.0 inches to about 236.0 inches).

In an exemplary embodiment, the laminated fabric 350 is produced in a continuous process indicated by the dashed box 101 in Figure 1A. The fibers produced by the fiberizer 318 are sent directly to the forming apparatus 332 (i.e., the fibers are not collected and packaged and then unpacked for use in a remote forming apparatus). The fabric 321 is provided directly to the lamination device 352 (i.e., the fabric is not formed or rolled and then unwound for use in a remote lamination device 352). In an exemplary embodiment of the continuous process, each of the processes (forming and layering in Figure 1A) is connected to the fiberization process, such that the fibers from the fiberizer are used by the other processes without being stored for later use. In another exemplary embodiment of the continuous process, the fiberizer or fiberizers 318 may have more output than is needed by the forming apparatus 332 and the layering device 352. As such, it is not necessary for fibers to be continuously supplied by the fiberizer 318 to the apparatus. of training 332 so that the process is continuous. For example, fiberizer 318 may produce batches of fibers that are pooled and supplied to forming apparatus 332 in the same factory in the continuous process, but the fibers are not compressed, shipped, or reopened in the continuous process. As another example of a continuous process, fibers produced by fiberizer 318 may alternatively be diverted to forming apparatus 332 and to another forming apparatus or for some other use or product. In another example of a continuous process, a portion of the fibers produced by the fiberizer 318 are continuously directed to the forming apparatus 332 and the remainder of the fibers are directed to another forming apparatus or for some other use or product.

Figure 3E illustrates that fibers 322 can be collected by an accumulator 390 in any of the examples illustrated in Figures 3A-3D. Arrow 392 indicates that the fibers 322 are provided by the accumulator 390 in a controlled manner to the forming apparatus 332. The fibers 322 may remain in the accumulator 390 for a predetermined period of time before being provided to the forming apparatus 332 to allow the fibers cool. In an exemplary embodiment, the fibers 322 are provided by the accumulator 390 to the forming apparatus 332 at the same rate that the fibers 322 are provided to the accumulator 390. As such, in this exemplary embodiment, the time that the fibers remain and cool in The accumulator is determined by the number of fibers 322 in the accumulator. In this example, the dwell time is the number of fibers in the accumulator divided by the rate at which the accumulator provides the fibers to the forming apparatus 332. In another exemplary embodiment, the accumulator 390 can selectively start and stop the distribution of the fibers and/or adjust the rate at which the fibers are distributed.

Figure 3F illustrates that fibers 322 can be selectively diverted between the forming station 332 and a second forming station 332' by a diverting mechanism 398 in any of the examples illustrated in Figures 3A-3D. In an exemplary embodiment, the embodiments illustrated in Figures 3A-3D may have both the accumulator 390 and the diverter mechanism 398.

In an exemplary embodiment, the fabric 321 is relatively thick and has a low surface weight, however, the continuous process has a high throughput and all of the fibers produced by the fiberizer are used to manufacture the fabric. For example, a single layer of fabric 321 may have a surface weight of about 53.82 to about 538.2 grams per square meter (about 5 to about 50 grams per square foot). The low surface weight fabric may have the density and thickness ranges mentioned above. The high-throughput continuous process can produce between about 340.2 kg/h and 680.4 kg/h (between about 750 lbs/h and 1,500 lbs/h), such as at least 408.2 kg/h (900 lbs/h) or at least 567.0 kg /h (1,250 lbs/h). 350 laminate fabric can be used in a wide variety of different applications.

Figures 1B and 3B illustrate a second exemplary embodiment of a method 150 for forming a package 300 (see Figure 3B) from fibrous materials without the use of a binder. The dashed line 151 around the steps of method 150 indicates that the method is a continuous method. Referring to Figure 1B, the glass is melted 102. The glass may be melted as described above with respect to Figure 3A. The molten glass 312 is processed to form 104 glass fibers 322. The molten glass 312 can be processed as described above with respect to Figure 3A to form the fibers 322. A web 321 of fibers is formed 106 without a binder or other material that joins the fibers together. Fabric 321 may be formed as described above with respect to Figure 3A.

Referring to Figure 1B, the fibers 322 of the fabric 321 are mechanically intertwined 202 to form an interlaced fabric 352 (see Figure 3B). Referring to Figure 3B, the fibers of the fabric 321 can be mechanically intertwined by an interlacing mechanism 345, such as a needling device. The interlacing mechanism 345 is configured to intertwine the individual fibers 322 of the fabric 321. The interlacing of the glass fibers 322 binds the fibers of the fabric together. Interlacing improves the mechanical properties of the fabric, such as, for example, tensile strength and cut resistance. In the illustrated embodiment, the interlocking mechanism 345 is a punching mechanism. In other embodiments, the interlocking mechanism 345 may include other structures, mechanisms, or devices or combinations thereof, including the non-limiting example of stitching mechanisms.

The interlocking fabric 352 may have any desired thickness. The thickness of the interlaced fabric is a function of the thickness of the continuous fabric 321 formed by the forming apparatus 332 and the amount of compression of the continuous fabric 321 by the interlacing mechanism 345. In an exemplary embodiment, the interlaced fabric 352 has a thickness of a range of about 0.25 cm to about 5.08 cm (about 0.1 inch to about 2.0 inches). In an exemplary embodiment, the interlock fabric 352 has a thickness in a range of about 1.27 cm to about 4.45 cm (about 0.5 inches to about 1.75 inches). For example, in an exemplary embodiment, the thickness of the interwoven fabric is approximately 1.27 cm (approximately 1^").

In an exemplary embodiment, the interlacing fabric 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 packaged and then unpacked for processing. use on a remote training device). The fabric 321 is provided directly to the interlacing device 345 (i.e., the fabric is not formed or wound and then unwound for use in a remote interlacing device 345). The 352 interlock fabric can be used in a wide variety of different applications. In an exemplary embodiment of the continuous process, each of the processes (forming and interlacing in Figure 1B) is connected to the fiberization process, such that the fibers from the fiberizer are used by the other processes without being stored for later use. In another exemplary embodiment of the continuous process, the fiberizer(s) 318 may have more throughput than is required by the forming apparatus 332 and/or the interlacing device 345. As such, it is not necessary for the fibers to be continuously supplied by the fiberizer 318. to the forming apparatus 332 so that the process is continuous. For example, fiberizer 318 may produce batches of fibers that are pooled and supplied to forming apparatus 332 in the same factory in the continuous process, but the fibers are not compressed, shipped, or reopened in the continuous process. As another example of a continuous process, fibers produced by fiberizer 318 may alternatively be diverted to forming apparatus 332 and to another forming apparatus or for some other use or product. In another example of a continuous process, a portion of the fibers produced by the fiberizer 318 are continuously directed to the forming apparatus 332 and the remainder of the fibers are directed to another forming apparatus or for some other use or product.

Figure 3D illustrates an exemplary embodiment of an apparatus that is similar to the embodiment illustrated in Figure 3B for forming a single-layer high-density package 300. For example, the embodiment illustrated in Figure 3D may produce packets 300 that are denser than the densest packet produced by the embodiment illustrated in Figure 3B. The apparatus of Figure 3D corresponds to the embodiment of Figure 3B, except that a compression mechanism 375 is provided between the forming station 332 and the interleaving mechanism 345 and/or the interleaving mechanism 345 includes a compression mechanism. The compression mechanism 375 compresses the fabric 321 as indicated by the arrows 377 before the fabric is supplied to the interlacing mechanism 345 and/or the fabric 321 is compressed at the entrance of the compression mechanism. The interwoven fabric 352 that is formed has a high density. The compression mechanism can take a wide variety of different forms. Examples of compression mechanisms 345 include, but are not limited to, rollers, belts, rotating staplers, additional punching mechanisms, perforated belts with negative pressure applied to the side of the belt that is opposite the interlocking fabric 352 (see similar example illustrated in Figure 4), any mechanism that includes any combination of the listed compression mechanisms, any mechanism that includes any combination of any of the features of the listed compression mechanisms, and the like. Any arrangement can be used to compress the tissue. When the interleaving mechanism 345 includes a compression mechanism, the compression mechanism 375 may be omitted in the embodiment of the single-layer high-density package 300 illustrated in Figure 3D. The compression performed by the compression mechanism 375 and/or the interlacing mechanism 345 may be any combination of compression and/or punching, which compresses the bundle in addition to interlacing the fibers. Examples of compression and punching sequences to produce a high-density package include, but are not limited to, roll compress then punch, double punch, roll compress then double punch, triple punch, prepunch - punch from above -punching from below, prepunching - punching from below - punching from above, compressing with rollers -punching from above - punching from below and compressing with rollers -punching from below - punching from above.

The high-density interwoven fabric 352 of Figure 3D can have any desired thickness. The thickness of the interwoven fabric is a function of the thickness of the continuous fabric 321 fanned by the forming apparatus 332 and the amount of compression of the continuous fabric 321 by the compression mechanism 375 and the interlacing mechanism 345. In an exemplary embodiment, the fabric high-density interleaving 352 of Figure 3D has a thickness in a range of about 0.25 cm to about 12.7 cm (about 0.1 inch to about 5 inches). In an exemplary embodiment, the high-density interlock fabric 352 has a thickness in a range of about 0.64 cm to about 7.62 cm (about 0.250 inches to about 3.0 inches). In an exemplary embodiment, the high-density interlock fabric has a density in a range of from 6.41 kg/m3 to about 192.22 kg/m3 (0.4 lb/ft3 to about 12 lb/ft3). In an exemplary embodiment, the high-density interlocking fabric 352 of Figure 3D is produced in a continuous process in a manner similar to that described with respect to Figure 3B.

Figures 1C and 3C illustrate another exemplary embodiment of a method 170 for forming a package 370 (see Figure 3C) from fibrous materials without the use of a binder. Referring to Figure 1C, the glass melts 102. The dashed line 171 around the method steps 170 indicates that the method is a continuous method. The glass can be cast as described above with respect to Figure 3A. Returning to Figure 1C, the molten glass 312 is processed to form 104 glass fibers 322. The molten glass 312 can be processed as described above with respect to Figure 3A to form the fibers 322. Referring to Figure 1C, a fabric 321 of fibers is formed 106 without a binder or other material that binds the fibers together. Fabric 321 may be formed as described above with respect to Figure 3A. Referring to Figure 1C, fabric 321 or multiple fabrics are laminated 108. Fabric 321 or multiple fabrics may be laminated as described above with respect to Figure 3A. Referring to Figure 1C, the fibers 322 of the laminated fabrics 350 are mechanically intertwined 302 to form an interlaced bundle 370 of laminated fabrics.

Referring to Figure 3C, the fibers of the laminated fabrics 350 can be mechanically interlaced by an interlacing mechanism 345, such as a needling device. The interlacing mechanism 345 is configured to intertwine the individual fibers 322 that form the layers of the laminated fabric. The interlacing of glass fibers 322 joins the fibers of the laminated fabrics 350 to form the bundle. Mechanical interlocking improves mechanical properties, such as tensile strength and shear strength. In the illustrated embodiment, the interlocking mechanism 345 is a punching mechanism. In other embodiments, the interlocking mechanism 345 may include other structures, mechanisms, or devices or combinations thereof, including the non-limiting example of stitching mechanisms.

The interwoven bundle 370 of laminated fabrics 350 may have any desired thickness. The thickness of the interlaced bundle is a function of several variables. First, the thickness of the interlocking package is a function of the thickness of the continuous fabric 321 formed by the forming apparatus 332. Second, the thickness of the interlocking package 370 is a function of the speed at which the hanging mechanism or Cross-laying 334 deposits layers of the continuous fabric 321 onto the conveyor 336. Third, the thickness of the interlocking bundle 370 is a function of the speed of the conveyor 336. Fourth, the thickness of the interlocking bundle 370 is a function of the quantity compression of the laminated fabrics 350 by the interlocking mechanism 345. The interlocking bundle 370 may have a thickness in a range of about 0.25 cm to about 50.8 cm (about 0.1 inches to about 20.0 inches). In an exemplary embodiment, the interleaved packet 370 may have from 1 layer to 60 layers. Each layer of interlock fabric 352 may have a thickness of 0.25 to 5.08 cm (0.1 to 2 inches). For example, each layer of interlock fabric may be approximately 1.27 cm (about 0.5 inches) thick.

In an exemplary embodiment, the interleaved packet 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 packaged and then unpacked for use in a remote forming apparatus). The fabric 321 is provided directly to the lamination device 352 (i.e., the fabric is not formed or rolled and then unwound for use in a remote lamination device 352). The laminated fabric 350 is supplied directly to the interlacing device 345 (i.e., the laminated fabric is not formed or wound and then unwound for use in a remote interlacing device 345). In an exemplary embodiment of the continuous process, each of the processes (forming, layering and interlacing in Figure 1C) is connected to the fiberization process, such that the fibers from the fiberizer are used by the other processes without being stored for later use. . In another exemplary embodiment of the continuous process, the fiberizer(s) 318 may have more throughput than is required by the forming apparatus 332, the layering device 352, and/or the interlacing device. As such, it is not necessary for the fibers to be continuously supplied by the fiberizer 318 to the forming apparatus 332 for the process to be continuous. For example, fiberizer 318 may produce batches of fibers that are pooled and supplied to forming apparatus 332 in the same factory in the continuous process, but the fibers are not compressed, shipped, or reopened in the continuous process. As another example of a continuous process, fibers produced by fiberizer 318 may alternatively be diverted to forming apparatus 332 and to another forming apparatus or for some other use or product. In another example of a continuous process, a portion of the fibers produced by the fiberizer 318 are continuously directed to the forming apparatus 332 and the remainder of the fibers are directed to another forming apparatus or for some other use or product.

In an exemplary embodiment, the interlocking bundle 370 of laminated fabrics is made of a fabric 321 or fabrics that are relatively thick and have a low surface weight, however, the continuous process has a high throughput and all fibers produced by the fiberizer to make the interlocking bundle. For example, a single layer of fabric 321 may have the area weights, thicknesses, and densities mentioned above. The high-throughput continuous process can produce between about 340.19 kg/hour and 680.39 kg/hour (between about 750 lbs/hr and 1,500 lbs/hr), such as at least 408.23 kg/hr (900 lbs/hr) or at least 567.0 kg/h (1250 lbs/h). In the present invention, the combination of high fabric performance and mechanical interlacing, such as needling, of a continuous process is facilitated by fabric layering 321, such as brushing or cross-racking of the fabric. By laminating the fabric 321, the linear speed of the material moving through the laminating device is slower than the speed at which the fabric is formed. For example, in a continuous process, a two-ply fabric will travel through interlacing apparatus 345 at half the speed at which the fabric is formed (3 layers -1/3 speed, etc.). This reduction in speed allows for a continuous process where a high performance, low area weight fabric 321 is formed and converted into a multi-layer mechanically interlaced package 370. The 370 interlocking bundle of laminated fabrics can be used in a wide variety of different applications.

In an exemplary embodiment, the layering and interlacing of the long, thin fibers results in a strong fabric 370. For example, the interlacing of the long, thin glass fibers described in this application results in a laminated, interlaced fabric with high tensile strength and high bond strength. Tensile strength is the strength of the fabric 370 when the fabric is pulled in the direction of the length or width of the fabric. Bond strength is the strength of the fabric when the fabric 370 is pulled in the direction of the thickness of the fabric.

Tensile strength and bond strength can be tested in a wide variety of different ways. In an exemplary embodiment, a machine, such as an Instron machine, separates tissue 370 at a fixed speed (12 inches per second in the examples described below) and measures the amount of force required to separate the tissue. The forces required to separate the tissue are recorded, including the maximum force applied to the tissue before it breaks or fails.

In a method of testing tensile strength, the tensile strength in the longitudinal direction is measured by holding the ends of the fabric along the width of the fabric, pulling the fabric 370 along the length of the fabric with the machine at the fixed speed (30.48 cm (12 inches) per second in the examples provided below) and recording the maximum force applied in the direction of the length of the fabric. Tensile strength in the width direction is measured by holding the sides of the fabric across the width of the fabric, pulling the fabric 370 across the width of the fabric at a fixed speed (12 inches per second in examples provided below) and recording the maximum force applied. The tensile strength in the longitudinal direction and the tensile strength in the width direction are averaged to determine the tensile strength of the sample.

In one method of testing bond strength, a sample of a predetermined size is provided (15.24 cm by 15.24 cm (6" by 6") in the examples described below). Each side of the sample is attached to a substrate, for example by gluing. The substrates on the opposite side of the sample are separated with the machine at a fixed speed (12 inches per second in the examples provided below) and the maximum force applied is recorded. The maximum force applied is divided by the area of the sample (15.24 cm by 15.24 cm (6" by 6") in the examples described below) to provide the bond strength in terms of force over area.

The following examples are provided to illustrate the increased strength of the laminated interlock fabric 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 mentioned in the claims. Examples are provided of laminated interlock fabrics having 4, 6 and 8 layers. However, the laminated interlock fabric 370 may be provided with any number of layers. The length, width, thickness, number of plies, and weight of the laminated interlock fabric 370 may vary depending on the application of the fabric 370. In the dense single-ply embodiment illustrated in Figure 3D, the high-density bundle 300 A single layer density may have a weight per square meter (weight per square foot) that is greater, such as two or more times greater, than in the examples in the following six paragraphs for the same thicknesses listed.

In an exemplary embodiment, a fabric sample 370 measuring 15.24 cm by 30.48 cm (6 inches by 12 inches), has multiple layers, such as two layers (i.e., four layers), has between 1.27 cm (0.5 inches) of thickness and 5.08 cm (2.0 inches) thick, has a weight per square meter between 0.49 and 1.46 kg/m2 (a weight per square foot between 0.1 and 0.3 lbs/ft2), has a tensile strength greater than 13.34 N ( 3 lbf) and has a tensile strength to weight ratio that is greater than 392.27 N/kg (40 lbf/lbm), such as from about 392.27 N/kg to about 1176.8 N/kg (from about 40 to about 120 lbf/lbm). In an exemplary embodiment, a bond strength of this sample is greater than 0.49 kg/m2 (0.1 lbs/ft2). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 22.24 N (5 lbf). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 33.36 N (7.5 lbf). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 44.48 N (10 lbf). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 55.6 N (12.5 lbf). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 61.16 N (13.75 lbf). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is between 13.34 and 66.72N (between 3 and 15 lbf). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 9.76 kg/m2. (2 lbs/ft2). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 24.41 kg/m2. (5 lbs/ft2). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 48.82 kg/m2. (10 lbs/ft2). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 73.24 kg/m2. (15 lbs/ft2). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 97.65 kg/m2. (20 lbs/ft2). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 22.24 N (5 lbf) and the bond strength is greater than 9.76 kg/m2 (2 lbs/ft2). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 33.36 N (7.5 lbf) and the bond strength is greater than 36.62 kg/m2 (7.5 lbs/ft2). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 44.48 N (10 lbf) and the bond strength is greater than 48.82 kg/m2 (10 lbs/ft2). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 55.6 N (12.5 lbf) and the bond strength is greater than 73.24 kg/m2 (15 lbs/ft2). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 61.16 N (13.75 lbf) and the bond strength is greater than 97.65 kg/m2 (20 lbs/ft2). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is between 13.34 and 66.72 N (between 3 and 15 lbf) and the bond strength is between 1.46 and 146.47 kg/m2 (between 0.3 and 30 lbs/ ft2).

In an exemplary embodiment, a fabric sample 370 measuring 15.24 cm by 30.48 cm (6 inches by 12 inches), has multiple layers, such as two layers (i.e., four layers), has between 1.27 cm (0.5 inches) of thickness and 4.45 cm (1.75 inches) thick, has a weight per square meter between 0.59 and 1.32 kg/m2 (a weight per square foot between 0.12 and 0.27 lbs/ft2), has a tensile strength greater than 13.34 N ( 3 lbf), and has a tensile strength to weight ratio greater than 392.27 N/kg (40 lbf/lbm), such as about 392.27 N/kg to about 1176.8 N/kg (about 40 to about 120 lbf/kg). lbm), and a bond strength greater than 4.88 kg/m2 (1 lb/ft2). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 22.24 N (5 lbf). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 33.36 N (7.5 lbf). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 44.48 N (10 lbf). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 55.6 N (12.5 lbf). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 61.16 N (13.75 lbf). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is between 13.34 and 66.72 N (between 3 and 15 lbf). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 9.76 kg/m2 (2 lbs/ft2). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 24.41 kg/m2. (5 lbs/ft2). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 48.82 kg/m2. (10 lbs/ft2). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 73.24 kg/m2. (15 lbs/ft2). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 97.65 kg/m2. (20 lbs/ft2). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 22.24 N (5 lbf) and the bond strength is greater than 9.76 kg/m2 (2 lbs/ft2). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 33.36 N (7.5 lbf) and the bond strength is greater than 36.62 kg/m2 (7.5 lbs/ft2). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 44.48 N (10 lbf) and the bond strength is greater than 48.82 kg/m2 (10 lbs/ft2). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 55.6 N (12.5 lbf) and the bond strength is greater than 73.24 kg/m2 (15 lbs/ft2). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 61.16 N (13.75 lbf) and the bond strength is greater than 97.65 kg/m2 (20 lbs/ft2). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is between 13.34 and 66.72 N (between 3 and 15 lbf) and the bond strength is between 1.46 and 146.47 kg/m3 (between 0.3 and 30 lbs/ ft2).

In an exemplary embodiment, a fabric sample 370 measuring 15.24 cm by 30.48 cm (6 inches by 12 inches), has multiple layers, such as two overlaps (i.e., four layers), is between 1.27 cm (0.5 inches) thick ) and 3.18 cm (1.25 inches) thick, has a weight per square meter between 0.98 and 1.46 kg/m2 (a weight per square foot between 0.2 and 0.3 lbs/ft2), has a tensile strength that is greater than 44.48 N (10 lbf) and a tensile strength to weight ratio that is greater than 735.50 N/kg (75 lbf/lbm), such as from about 735.50 to about 1176.8 N/kg (about 75 to about 120 lbf/lbm ). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 55.6 N (12.5 lbf). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 61.16 N (13.75 lbf). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is between 13.34 and 66.72 N (between 3 and 15 lbf). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 14.65 kg/m2 (3 lb/ft2). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 48.82 kg/m2 (10 lb/ft2). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 73.24 kg/m2 (15 lb/ft2). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 44.48 N (10 lbf) and the bond strength is greater than 14.65 kg/m2 (3 lb/ft2). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 55.6 N (12.5 lbf) and the bond strength is greater than 48.82 kg/m2 (10 lb/ft2). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 61.16 N (13.75 lbf) and the bond strength is greater than 73.24 kg/m2 (15 lb/ft2).

In an exemplary embodiment, a fabric sample 370 measuring 15.24 cm by 30.48 cm (6 inches by 12 inches), has multiple layers, such as three layers (i.e., six layers), has between 2.54 cm (1.0 inches) of thickness and 5.72 cm (2.25 inches) thick, has a weight per square meter between 0.73 and 1.95 kg/m2 (a weight per square foot between 0.15 and 0.4 lbs/ft2), has a tensile strength that is greater than 22.24 N (5 lbf) and a tensile strength to weight ratio greater than 392.27 N/kg (40 lbf/lbm), such as about 392.27 to about 1372.93 N/kg (about 40 to about 140 lbf/lbm). In an exemplary embodiment, the bond strength of this sample is greater than 0.49 kg/m2 (0.1 lbs/ft2). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 33.36 N (7.5 lbf). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 44.48 N (10 lbf). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 55.60 N (12.5 lbf). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 61.16 N (13.75 lbf). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is between 22.24 and 88.96 N (between 5 and 20 lbf). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 2.44 kg/m2. (0.5 lbs/ft2). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 4.88 kg/m2. (1.0 lbs/ft2). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 7.32 kg/m2. (1.5 lbs/ft2). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 9.76 kg/m2. (2.0 lbs/ft2). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 12.21 kg/m2. (2.5 lbs/ft2). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 14.65 kg/m2. (3.0 lbs/ft2). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 33.36 N (7.5 lbf) and the bond strength is greater than 1.95 kg/m2 (0.40 lbs/ft2). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 44.48 N (10 lbf) and the bond strength is greater than 2.93 kg/m2 (0.6 lbs/ft2). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 55.60 N (12.5 lbf) and the bond strength is greater than 4.39 kg/m2 (0.9 lbs/ft2). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is between 22.24 and 88.96 N (between 5 and 20 lbf) and the bond strength is between 0.49 and 19.53 kg/m2 (between 0.1 and 4 lbs/ ft2).

In an exemplary embodiment, a fabric sample 370 measuring 15.24 cm by 30.48 cm (6 inches by 12 inches), has multiple layers, such as three layers (i.e., six layers), has between 2.54 cm (1.0 inches) of thickness and 3.81 cm (1.50 inches) thick, and has a weight per square meter between 1.22 and 1.95 kg/m2 (a weight per square foot between 0.25 and 0.4 lbs/ft2), has a tensile strength that is greater than 40.03 N (9 lbf) and a tensile strength to weight ratio that is greater than 490.33 N/kg (50 lbf/lbm), such as from about 490.33 to about 1372.93 N/kg (about 50 to about 140 lbf/kg). lbm). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 55.60 N (12.5 lbf). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 61.16 N (13.75 lbf). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is between 40.03 and 66.72 N (between 9 and 15 lbf). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 2.44 kg/m2. (0.5 lbs/ft2). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 4.88 kg/m2. (1.0 kg/ft2). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 7.32 kg/m2. (1.5 lbs/ft2). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 9.76 kg/m2. (2.0 lbs/ft2). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 12.21 kg/m2. (2.5 lbs/ft2). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 14.65 kg/m2. (3.0 lbs/ft2). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 40.03 N (9 lbf) and a bond strength that is greater than 2.44 kg/m2 (0.5 lbs/ft2). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 55.60 N (12.5 lbf) and a bond strength that is greater than 4.88 kg/m2 (1.0 lbs/ft2). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 61.16 N (13.75 lbf) and a bond strength that is greater than 9.76 kg/m2 (2 lbs/ft2).

In an exemplary embodiment, a fabric sample 370 measuring 15.24 cm by 30.48 cm (6 inches by 12 inches), has multiple layers, such as four layers (i.e., eight layers), has between 2.22 cm (0.875 inches) of thickness and 5.08 cm (2.0 inches) thick and has a weight per square foot between 0.73 and 19.53 kg/m2 (0.15 and 0.4 lbs/ft2), has a tensile strength that is greater than 13.34 N (3 lbf) and has a tensile strength to weight ratio that is greater than 392.27 N/kg (40 lbf/lbm), such as from about 392.27 to about 1274.86 N/kg (about 40 to about 130 lbf/lbm). In an exemplary embodiment, the fabric has a bond strength that is greater than 1.46 kg/m2 (0.3 lbs/ft2). In an exemplary embodiment, the bond strength of this sample is greater than 0.49 kg/m2 (0.1 lbs/ft2). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 33.36 N (7.5 lbf). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 44.48 N (10 lbf). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is between 13.34 and 66.72 N (between 3 and 15 lbf). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 2.44 kg/m2. (0.5 lbs/ft2). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 4.88 kg/m2. (1.0 kg/ft2). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 9.76 kg/m2. (2 lbs/ft2). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 14.65 kg/m2. (3 lbs/ft2). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 19.53 kg/m2. (4 lbs/ft2). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 24.41 kg/m2. (5 lbs/ft2). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 48.82 kg/m2 (10 lbs/ft2). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 33.36 N (7.5 lbf) and the bond strength is greater than 2.44 kg/m2 (0.5 lbs/ft2). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 44.48 N (10 lbf) and the bond strength is greater than 4.88 kg/m2 (1.0 lbs/ft2). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is between 13.34 and 66.72 N (between 3 and 15 lbf) and the bond strength is between 1.46 and 73.24 kg/m2 (0.3 and 15 lbs/ft2 ).

In an exemplary embodiment, a fabric sample 370 measuring 15.24 cm by 30.48 cm (6 inches by 12 inches), has multiple layers, such as four layers (i.e., eight layers), has between 2.54 cm (1.0 inches) of thickness and 5.08 cm (2.0 inches) thick and has a weight per square meter between 0.49 and 1.46 kg/m2 (a weight per square foot between 0.1 and 0.3 lbs/square foot), has a tensile strength greater than 40.03 N (9 lbf) and a tensile strength to weight ratio greater than 686.47 N/kg (70 lbf /lbm). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 44.48 N (10 lbf). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 2.44 kg/m2- (0.5 lbs/ft2). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 4.88 kg/m2- (1.0 lbs/ft2). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 9.76 kg/m2. (2 lbs/ft2). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 14.65 kg/m2. (3 lbs/ft2). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 19.53 kg/m2. (4 lbs/ft2). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 24.41 kg/m2. (5 lbs/ft2). In an exemplary embodiment, the bond strength of the sample described in this paragraph is greater than 48.82 kg/m2. (10 lbs/ft2). In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 44.48 N (10 lbf) and the bond strength is greater than 24.41 kg/m2 (5 lbs/ft2).

In an exemplary embodiment, an interlock fabric made according to Figures 1A-1C and Figures 3A-3C has combined physical properties in the ranges set forth in Table 1 below.

Table 1

In an exemplary embodiment, the fiber diameters and fiber lengths identified in this application refer to the majority of fibers of a group of fibers that are provided by a fiberizer or other fiber-forming apparatus, but that are not processed. otherwise after the formation of the fibers. In another exemplary embodiment, the fiber diameters and fiber lengths identified in this application refer to a group of fibers that are provided by a fiberizer or other fiber forming apparatus, but that are not otherwise processed after formation. of the fibers, where a minority or any number of the fibers have the fiber diameter and/or the fiber length.

Figures 2A-2C illustrate examples of methods not covered by the present invention that are similar to the embodiments of Figures 1A-1C, except that the fabric 521 (see Figure 5) is formed 260 with a dry or non-aqueous binder. Method 200 of Figure 2A generally corresponds to method 100 of Figure 1A. Method 250 of Figure 2B generally corresponds to method 150 of Figure 1B. Method 270 of Figure 2C generally corresponds to method 170 of Figure 1C.

Figure 2D illustrates a method 290 that is similar to method 270 of Figure 2C. In Figure 2D, steps in dashed boxes are optional. In the method illustrated in Figure 2D, the dry binder may optionally be added to the fabric step 292 and/or to the laminated fabric in step 294, instead of (or in addition to) before the fabric is formed. For example, if step 292 is included, the fabric can be formed without a dry binder, and then the dry binder is added to the fabric before lamination and/or during lamination. If step 294 is included, the fabric can be formed and laminated without a dry binder, and then the dry binder is added to the laminated fabric.

Referring to Figure 5, the dry binder (indicated by the large arrows) can be added to the fibers 322 and/or fabric 521 at a variety of different points in the process. Arrow 525 indicates that the dry binder may be added to the fibers 322 at or above the collection member. Arrow 527 indicates that dry binder can be added to fibers 322 in conduit 330. Arrow 529 indicates that dry binder can be added to fibers 322 in forming apparatus 332. Arrow 531 indicates that dry binder can be added to the fabric 321 after the fabric leaves the forming apparatus 332. The arrow 533 indicates that the dry binder can be added to the fabric 321 as the fabric is laminated by the laminating apparatus 334. The arrow 535 indicates that the dry binder may be added to fabric 321 after the fabric is laminated. The arrow 537 indicates that the dry binder can be added to the fabric 321 or the laminated fabric in the oven 550. Referring to Figure 8, the arrow 827 indicates that the dry binder can be added to the fibers 322 in the conduit 330 in a position near the fiberizer. Arrow 829 indicates that the dry binder can be added to the fibers 322 in the conduit 330 at an elbow of the conduit. Arrow 831 indicates that the dry binder can be added to the fibers in conduit 330 at an exit end of the conduit. Arrow 833 indicates that the dry binder can be added to the fibers 322 in a forming apparatus 332 having a drum-shaped forming surface. The dry binder may be added to the fibers 322 or fabric 321 to form a dry binder fabric 521 in either manner.

Figure 5A is an apparatus similar to the apparatus of Figure 5, except that the fibers 322 are collected by an accumulator 590. The arrow 592 indicates that the fibers 322 are provided by the accumulator 590 in a controlled manner to the forming apparatus 332. The Fibers 322 may remain in accumulator 590 for a predetermined period of time before being provided to forming apparatus 332 to allow the fibers to cool. In one example, the fibers 322 are provided by the accumulator 590 to the forming apparatus 332 at the same rate that the fibers 322 are provided to the accumulator 590. As such, in this example, the time that the fibers remain and cool in the accumulator is determined by the number of fibers 322 in the accumulator. In this example, the residence time is the number of fibers in the accumulator divided by the rate at which the accumulator provides the fibers to the forming apparatus 332. In another example, the accumulator 390 can selectively start and stop the distribution of the fibers. fibers and/or adjust the rate at which the fibers are distributed. The dry binder may be applied to the fibers 322 at any of the locations indicated in Figure 5. Additionally, the dry binder may be applied to the fibers 322 in the accumulator as indicated by arrow 594 and/or when the fibers are transferred from the accumulator 590 to the forming apparatus 332 as indicated by arrow 596.

Figure 5B is an apparatus similar to the apparatus of Figure 5, except that the fibers 322 can be selectively diverted between the forming apparatus 332 and a second forming apparatus and/or for some other use by a diverting mechanism 598. In one embodiment Exemplarily, the embodiment illustrated in Figure 5 may have both the accumulator 590 and the diverter mechanism 598. The dry binder may be applied to the fibers 322 at any of the locations indicated in Figure 5. Additionally, the dry binder may be applied to the fibers 322. fibers 322 in the diverter mechanism as indicated by arrow 595 and/or when the fibers are transferred from the diverter mechanism 598 to the forming apparatus 332 as indicated by arrow 597.

In an example described herein that is not encompassed by the present invention, the dry binder is applied to the fibers 322 at a location that is a significant distance downstream of the fiberizer 318. For example, the dry binder can be applied to the fibers in a location where the temperature of the fibers and/or the temperature of the air surrounding the fibers is significantly lower than the temperature of the fibers and the surrounding air in the fiberizer. In one example, the dry binder is applied at a location where the temperature of the fibers and/or a temperature of the air surrounding the fibers is below a temperature at which the dry binder melts or a temperature at which the Dry binder cures completely or reacts. For example, a thermoplastic binder may be applied at a point on the production line where the temperature of the fibers 322 and/or the temperature of the air surrounding the fibers is below the melting point of the thermoplastic binder. A thermosetting binder may be applied at a point in the production line where the temperature of the fibers 322 and/or a temperature of the air surrounding the fibers is below the curing temperature of the thermosetting binder. That is, the thermoset binder may be applied at a point where the temperature of the fibers 322 and/or the temperature of the air surrounding the fibers is below a point where the thermoset binder reacts completely or complete cross-linking of the thermoset binder occurs. In one example, the dry binder is applied at a production line location where the temperature of the fibers 322 and/or the temperature of the air surrounding the fibers is below 148.89 °C (300 degrees F). In one example, the dry binder is applied at a location on the production line where the temperature of the fibers 322 and/or the temperature of the air surrounding the fibers is below 121.11°C (250 degrees F). In one example, the temperature of the fibers and/or a temperature of the air surrounding the fibers at the locations indicated by arrows 527, 529, 531, 533 and 535 in Figure 5 is below a temperature at which the dry binder melts or cures completely.

In one example, the binder applicator is a sprayer configured for dry powders. The sprayer can be configured so that the force of the spray is adjustable, thus allowing greater or lesser penetration of the dry powder into the continuous web of the fibrous material. Alternatively, the binder applicator may 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 of glass fibers 321. For example, the dry binder may comprise binder-containing fibers that are provided in the form of bales. The binder applicator comprises a bale opener and a blower that opens the bale, separates the binder fibers from each other, and blows the binder fibers into the duct where the binder is mixed with the fiberglass fibers. The dry binder may comprise a powder. The binder applicator may comprise a screw delivery device that supplies the binder powder to an air nozzle that supplies the binder powder to the duct, where the binder powder is mixed with the fibers. The dry binder may comprise a non-aqueous liquid. The binder applicator may comprise a nozzle that delivers the liquid binder into the conduit, where the binder is mixed with the fibers.

Figures 9, 9A and 9B illustrate an example not covered by the invention where the binder 900, such as a binder in fiber or powder form, fiber form or non-aqueous liquid form, is applied with a modified pneumatic web frame 902. Pneumatic web frames are well known in the art. Examples of pneumatic web frames are described in United States Patent Nos. 4,266,960; 5,603,743; and 4,263,033 and PCT International Publication Number WO 95/30036. Any of the features of pneumatic web frames described in United States Patent Nos. 4,266,960; 5,603,743; and 4,263,033 and PCT International Publication Number WO 95/30036 can be used in the pneumatic web draw frame 902 which is schematically illustrated in this patent application. An existing type of pneumatic web frame 902 is a full veil pneumatic web frame (AFVL). The pneumatic web draw frame 902 illustrated in Figures 9, 9A and 9B differs from conventional pneumatic web draw frames in that the pneumatic web draw frame is configured to apply the binder 900.

Figure 8 illustrates a rotary fiberizer 318, an optional shirring member 324, a conduit 330, and a forming apparatus 332. The apparatus illustrated in Figure 8 will typically also include the hot extruder 314 and forehearth 316 illustrated in Figure 5. The hot extruder 314, forehearth and other components illustrated in Figure 5 are omitted from Figure 8 to simplify the drawing.

Referring to Figure 8, the forming apparatus 332 can be configured to form a continuous web 321 of fibrous material having a desired thickness. The training apparatus 332 can take a wide variety of different forms. Any arrangement can be used to form a fabric 321 of glass fibers. In the exemplary embodiment illustrated in Figure 8, the forming apparatus 332 includes a rotating drum 910 with forming surfaces 462 and areas of greater or lesser pressure. Collection of the fibers using a pressure drop AP across surface 462 is as described with respect to Figure 4.

Referring to Figures 9A and 9B, the pneumatic web frame 902 includes a first blower 920 and a second blower 922. The pneumatic web frame operates by blowing, such as by blowing alternately with the first and second blowers 920, 922. Blower 920 provides airflow against fibers traveling in the duct toward forming surface 462, while blower 922 does not provide airflow (see Figures 9A and 9B). After a controlled period of time, blower 922 provides airflow against fibers traveling in the duct toward forming surface 462, while blower 920 provides no airflow. This alternative operation by the first and second blowers 920, 922 provides a uniform distribution of the collected fibers 322 on the forming surface 462.

The pneumatic web draw frame 902 illustrated in Figures 9, 9A and 9B differs from conventional pneumatic web draw frames in that each of the blowers 920, 922 includes one or more binder introduction devices 904. The binder introduction devices 904 can take a wide variety of different forms. For example, the binder introducing devices 904 can provide binder 900 into the interior 930 of a housing 932 of the blowers 920, 922 as illustrated, or the binder introducing device can be positioned to introduce the binder 900 into the flow of air from the blowers 920, 922. For example, a nozzle of a binder introducing device can distribute binder in an air flow stream from the blowers 920, 922. Examples of binder introducing devices include, but are not limited to a, nozzles and blowers that provide less air flow than blowers 920, 922. In one example, binder introduction device 904 injects binder 900 into the interior 930 of housing 932 when blower 920 or 922 is not blowing. Then, when the blower 920 or 922 is turned on, the interior 930 is pressurized and the binder 900 is transported from the interior 930 to the fiber air stream. In the air stream, the air from the pneumatic web draw frame will move the fibers to provide a forming effect on the distribution of the fibers on the forming surface 462 and the air will also inject the binder to mix with the fibers in the forming stream. air.

Referring to Figures 9A and 9B, the pneumatic web frame 902 mixes the binder 900 into the fibers 322 that are collected on the forming surface 462 to form the fabric 321. In one example, when the blower 920 provides a flow of air 921 against the fibers traveling in the duct towards the forming surface 462, the binder introduction device 904 introduces the binder 900 to the blower 920 and the air flow 921 provided by the blower 920 mixes the binder with the fibers 322 ( shown in Figures 9A and 9B). Similarly, in this example, when the blower 922 provides an air flow 921 against the fibers traveling in the duct toward the forming surface 462, the binder introducing device 904 introduces the binder 900 to the blower 922 and the Air flow 921 provided by blower 922 mixes the binder with fibers 322 (air flow provided by blower 922 is not shown, but is the same as air flow provided by blower 920). As a result, the binder 900 is evenly mixed with the fibers 322.

Dry binders can take a wide variety of different forms. Any non-aqueous medium that holds the fibers 322 together can be used to form a fabric 521. In an example not covered by the present invention, the dry binder, although initially applied to the fibers, is composed of substantially 100% solids. The term "substantially 100% solids," as used herein, means any binder material that has diluents, such as water, in an amount less than or equal to about two percent, and preferably less than or equal to one percent by weight of the binder. (while the binder is applied, rather than after the binder has dried or cured). However, it should be appreciated that in certain cases, the binder may include diluents, such as water, in any desired amount depending on the specific application and design requirements. In one example, the dry binder is a thermoplastic resin-based material that is not applied in liquid form and is also not water-based. In other examples, the dry binder may be other materials or other combinations of materials, including the non-limiting example of thermosetting polymer resins. The dry binder may have any form or combination of forms, including 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 an exemplary embodiment, the dry binder is a dry binder without added formaldehyde, meaning that the dry binder does not contain formaldehyde. However, formaldehyde may form if the dry formaldehyde-free binder is burned. In one example, enough dry binder is applied so that a cured fibrous package can be compressed for packaging, storage and shipping, and still regain its thickness - a process known as "height recovery" - when installed.

In the examples illustrated by Figures 2A-2D and 5 that are not covered by the present invention, the glass fibers 322 may be optionally or partially coated with a lubricant before or after applying the dry binder to the glass fibers. In one example described herein, the lubricant is applied after the dry binder to improve adhesion of the dry binder to the glass fibers 322. The lubricant may be any of the lubricants described above.

Referring to Figure 5, the continuous fabric with the dry unreacted binder 521 is transferred from the forming apparatus 332 to the optional lamination mechanism 334. The lamination mechanism can take a wide variety of different forms. For example, the laying mechanism may be a laying mechanism that lays the fabric 321 in the machine direction D1 or a cross laying mechanism that lays the fabric in a direction that is substantially orthogonal to the machine direction. The cross-laying device described above for laminating fabric without binder 321 can be used to laminate fabric 521 with unreacted dry binder.

In one example described herein, the dry binder of the continuous fabric 521 is configured to thermally solidify in a curing oven 550. In one example, the curing oven 550 replaces the interlocking mechanism 345, as the dry binder holds together fibers 322. In another exemplary embodiment, both a curing oven 550 and an interlacing mechanism 345 are included.

Figures 6 and 7 schematically illustrate another exemplary embodiment of a method of forming a package from fibrous materials generally illustrated at 610. Referring to Figure 6, molten glass 612 is supplied from a hot extruder 614 to a antecrucible 616. Molten glass 612 can be formed from various raw materials combined in such proportions as to provide the desired chemical composition. Molten glass 612 flows from forehearth 616 to a plurality of rotating fiberizers 618.

Referring to Figure 6, rotating fiberizers 618 receive molten glass 612 and subsequently form veils 620 of glass fibers 622 entrained in a flow of hot gases. As will be explained in more detail below, the glass fibers 622 formed by the rotating fiberizers 618 are long and thin. Accordingly, any desired fiberizer, rotary or otherwise, sufficient to form long, thin glass fibers 22 can be used. Although the embodiment illustrated in Figures 6 and 7 shows a number of two rotating fiberizers 618, it should be appreciated that any desired number of rotating fiberizers 18 can be used.

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 web 620 of glass fibers 622 in a given direction, typically in a downward manner. It should be understood that the flow of hot gases can be created by any desired structure, mechanism or device or any combination thereof.

As shown in Figure 6, optional spray mechanisms 626 can be placed below the rotating 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. and protect the fibers 622 from contact damage and/or improve the bonding ability of the fibers 622. The spray mechanisms 626 may be any desired structure, mechanism or device sufficient to spray fine water droplets onto the hot gases in the webs. 620 to help cool the flow of hot gases, protect the fibers 622 from contact damage, and/or improve the bonding ability of the fibers 22. Although the embodiment shown in Figure 6 illustrates the use of the spray mechanisms 626, It should be appreciated that the use of the spray mechanisms 626 is optional and the method of forming the package from fibrous materials 610 can be practiced without the use of the spray mechanisms 626.

Optionally, the glass fibers 622 may be coated with a lubricant after the glass fibers are formed. In the illustrated embodiment, a plurality of nozzles 628 may be positioned around the webs 620 in a position below the rotating fiberizers 618. The nozzles 628 may be configured to supply a lubricant (not shown) to the glass fibers 622 from a source of lubricant (not shown).

The application of the lubricant can be precisely controlled by any desired structure, mechanism or device, such as the non-limiting example of a valve (not shown). In certain embodiments, the lubricant may be a silicone compound, such as siloxane, dimethylsiloxane and/or silane. The lubricant may also be other materials or combinations of materials, such as an oil or an oil emulsion. The oil or oil emulsion may be a mineral oil or a mineral oil emulsion and/or a vegetable oil or a 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 package of fibrous materials. However, in other embodiments, the amount of lubricant may be more or less than about 1.0 weight percent of the oil and/or silicone compound.

Although the embodiment shown in Figure 6 illustrates the use of nozzles 628 to supply a lubricant (not shown) to the glass fibers 622, it should be appreciated that the use of nozzles 628 is optional and the method of forming the package from materials fibrous 610 can be practiced without the use of the nozzles 628.

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. Gathering member 624 is configured to divert glass fibers 622 and hot gas flow to a conduit 630 for transfer to downstream processing stations, such as forming apparatuses 632a and 632b. In other embodiments, the glass fibers 622 can be gathered together in a transport mechanism (not shown) to form a blanket or batting (not shown). The batting can be transported by the transport mechanism to other processing stations (not shown). The gathering member 624 and conduit 630 may be any structure having a generally hollow configuration that is suitable for receiving and transporting the glass fibers 622 and the flow of hot gases. Although the embodiment shown in Figure 6 illustrates the use of the gathering member 624, it should be appreciated that the use of the 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 bundle of fibrous materials 610 can be made without the use of the gathering member 624.

In the embodiment shown in Figures 6 and 7, a single fiberizer 618 is associated with a single duct 630, so that the glass fibers 622 and the flow of hot gases from the single fiberizer 618 are the only source of the glass fibers. glass 622 and the flow of hot gases entering the conduit 630. Alternatively, a single conduit 630 may be adapted to receive the glass fibers 622 and the flow of hot gases from multiple fiberizers 618 (not shown).

Referring again to Figure 6, optionally, a head system (not shown) may be placed between the forming apparatuses 632a and 632b and the fiberizers 618. The head system may be configured as a chamber in which glass fibers may be combined. 622 and gases flowing from the plurality of fiberizers 618 while controlling the characteristics of the resulting combined flow. In certain embodiments, the head system may include a control system (not shown) configured to combine the flows of the glass fibers 622 and the gases from the fiberizers 618 and further configured to direct the resulting combined flows to the forming apparatus 632a. and 632b. Such a head system may allow maintenance and cleaning of certain fiberizers 618 without the need to shut down the remaining fiberizers 618. Optionally, the head system may incorporate any desired means for controlling and directing the glass fibers 22 and flows. of gases.

Referring now to Figure 7, the momentum of the flow of the gases, which have the glass fibers 622 entrained, will cause the glass fibers 622 to continue to flow through the conduit 630 towards the forming apparatuses 632a and 632b. The training devices 632a and 632b can be configured for various functions. First, the forming apparatus 632a and 632b can be configured to separate the entrained glass fibers 622 from the gas flow. Second, the forming apparatuses 632a and 632b can be configured to form a continuous, thin, dry web of fibrous material having a desired thickness. Third, the forming apparatuses 632a and 632b can be configured to allow the glass fibers 622 to be separated from the gas flow in a manner that allows the fibers to orient within the fabric 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, may be oriented non-preferentially in any of the X, Y, or Z dimensions. In certain cases, It may be desirable to have a high degree of randomness. In other cases, it may be desired to control the randomness of the fibers 622 so that the fibers 622 are oriented in a non-random manner, in other words, the fibers are substantially coplanar or substantially parallel to each other. Fourth, the forming apparatuses 632a and 632b may be configured to transfer the continuous web of fibrous material to other downstream operations.

In the embodiment illustrated in Figure 7, each of the forming apparatuses 632a and 632b includes a drum (not shown) configured for rotation. The drum may include any desired number of foraminous surfaces and areas of greater or lesser pressure. Alternatively, each of the forming apparatuses 632a and 632b may be formed from other structures, mechanisms and devices, sufficient to separate the entrained glass fibers 622 from the flow of gases, form a continuous web of fibrous material having a thickness desired and transfer the continuous web of fibrous material to other downstream operations. In the illustrated embodiment, shown in Figure 7, each of the training apparatuses 632a and 632b are the same. However, in other embodiments, each of the training apparatuses 632a and 632b may be different from each other.

Referring again to Figure 7, the continuous web of fibrous material is transferred from the forming apparatus 632a and 632b to an optional binder applicator 646. The binder applicator 646 is configured to apply a "dry binder" to the continuous web of fibrous material. fibrous material. The term "dry binder," as used herein, is defined to mean that the binder is substantially 100% solids while the binder is applied. The term "substantially 100% solids," as used herein, is defined to mean any binder material that has diluents, such as water, in an amount less than or equal to about two percent, and preferably less than or equal to approximately one percent by weight of the binder (while the binder is applied, rather than after the binder has dried and/or cured). However, it should be appreciated that in certain embodiments, the binder may include diluents, such as water, in any desired amount depending on the specific application and design requirements. The binder may be configured to thermally solidify in a curing oven 650. In this application, the terms "cure" and "thermal solidify" refer to a chemical reaction and/or one or more phase changes that cause the dried binder to the fibers of the fabric with each other. For example, a thermoset dry binder (or thermoset component of the dry binder) cures or solidifies thermally as a result of a chemical reaction that occurs as a result of an application of heat. A thermoplastic dry binder (or thermoplastic dry binder component) thermally cures or solidifies as a result of heating it to a softened or molten phase and then cooling it to a solid phase.

In an exemplary embodiment, the dry binder is a thermoplastic resin-based material that is not applied in liquid form and is not water-based. In other embodiments, the dry binder may be other materials or other combinations of materials, including the non-limiting example of thermosetting polymer resins. The dry binder may be any form or combination of foams, including 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. Enough dry binder is applied so that a cured fibrous package can be compressed for packaging, storage and shipping, but regain its thickness - a process known as "height recovery" - when installed. Application of the dry binder to the continuous web of fibrous material forms a continuous web, optionally with unreacted binder.

In the embodiment illustrated in Figures 6 and 7, the binder applicator 646 is a sprayer configured for dry powders. The sprayer is configured so that the force of the spray is adjustable, thus allowing greater or lesser penetration of the dry powder into the continuous web of fibrous material. Alternatively, the binder applicator 646 may 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.

Although the embodiment illustrated in Figure 7 shows a binder applicator 646 configured to apply a dry binder to the continuous web of fibrous material, it is within the contemplation of this invention that in certain embodiments no binder will be applied to the continuous web of fibrous material. .

Referring again to Figure 7, the continuous fabric, optionally with unreacted binder, is transferred from the binder applicators 646 to the corresponding cross-laying mechanism 634a and 634b. As shown in Figure 7, the forming apparatus 632a is associated with the cross-laying mechanism 634a and the forming apparatus 632b is associated with the cross-laying mechanism 634b. The transverse racking mechanisms 634a and 634b operate in association with a first conveyor 636. The first conveyor 636 is configured to move in the machine direction as indicated by arrow D1. The cross laying mechanism 634a is configured to receive the continuous fabric, optionally with unreacted binder, from the optional binder applicators 646 and is further configured to deposit alternating layers of the continuous fabric, optionally with unreacted binder, on the first conveyor 636 as the first conveyor 636 moves in the machine direction D1, thus forming the initial layers of a fibrous body. In the deposition process, the cross-laying mechanism 634a forms the alternating layers in a cross-machine direction as indicated by arrows D2. Accordingly, as the deposited continuous fabric, optionally with unreacted binder, from the laying mechanism 634a moves in the machine direction D1, the downstream laying mechanism 634b deposits additional layers on the fibrous body. The resulting layers of the fibrous body deposited by the transverse laying mechanisms 634a and 634b form a package.

In the illustrated embodiment, the cross-laying mechanisms 634a and 634b are devices configured to precisely control the movement of the continuous fabric with unreacted binder and deposit the continuous fabric with unreacted binder on the first conveyor 636 such that the continuous fabric, optionally with unreacted binder, it is not damaged. The transverse racking mechanisms 634a and 634b may include any desired structure and may be configured to operate in any desired manner. In one example, the cross-racking mechanisms 634a and 634b may 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 so that the movement of the head in both directions transverse to the machine is substantially the same, thus providing uniformity of the resulting layers of the fibrous body. In another example, vertical conveyors (not shown) configured to center with a centerline of the first conveyor 636 may be used. The vertical conveyors are further configured to swing from a pivot mechanism above the first conveyor 636 to deposit the continuous fabric, optionally with unreacted binder, in the first conveyor 36. Although several examples of cross-racking mechanisms have been described above, it should be appreciated that the cross-racking mechanisms 634a and 634b may be other structures, mechanisms or devices or combinations thereof.

Referring again to Figure 7, optionally placement of the continuous fabric, optionally with unreacted binder, on the first conveyor 636 can be achieved by a controller (not shown), to provide improved package uniformity. The controller may be any desired structure, mechanism or device or combinations thereof.

The laminated fabric or package may have any desired thickness. Package thickness is a function of several variables. First, the thickness of the package is a function of the thickness of the continuous fabric, optionally with unreacted binder, formed by each of the forming apparatuses 632a and 632b. Second, the thickness of the package is a function of the rate at which the cross-laying mechanisms 634a and 634b alternately deposit layers of the continuous fabric, optionally with unreacted binder, on the first conveyor 636. Third, the thickness of the package is a function of the speed of the first conveyor 636. In the illustrated embodiment, the package has a thickness in a range of about 0.25 cm to about 50.8 cm (0.1 inch to about 20.0 inches). In other embodiments, the package may have a thickness of less than about 0.25 cm (about 0.1 inches) or greater than about 50.8 cm (about 20.0 inches).

As discussed above, the cross laying mechanisms 634a and 634b are configured to deposit alternating layers of the continuous fabric, optionally with unreacted binder, on the first conveyor 636 as the first conveyor 636 moves in the machine direction D1 , thus forming layers of a fibrous body. In the illustrated embodiment, the transverse racking mechanism 634a and 634b and the first conveyor 636 are coordinated to form a fibrous body having a number of layers ranging from about 1 layer to about 60 layers. In other embodiments, the transverse racking mechanism 634a and 634b and the first conveyor 636 can be coordinated to form a fibrous body having any desired number of layers, including a fibrous body having more than 60 layers.

Optionally, the cross racking mechanisms 634a and 634b may be adjustable, thereby allowing the cross racking mechanisms 634a and 634b to form a package having any desired width. In certain embodiments, the package may have an overall width in a range of about 248.92 cm (about 98.0 inches) to about 599.44 cm (about 236.0 inches). Alternatively, the package may have an overall width less than about 248.92 cm (approximately 98.0 inches) or greater than about 599.44 cm (approximately 236.0 inches).

Although the cross-laying mechanisms 634a and 634b have been described above as being involved together in the formation of a fibrous body, it should be appreciated that in other embodiments, the cross-laying mechanisms 634a and 634b may operate independently of each other, such as to form discrete bands of fibrous bodies.

Referring to Figures 6 and 7, the package, which has the layers formed by the transverse racking mechanisms 634a and 634b, is transported by the first conveyor 636 to an optional trimming mechanism 640. The optional trimming mechanism 640 is configured to trim the edges of the package, to form a desired width of the package. In an exemplary embodiment, the package may have a width after trimming in a range of about 248.92 cm (about 98.0 inches) to about 599.44 cm (about 236.0 inches). Alternatively, the package may have a width after trimming less than about 248.92 cm (approximately 98.0 inches) or greater than about 599.44 cm (approximately 236.0 inches).

In the illustrated embodiment, the optional trimming mechanism 640 includes a saw system having a plurality of rotating saws (not shown) positioned on each side of the package. Alternatively, the trimming mechanism 640 may be other structures, mechanisms or devices or combinations thereof, including the non-limiting examples of water jets and compression blades.

In the illustrated embodiment, the trimming mechanism 640 is advantageously placed upstream of the curing oven 650. Placing the trimming mechanism 640 upstream of the curing oven 650 allows the package to be trimmed before it is thermally solidified in the curing oven 650. Optionally, materials that are trimmed from the package by trimming mechanism 640 may be returned to the gas flow and glass fibers in conduits 630 and recycled into forming apparatus 632a and 632b. Recycling the trimmings advantageously prevents potential environmental problems related to the disposal of the trimmings. As shown in Figure 6, conduits 642 connect trimming mechanism 640 to conduits 630 and are configured to facilitate return of trimming materials to forming apparatus 632a and 632b. Although the embodiment shown in Figures 6 and 7 illustrates the recycling of the cut materials, it should be appreciated that the recycling of the cut materials is optional and the method of forming the package from fibrous materials 610 can be practiced without recycling the cut materials. In another exemplary embodiment, the trimming mechanism 640 is positioned downstream of the curing oven 650. This placement is particularly useful if the trimmed materials are not recycled. Trimming the packet forms a trimmed packet.

The trimmed package is transported by the first conveyor 636 to a second conveyor 644. As shown in Figure 6, the second conveyor 644 may be positioned to "reduce" from the first conveyor 636. The term "reduced," as used in Here, it is defined to mean that the top surface of the second conveyor 644 is positioned to be vertically below the top surface of the first conveyor 636. The reduction of the conveyors will be discussed in more detail below.

Referring again to Figures 1 and 2, the cut package is transported by the second conveyor 644 to an interlacing mechanism 645. The interlacing mechanism 645 is configured to intertwine the individual fibers 622 that form the layers of the cut package. Interlacing the 622 glass fibers within the bundle binds the bundle together. In embodiments where dry binder is included, the interlacing of the glass fibers 622 advantageously allows the mechanical properties to be improved, such as, for example, tensile strength and cut resistance. In the illustrated embodiment, the interlocking mechanism 645 is a punching mechanism. In other embodiments, the interlocking mechanism 645 may include other structures, mechanisms, or devices or combinations thereof, including the non-limiting example of stitching mechanisms. Interlacing the fibers within the bundle forms an interlocking bundle.

The second conveyor 644 transports the package with optional dry binder, which is optionally trimmed and/or interlaced (hereinafter, both the trimmed package and the interlaced package will be simply referred to as "package") to a third conveyor 648. When the package includes a dry binder, the third conveyor 648 is configured to carry the package to an optional curing oven 650. The curing oven 650 is configured to blow a fluid, such as hot air through the package to cure the dry binder and rigidly bonding the glass fibers 622 together in a generally random three-dimensional structure. Curing the package in the 650 curing oven forms a cured package.

The use of the dry binder, instead of a traditional wet binder, advantageously allows the curing oven 650 to use less energy to cure the dry binder within the package. In the illustrated example, the use of the dry binder in the curing oven 650 results in energy savings in a range of about 30.0% to about 80.0% compared to the energy used by conventional curing ovens to cure the binder. moist or watery. In still other examples, energy savings may exceed 80.0%. The curing oven 650 may be any desired structure, mechanism or curing device or combinations thereof.

The third conveyor 648 transports the cured package to a fourth conveyor 652. The fourth conveyor 652 is configured to carry the cured package to a cutting mechanism 654. Optionally, the cutting mechanism 654 can be configured for various cutting modes. In an optional first cutting mode, the cutting mechanism is configured to cut the cured package in vertical directions along the machine direction D1 to form strips. The strips formed can have any desired width. In a second optional cutting mode, the cutting mechanism is configured to bisect the cured package in a horizontal direction to form continuous packages having thicknesses. The resulting split packages can have any desired thickness. Cutting the cured package forms the cut package.

In the illustrated embodiment, the cutting mechanism 654 includes a system of saws and blades. Alternatively, the cutting mechanism 654 may be other structures, mechanisms or devices or combinations thereof. Referring again to Figures 6 and 7, the cutting mechanism 654 is advantageously positioned to allow the capture of dust and other waste materials formed during the cutting operation. Optionally, dust and other waste materials arising from the cutting mechanism may be returned to the flow of gases and glass fibers in conduits 630 and recycled in the forming apparatus 632a and 632b. Recycling of dust and waste materials advantageously prevents potential environmental problems related to the disposal of dust and waste materials. As shown in Figures 6 and 7, conduits 655 connect cutting mechanism 654 to conduits 630 and are configured to facilitate the return of dust and waste materials to forming apparatus 632a and 632b. Although the embodiment shown in Figures 6 and 7 illustrates the recycling of the powder and waste materials, it should be appreciated that the recycling of the powder and waste materials is optional and the method of forming the package from fibrous materials 10 can be practiced without recycling of dust and waste materials.

Optionally, prior to transportation of the cured package to the cutting mechanism 654, the main surfaces of the cured package may be coated with coating material or materials by coating mechanisms 662a, 662b as shown in Figure 6. In the illustrated embodiment, the surface The upper main surface of the cured package is coated with a coating material 663a provided by the coating mechanism 662a and the lower main surface of the cured package is coated with a coating material 663b provided by the coating mechanism 662b. The liner materials can be any desired material, including paper, polymeric materials or nonwoven continuous tapes. The coating mechanisms 662a and 662b can be any desired structure, mechanism or device or combinations thereof. In the illustrated embodiment, the coating materials 663a and 663b are applied to the cured package (if the package includes a binder) by means of adhesives. In other embodiments, coating materials 663a and 663b may be applied to the cured package by other methods, including the non-limiting example of sonic welding. Although the embodiment shown in Figure 6 illustrates the application of the coating materials 663a and 663b to the main surfaces of the cured package, it should be appreciated that the application of the coating materials 663a and 663b to the main surfaces of the cured package is optional. and the method of forming the package from fibrous materials 610 can be practiced without applying the coating materials 663a and 663b to the main surfaces of the cured package.

Referring to Figures 6 and 7, the fourth conveyor 652 transports the cut package to an optional slicing mechanism 656. The slicing mechanism 656 is configured to section the cut package into desired lengths along machine direction D1. . In the illustrated embodiment, the slicing mechanism 656 is configured to section the cut package as the cut package continuously moves in machine direction D1. Alternatively, the chopping mechanism 656 may be configured for batch chopping operation. Sectioning the cut package into lengths forms a sized package. The lengths of the chopped package can be any desired dimension.

The chopping mechanisms are known in the art and will not be described herein. The chopping mechanism 656 may be any desired structure, mechanism or device or combinations thereof.

Optionally, prior to transportation of the cut package to the cutting mechanism 656, the minor surfaces of the cut package may be coated with edging material(s) by the edging mechanisms 666a, 666b as shown in Figure 7. The edging materials may be any desired material, including paper, polymeric materials or continuous non-woven tapes. The edging mechanisms 666a and 666b may be any desired structure, mechanism or device or combinations thereof. In the illustrated embodiment, the edging materials 667a and 667b are applied to the cut package by means of adhesives. In other embodiments, the edging materials 667a and 667b may be applied to the cut package by other methods, including the non-limiting example of sonic welding. Although the embodiment shown in Figure 7 illustrates the application of the edging materials 667a and 667b to the minor surfaces of the cut package, it should be appreciated that the application of the edging materials 667a and 667b to the minor surfaces of the cut package is optional and The method of forming the package from fibrous materials 610 can be practiced without applying the edging materials 667a and 667b to the minor surfaces of the cut package.

Referring again to Figure 6, the fourth conveyor 652 transports the sized package to a fifth conveyor 658. The fifth conveyor 658 is configured to transport the sized package to a packaging mechanism 660. The packaging mechanism 660 is configured to package the package sized for future operations. The term "future operations," as used herein, is defined to include any activity subsequent to the formation of the sized package, including the non-limiting examples of storage, shipping, sales and installation.

In the illustrated embodiment, the packaging mechanism 660 is configured to form the sized package into a roll-shaped package. In other embodiments, the packaging mechanism 660 may form packages having other desired shapes, such as non-limiting examples of slabs, batts, and irregularly shaped or die-cut pieces. The packaging mechanism 660 may be any desired structure, mechanism or device or combinations thereof.

Referring again to Figure 6, conveyors 636, 644, 648, 652 and 658 are in a "reduced" ratio in machine direction D1. The "reduced" ratio means that the top surface of the successive conveyor is positioned to be vertically below the top surface of the previous conveyor. The "reduced" ratio of the conveyors advantageously provides a self-tapping feature to the transport of the package. In the illustrated embodiment, the vertical offset between adjacent conveyors is in a range of about 7.62 cm (about 3.0 inches) to about 25.4 cm (about 10.0 inches). In other embodiments, the vertical offset between adjacent conveyors may be less than about 7.62 cm (about 3.0 inches) or greater than about 25.4 cm (about 10.0 inches).

As illustrated in Figures 6 and 7, the method of forming a package from fibrous materials 610 eliminates the use of a wet binder, thereby eliminating traditional needs for wash water and wash water-related structures, such as hoods. formers, return pumps and pipes. 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 reduce implementation costs, operation costs and maintenance and repair costs.

As illustrated in more detail in Figures 6 and 7, the method of forming a bundle from fibrous materials 610 advantageously allows for uniform and consistent deposition of long, thin fibers in the forming apparatus 632a and 632b. In the present invention, the fibers 622 have a length in a range of about 0.64 cm (about 0.25 inches) to about 25.4 cm (about 10.0 inches) and a diameter dimension in a range of about 2.3 micrometers to 8.9 micrometers (about 9 HT to approximately 35 HT). In other embodiments, the fibers 22 have a length in a range of about 2.54 cm (about 1.0 inches) to about 12.7 cm (about 5.0 inches) and a diameter dimension in a range of about 3.5 micrometers (about 14<h>T ) at about 6.3 micrometers (approximately 25 HT). Without being limited by any theory, it is believed that the use of relatively long and thin fibers advantageously provides a package that has better thermal and acoustic insulation performance than a package of similar size that has shorter and thicker fibers.

Although the embodiment illustrated in Figures 6 and 7 has been generally described above for forming bundles of fibrous materials, it should be understood that the same apparatus may be configured to form "unbonded loose fill insulation." The term "unbonded loose fill insulation," as used herein, is defined to mean any conditioned insulating material configured for application in an air stream.

Although exemplary embodiments of packages and methods for venting a package from fibrous materials 610 have been generally described, it should be appreciated that other embodiments and variations of method 610 are available and will be described generally below.

Referring to Figure 7 in another embodiment of method 610, the cross-laying mechanisms 634a and 634b are configured to provide precise deposition of alternating layers of the continuous fabric on the first conveyor 36, thus allowing the elimination of the current trimming mechanism 40. below.

Referring again to Figure 7 in another embodiment of method 610, the various layers of the package may be "layered." The term "laminated", as used herein, is defined to mean that each of the layers and/or portions of a layer can be configured with different characteristics, including non-limiting examples of fiber diameter, fiber length, fiber orientation, density, thickness and composition of glass. It is contemplated that the associated mechanisms that form a layer, i.e., the associated fiberizer, forming apparatus, and cross-laying mechanism, may be configured to provide a layer and/or portions of the layer having specific and desired characteristics. Accordingly, a package may be formed from layers and/or portions of layers having different characteristics.

Figures 10A-10C illustrate exemplary embodiments of insulating products 1000 that include one or more thick light density cores 1002 and one or more thin high-density tensile layers 1004. The thick light density core 1002 can take on a wide variety of shapes. different. For example, the light density core 1002 can be manufactured from any of the lightweight packages described above. In an exemplary embodiment, the light density core 1002 is made of needled and/or laminated fiberglass fibers. In an exemplary embodiment, the light density core 1002 has no binder.

The high-density tensile thin layer 1004 can take a wide variety of different shapes. In an exemplary embodiment, the high-density tensile thin layer 1004 is made of fiberglass fibers that are needled together. However, 1000 high-density tensile fibers can be processed with other processes and/or products to achieve the appropriate tensile strength. In an exemplary embodiment, the high-density tensile layer 1004 is made of the high-density package 300 of the embodiment of Figure 3D.

In an exemplary embodiment, the high-density tensile layers 1004 are bonded to the light-density core 1002. The high-density tensile layers 1004 can be bonded to the light-density core 1002 in a wide variety of different ways. For example, layers 1002, 1004 may be bonded together with an adhesive, by an additional needling step, by thermal bonding (when one or both layers 1002, 1004 include a binder), and the like. Any way of joining the layers together can be used. In an exemplary embodiment, layers 1002, 1004 provide distinct properties to insulating product 1000.

In an exemplary embodiment, the thick light density layer 1002 provides a high thermal resistance R value, but has a low tensile strength and the thin high density tensile layer 1004 provides a low thermal resistance R value, but a high tensile strength. The combination of the two layers provides a 1000 insulating product with a high tensile strength and a high R-value.

Figures 10D-10F illustrate exemplary embodiments of insulating products 1000 that include one or more thick light density cores 1002 and one or more thin cladding layers 1004. The thick light density core 1002 can take on a wide variety of different shapes as shown. describes with respect to the embodiment illustrated in Figures 10A-10C. The liner layers 1004 can take a wide variety of different shapes. The material of the facing layer 1004 can be selected to provide a wide variety of different properties to the insulating product. For example, the facing material may be selected to provide a desired amount of strength, reflectivity, acoustic performance, water impermeability and/or vapor impermeability to the insulating product. The liner layer can be made of a wide variety of different materials including, but not limited to, plastic, metal foil, mesh, paper, combinations of these materials and the like. Any known coating layer can be used.

In an exemplary embodiment, the skin layers 1004 are bonded to the light density core 1002. The skin layers 1004 can be bonded to the light density core 1002 in a wide variety of different ways. For example, layers 1002, 1004 may be bonded together with an adhesive, heat bonding, and the like. Any way of joining the layers together can be used. In an exemplary embodiment, the layers 1002, 1004 provide different properties to the insulating product 1000. In an exemplary embodiment, the thick light density layer 1002 provides a high thermal resistance value R, but has a low tensile strength and the layer 1004 coating provides tensile strength and other properties.

The examples illustrated in Figures 10G-10I are described in terms of strata having different densities. However, strata may have different properties, which may or may not include different densities. These variable properties can be achieved by varying fiber density, fiber length, fiber diameter and/or fiber type throughout the bundle thickness. Figures 10G-10I illustrate exemplary embodiments of laminated batts or packages 1050 that include one or more light density layers 1052 and one or more high density layers 1054. However, the transition between a light density layer 1052 and a layer of high density 1054 can be gradual. In the examples illustrated by Figures 10A-10F, the insulating products 1000 are formed from separate layers. In the exemplary embodiment illustrated by Figures 10G-10I, the laminated batts or packages 1050 are formed with variable properties along the thickness of the batt or package. The light density layer 1052 can take a wide variety of different shapes. For example, the light density layer 1052 can be manufactured in the same manner as any of the low area weight packages described above. In an exemplary embodiment, the light density layer 1052 is made of fiberglass fibers. In an exemplary embodiment, the light density layer 1052 has no binder.

The high-density thin layer 1054 can take a wide variety of different shapes. In an exemplary embodiment, the high-density layer 1054 is made of fiberglass fibers that are needled together. However, the high-density layer 1054 fibers can be processed with other processes and/or products to achieve the appropriate tensile strength. In an exemplary embodiment, the high layer 1054 is manufactured in the same manner as the high density package 300 of the embodiment of Figure 3D is manufactured.

In an exemplary embodiment, the fibers of the high density layer 1054 are bonded and/or intertwined with the fibers of the light layer 1052. The fibers of the high density layer 1054 can be bonded to the fibers of the light density layer 1052 in a wide variety in different ways. For example, the fibers of the layers 1002, 1004 may be bonded together with adhesive, such as a binder that is applied to the package and/or by needling that is performed as the package 1050 is manufactured, and the like. Any way of joining and/or interlacing the fibers of the layers 1052, 1054 can be used. In an exemplary embodiment, the layers 1052, 1054 provide different properties to the insulating product 1000.

The batts, packages and insulating products of the embodiments of Figures 10A-10I can be combined with each other. For example, any of the layers of the insulating products illustrated in Figures 10A-10F may be laminated, the batts or laminated packages of Figures 10G-10I may be provided with one or more coating layers or separate dense layers, etc. Different isolation configurations can be constructed from the embodiments illustrated in Figures 10A-10I.

In an exemplary embodiment, a thick light density layer 1052 provides a high thermal resistance value R, but has a low tensile strength and a thin high density tensile layer 1004 provides a low thermal resistance value R, but a high tensile strength. The combination of the two layers provides a 1050 batt or package with a high tensile strength and a high R-value. The layers can be configured to provide a variety of different properties to the batt or package. For example, alternating thin, high-density and thick, low-density layers results in a batt or package with excellent acoustic properties.

In an exemplary embodiment, the dry binder may include or be coated with additives to impart desired characteristics to the package. A non-limiting example of an additive is a fire retardant material, such as, for example, sodium bicarbonate. Another non-limiting example of an additive is a material that inhibits the transmission of ultraviolet light through the package. Yet another non-limiting example of an additive is a material that inhibits the transmission of infrared light through the package.

Referring to Figure 6 in another embodiment of 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 ). The heat created by annular blowers and annular burners is known in the art as "fibrization heat." It is contemplated in this embodiment that the fiberization heat is captured and recycled for use in other mechanisms or devices. Fiberization heat can be captured at various locations in method 610. As shown in Figures 6 and 7, conduit 670 is configured to capture heat emanating from fiberizers 618 and transmit the heat for use in other mechanisms, such as, for example, optional curing oven 650. Similarly, ducts 672 are configured to capture heat emanating from the flow of hot gases within duct 30 and ducts 674 are configured to capture heat emanating from the training apparatus 632a and 632b. The recycled heat can also be used for purposes other than the formation of fibrous bundles, such as, for example, heating an office.

In certain embodiments, the duct 630 may include heat capture devices, such as, for example, heat extraction fittings configured to capture heat without significantly interfering with the flow momentum of the hot gases and entrained glass fibers 622. In other embodiments, any desired structure, device or mechanism sufficient to capture the heat of fiberization can be used.

Referring to Figure 6 in another embodiment of method 610, fibers or other materials having other desired characteristics may be mixed with glass fibers 622 entrained in the gas flow. In this embodiment, a source 676 of other materials, such as, for example, synthetic or ceramic fibers, coloring agents and/or particles, may be provided to allow such materials to be introduced into a conduit 678.

Conduit 678 may be connected to conduit 630 in a manner that allows mixing with glass fibers 622 entrained in the gas flow. In this way, the characteristics of the resulting package can be designed or tailored for the desired properties, such as non-limiting examples of acoustic, thermal enhancement or UV inhibition characteristics.

In still other embodiments, it is contemplated that other materials may be placed between the layers deposited by the cross-laying mechanisms 634a and 634b on the first conveyor 636. The other materials may include sheet materials, such as, for example, liners, barriers of steam or wire mesh, or other non-sheet materials, including non-limiting examples of powders, particles or adhesives. Other materials can be placed between the layers in any way desired. In this way, the features of the resulting package can be further designed or adapted as desired.

Although the embodiments shown in Figure 6 illustrate the application of a dry binder by the binder applicator 646, it should be appreciated that in other examples not covered by the present invention, the dry binder can be applied to the glass fibers 622 entrained in the flow of gases. In this example, a source 680 of dry binder may be introduced into a conduit 682. Conduit 682 may be connected to conduit 630 in a manner that allows mixing of the dry binder with glass fibers 622 entrained in the gas flow. The dry binder can be configured to bond to the glass fibers in any desired manner, including through electrostatic processes.

Although the embodiment illustrated in Figure 6 illustrates the use of the continuous fabric by the cross-racking mechanisms 634a and 634b, it should be appreciated that in other embodiments, the fabric may be removed from the forming apparatus 632a and 632b and stored for later use.

As discussed above, the cut materials may optionally be returned to the flow of gases and glass fibers in the conduits 630 and recycled in the forming apparatus 632a and 632b. In one example, when an optional binder is included in the package, the operating temperature of the forming apparatus 332a and 332b is maintained below the softening temperature of the dry binder, thereby preventing the dry binder from curing prior to current operation. below curing oven 550. In this example, the maximum operating temperature of curing oven 650 is in a range of about 73.89°C (about 165°F) to about 82.22°C (about 180°F). In other examples, the maximum operating temperature of the curing oven 650 may be less than about 73.89°C (about 165°F) or greater than about 82.22°C (about 180°F).

In an exemplary embodiment, the long, thin fibers 322 described herein are used in applications other than those described above. For example, Figure 11 illustrates that the long, thin glass fibers 322 described above can be provided as staple fibers that are air-laid, carded, or otherwise processed for use in a wide variety of different applications, rather than to be formed into a fabric and/or a package. In one application, the unbonded staple fibers are blended with aramid fibers, such as Kevlar and Konex, and/or thermally bonded fibers, such as Celbond. These blended fibers can be used to form basic yarns and/or dry-laid nonwovens.

In the embodiment of Figure 11, a hot extruder 314 supplies molten glass 312 to a forehearth 316. The molten glass 312 is processed to form glass fibers 322. The molten glass 312 can be processed in a variety of different ways to form the fibers 322. For example, rotating fiberizers 318 receive molten glass 312 and subsequently form webs 320 of glass fibers 322. Any desired fiberizer, rotating or otherwise, sufficient to form long, thin glass fibers 322 can be used.

Referring to Figure 11, an applicator 1100 applies a lubricant, also called sizing, to the unbonded glass fibers. In the illustrated embodiment, the size is applied to the glass fibers beneath the fiberizer. However, in other embodiments, the sizing is applied to the glass fibers in other locations, such as in conduit 330. The sizing strengthens and/or provides lubricity to the fibers which assist in processing the fibers, such as needling. or carding of the fibers. Unbonded chopped fibers 322 are provided at the outlet of conduit 330 as indicated by arrow 1102 where the fibers are collected in a container 1103 for use in a variety of different applications, either alone or in combination with other fibers, such as aramid fibers.

Sizing can take a wide variety of different forms. For example, the size may comprise silicone and/or silane. However, any finish can be used depending on the application. The sizing can be adjusted based on the application in which the glass fibers will be used.

The small fiber diameter and long fiber length allow the sized fibers to be used in applications where the fibers could not previously be used, due to excessive fiber breakage. In an exemplary embodiment, a fiber 322 having a diameter of approximately four microns has a better bending coefficient and resulting strength than conventional fibers, because the finer fiber bends more easily without breaking. This improved bending coefficient and fiber strength helps the fiber survive processes that are normally destructive to conventional fibers, such as carding and air-laying processes. Additionally, the fine diameter of the glass fibers improves both thermal and acoustic performance.

Glass fabrics, bundles and chopped fibers can be used in a wide variety of different applications. Examples of applications include, but are not limited to, heated appliances, such as furnaces, stoves and water heaters, heating, ventilation and air conditioning (HVAC) components, such as HVAC ducts, soundproofing panels and materials, such as acoustic insulation panels for buildings and/or vehicles, and molded fiberglass components, such as compression molded or vacuum molded fiberglass components. In an exemplary embodiment, heated appliances, such as furnaces, stoves and water heaters, heaters, HVAC components, such as HVAC ducts, sound insulation panels and materials, such as sound insulation panels for buildings and/or vehicles , and/or molded fiberglass components, such as compression molded or vacuum molded fiberglass components, use or are manufactured from a binderless fiberglass package manufactured in accordance with one or more of the embodiments disclosed in the present patent application. In an exemplary embodiment, since the fiberglass bundle has no binder, there is no formaldehyde present in the fiberglass bundle. In an exemplary embodiment, heated appliances, such as furnaces, stoves and water heaters, heaters, HVAC components, such as HVAC ducts, sound insulation panels and materials, such as sound insulation panels for buildings and/or vehicles , and/or molded fiberglass components, such as compression molded or vacuum molded fiberglass components, use or are manufactured from a dry binder fiberglass package made in accordance with one or more of the examples described herein. In this example, the dry binder may be a formaldehyde-free dry binder or without added formaldehyde. In a binder without added formaldehyde, the binder itself does not have formaldehyde, but formaldehyde can be a byproduct if the binder is burned.

The fiberglass insulation packages described herein can be used on a wide variety of different cooktops and in a variety of different configurations on any given cooktop. United States Patent Application Published Publication No. 2008/0246379 discloses an example of an insulation system used in a stove. The fiberglass bundles described herein can be used in any of the heating appliance insulation configurations described in Published United States Patent Application Publication No. 2008/0246379, including so-called prior art configurations. Figures 12-14 correspond to Figures 1-3 of United States Patent Application Publication Published No. 2008/0246379.

Referring to Figure 12, a thermal oven 1210 includes a substantially flat upper cooking surface 1212. As shown in FIGURES 12-14, the thermal oven 1210 includes a pair of opposing side panels 1252 and 1254, a back panel 1224, a bottom panel 1225, and a front panel 1232. The opposing side panels 1252 and 1254, the panel back 1224, bottom panel 1225, front panel 1232, and cooking surface 1212 are configured to form an exterior oven cabinet 1233. Front panel 1232 includes an insulated oven door 1218 pivotally connected to front panel 1232. Oven door 1218 is hinged at a lower end to the front panel 1232 so that the oven door can be pivoted away from the front panel 1232 and the oven cavity 1216. In the example illustrated in Figure 12, the oven door 1218 includes a window. In the example illustrated in Figure 12A, the oven door 1218 does not include a window and the entire interior of the door is provided with insulation.

As shown in Figures 13 and 14, the outer oven cabinet 1233 supports an inner oven liner 1215. The inner oven liner 1215 includes opposite sides of liner 1215a and 1215b, a top part of liner 1215c, a bottom part of 1215d liner and a 1215e liner back. Opposite liner sides 1215a and 1215b, liner top 1215c, liner bottom 1215d, liner back 1215e, and oven door 1218 are configured to define oven cavity 1216.

As further shown in Figures 13 and 14, the exterior of the oven liner 1215 is covered by insulation, an insulating material 1238, which may be manufactured in accordance with any of the embodiments disclosed in this application. The oven door 1238 may also be filled with insulating material 1238, which may be manufactured in accordance with any of the embodiments disclosed in this application. The insulating material 1238 is placed in contact with an outer surface of the oven liner 1215. The insulating material 1238 is used for many purposes, including retaining heat within the oven cavity 1216 and limiting the amount of heat that is transferred by conduction, convection and radiation to the outer cabinet of oven 1233.

As shown in the example illustrated in Figures 13 and 14, an air gap 1236 is formed between the insulating material 1238 and the outer oven cabinet 1233. The air gap 1236 is used as additional insulation to limit heat transfer conductive between the oven liner 1215 and the outer oven cabinet 1233. The use of air space 1236 complements the insulating material 1238 to minimize surface temperatures on the exterior surfaces of the outer oven cabinet 1233. As shown in the illustrated example 13A and 14A, the insulating material 1238 may be sized so that no air gap is formed between the insulating material 1238 and the outer oven cabinet 1233. That is, in the embodiment of Figures 13A and 14A 13, 13A, 14, 14A and any of the other configurations disclosed in United States Patent Application Publication No.

2008/0246379 are manufactured from a binderless fiberglass bundle manufactured in accordance with one or more of the embodiments described in the present patent application. In an exemplary embodiment, since the fiberglass bundle has no binder, there is no formaldehyde present in the insulation layer 1238 of the embodiments of Figures 13, 13A, 14 and 14A.

The fiberglass insulation packages described in this patent application can be used in a wide variety of different heating, ventilation and air conditioning (HVAC) systems, such as ductwork in an HVAC system. Additionally, the insulation packages disclosed in this patent application can be provided in a variety of different configurations in any given HVAC duct. United States Patent No. 3,092,529, Patent Cooperation Treaty (PCT) International Publication Published Number WO 2010/002958 and Pending United States Patent Application Serial No. 13/764,920, filed on 12 February 2013, all assigned to the assignee of this application, discloses examples of fiberglass insulation systems used in HVAC ducts. The fiberglass bundles described herein can be used in any of the HVAC duct configurations described in United States Patent No.

3,092,529, PCT International Publication Number WO 2010/002958 and Pending United States Patent Application Serial No. 13/764,920.

In an example not covered by the invention, the insulating material used in HVAC ducts disclosed by United States Patent No. 3,092,529, PCT International Publication Number WO 2010/002958 and United States Patent Application Pending Serial No. 13/764,920 is constructed from a dry binder fiberglass bundle manufactured in accordance with one or more of the methods described herein. In this example, the dry binder may be a dry binder without formaldehyde or a dry binder without added formaldehyde. In a binder without added formaldehyde, the binder itself does not have formaldehyde, but formaldehyde can be a byproduct if the binder is burned.

In an exemplary embodiment, the insulating material used in HVAC ducts disclosed by United States Patent No. 3,092,529, PCT International Publication Number WO 2010/002958 and Pending United States Patent Application Serial No. 13/764,920 is constructed from a binderless fiberglass bundle made in accordance with one or more of the embodiments described herein. In an exemplary embodiment, since the fiberglass bundle has no binder, no formaldehyde is present in the insulating material.

The fiberglass insulation packages described in this patent application can be used in a wide variety of different acoustic applications and can have a variety of different configurations in each application. Examples of soundproofing batts include Owens Corning Sound Attenuation Batt insulation and Owens Corning Sonobatts, which can be placed behind a variety of building panels, such as roofing and wall shingles. United States Patent Nos. 7,329,456 and 7,294,218 describe examples of acoustic insulation applications. The fiberglass bundles described herein may be used in place of Owens Corning Sound Attenuation Batt and Owens Corning Sonobatts insulation and may be used in any of the applications disclosed in United States Patent Nos. 7,329,456 and 7,294,218. Additional acoustic applications for fiberglass insulation packages described in this patent application include, but are not limited to, duct lining, duct wrap, ceiling panels, wall panels, and the like.

In an exemplary embodiment, a sound insulation package manufactured in accordance with one or more of the embodiments of a binderless package or examples of a dry binder package disclosed herein tested in accordance with ASTM C522 within 1500 ft (457.2 m). ) from sea level has an average airflow resistivity of 3,000 - 150,000 (mks Rayls/m (Pas/m2))). In an exemplary embodiment, a sound insulation package manufactured in accordance with one or more of the embodiments of a binderless package or examples of a dry binder package described herein tested in accordance with ASTM C423 within 1500 ft (457.2 m). ) sea level has a Sound Absorption Average (SAA) in the range of 0.25 to 1.25. In an exemplary embodiment, a sound insulation package manufactured in accordance with one or more of the embodiments of a binderless package or examples of a dry binder package described herein tested in accordance with ISO 354 within 457.2 m (1500 feet) from sea level has a Sound Absorption Coefficient aw in the range of 0.25 to 1.25.

Table 2

In one example, the insulating material used in place of the insulation of Owens Coming Sound Attenuation Batt and Owens Coming Sonobatts and/or in any of the applications described in US Patent Nos. 7,329,456 and 7,294,218 is constructed from a dry binder fiberglass package manufactured in accordance with one or more of the examples described herein. In this example, the dry binder may be a dry binder without formaldehyde or a dry binder without added formaldehyde. In a binder without added formaldehyde, the binder itself does not have formaldehyde, but formaldehyde can be a byproduct if the binder is burned.

In an exemplary embodiment, the insulating material used in place of the insulation of Owens Coming Sound Attenuation Batt and Owens Coming Sonobatts and/or in any of the applications described in United States Patent Nos. 7,329,456 and 7,294,218 is constructed from a binderless fiberglass bundle manufactured in accordance with one or more of the embodiments disclosed in the present patent application. In an exemplary embodiment, since the fiberglass bundle has no binder, no formaldehyde is present in the insulating material.

The fiberglass insulating packages described in this patent application can be used in a wide variety of molded fiberglass products. For example, referring to Figures 15A-15C in an exemplary embodiment, the binderless and/or dry binder fiberglass bundles described herein can be used to manufacture a compression molded fiberglass product. Referring to Figure 15A, a binderless or dry binder fiberglass bundle 1522 manufactured in accordance with any of the exemplary embodiments or examples described in this application is placed between the first and second mold halves 1502. In one embodiment For example, only the fiberglass bundle without binder or with dry binder 1522 is placed between the mold halves. That is, no additional materials, such as plastic sheets or plastic resin, are molded with the fiberglass package.

Referring to Figure 15B, the mold halves compress the fiberglass bundle 1522 as indicated by arrows 1504. Heat is optionally applied to the mold halves and/or the fiberglass bundle as indicated by the arrows 1504. arrows 1506. For example, when the package 1522 is a fiberglass package without binder, the mold halves and/or the fiberglass package may be heated to a high temperature, such as a temperature above 371.11 ° C (700 degrees F), such as between 371.11 °C (700 degrees F) and 593.33 °C (1100 degrees F), and in an exemplary embodiment, about 482.22 °C (about 900 degrees F). When the package 1522 is a fiberglass package with dry binder, the mold halves and/or the fiberglass package may be heated to a lower temperature, such as the melting temperature of the dry binder in the package.

Referring to Figure 15C, the mold halves are then separated as indicated by the arrows 1508 and the compression molded fiberglass part 1510 is removed. In an exemplary embodiment, the compression molded fiberglass part 1510 consists or consists of essentially only the material of package 1522.

In the example illustrated by Figures 15A-15C, the compression molded fiberglass part is contoured. However, in other exemplary embodiments the compression molded fiberglass part may be substantially flat. In an exemplary embodiment, the binderless or dry binder compression molded fiberglass piece 1610 has a density that is substantially greater than the density of the originally provided fiberglass bundle 1522, such as four or more times the density of the originally provided fiberglass package 1522.

Referring to Figures 16A-16C, in an exemplary embodiment, the binderless and/or dry binder fiberglass bundles described in this application can be used to manufacture a vacuum molded fiberglass product. Referring to Figure 16A, a binderless or dry binder fiberglass bundle 1522 manufactured in accordance with any of the exemplary embodiments described in this application is placed in a vacuum mold component 1602. In an exemplary embodiment, only The binderless or dry binder fiberglass bundle 1522 is placed in the mold component 1602. That is, no additional materials, such as plastic sheets or plastic resin, are molded with the fiberglass bundle.

Referring to Figure 16B, the mold component applies a vacuum to the fiberglass bundle 1522 as indicated by arrows 1604. Optionally, heat is applied to the mold component 1602 and/or the fiberglass bundle as shown. indicated by arrows 1606. For example, when the bundle 1522 is a binderless fiberglass bundle, the vacuum mold component 1602 and/or the fiberglass bundle 1522 may be heated to a high temperature, such as a temperature above 371.11 °C (700 degrees F), such as between 371.11 °C (700 degrees F) and 593.33 °C (1100 degrees F), and in an exemplary embodiment, about 482.22 °C (about 900 degrees F) . When the package 1522 is a fiberglass package with dry binder, the mold halves and/or the fiberglass package may be heated to a lower temperature, such as the melting temperature of the dry binder in the package.

Referring to Figure 15C, the vacuum mold component 1602 stops applying vacuum and the vacuum molded fiberglass part 1610 is removed. In an exemplary embodiment, the compression molded fiberglass part 1610 consists of or It consists of essentially just the 1522 package material.

In the example illustrated by Figures 16A-16C, the vacuum molded fiberglass part is contoured. However, in other exemplary embodiments, the vacuum molded fiberglass part may be substantially flat. In an exemplary embodiment, the vacuum molded fiberglass piece 1610 without binder or with dry binder has a density that is substantially greater than the density of the fiberglass bundle 1522 originally provided, such as four or more times the density of the 1522 fiberglass package originally provided.

In an exemplary embodiment, the insulating material that is molded according to the embodiment illustrated in Figures 15A-15C or the embodiment illustrated in Figures 16A-16C is manufactured from a binderless fiberglass bundle made in accordance with one or more of the embodiments described by the present patent application. In an exemplary embodiment, since the fiberglass bundle has no binder, there is no formaldehyde present in the compression molded part 1510 or in the vacuum molded part of the embodiments illustrated in Figures 15A-15C and 16A-16C.

In one example, the insulating material that is molded according to the example illustrated in Figures 15A-15C or the example illustrated in Figures 16A-16C is manufactured from a dry binder glass fiber bundle made in accordance with one or more of the examples disclosed herein. In this example, the dry binder may be a dry binder without formaldehyde or a binder without added formaldehyde. In a binder without added formaldehyde, the binder itself does not have formaldehyde, but formaldehyde can be a byproduct if the binder is burned.

Disclosed in this application are several exemplary embodiments of mineral fiber fabrics, bundles and staple fibers and methods for producing mineral fiber fabrics, bundles and staple fibers. The mineral fiber fabrics and bundles and methods for producing the mineral fiber fabrics and bundles in accordance with the present invention may include any combination or subcombination of the features disclosed by the present application.

Claims (14)

1. A continuous method of forming a laminated bundle of glass fibers comprising: melt glass; processing molten glass to form glass fibers; collecting the glass fibers in an accumulator to allow the glass fibers to cool; forming a binderless fabric from the glass fibers; perching the binder-free glass fiber fabric to form a laminated glass fiber bundle; mechanically interweaving the fibers of the laminated glass fiber bundle, wherein the glass fibers have a diameter range of 2.3 micrometers (9 HT) to 8.9 micrometers (35 HT); and wherein the glass fibers have a length range of about 0.64 cm (0.25 inches) to about 25.4 cm (10.0 inches). 2. The continuous method of claim 1, wherein the fibers are intertwined by needling. 3. The continuous method of claim 1, wherein the binderless glass fiber fabric has a surface weight of 0.49 kg/m2 (0.10 pounds per square foot) to 1.86 kg/m2 (0.38 pounds per square foot). 4. The continuous method of claim 1, wherein the laminated bundle of glass fibers comprises 99% to 100% glass or 99% to 100% glass and inert components that do not bond the glass fibers together. 5. The continuous method of claim 1, wherein a first portion of the binder-free fabric is disposed on a top surface of the laminated package, and a second portion of the binder-free fabric is disposed on a bottom surface of the laminate package. 6. The continuous method of claim 1, wherein the glass fibers have a diameter range of 3.8 micrometers (15 HT) to 4.8 micrometers (19 HT). 7. Use of a laminated mechanically intertwined glass fiber bundle to insulate a heated apparatus, wherein the laminated mechanically intertwined glass fiber bundle comprises: a first fabric of glass fibers without binder; at least one additional binderless glass fiber web superimposed on the first binderless glass fiber web; wherein the first binderless fabric has an area weight of 0.24 kg/m2 (0.05 pounds per square foot) to 0.98 kg/m2 (0.2 pounds per square foot); wherein the glass fibers have a diameter range of about 2.3 micrometers (9 HT) to about 8.9 micrometers (35 HT); and wherein the glass fibers have a length range of about 0.64 cm (0.25 inches) to about 25.4 cm (10.0 inches). 8. The use of claim 7, wherein the first binderless glass fiber fabric is woven to form at least one additional binderless fabric. 9. The use of claim 7, wherein the first binderless glass fiber fabric is transversely strung to form at least one additional binderless fabric. 10. The use of claim 7, wherein the glass fibers have a diameter range of a range of 3.8 micrometers (15 HT) to 4.8 micrometers (19 HT). 11. The use of claim 7, wherein the glass fiber bundle comprises 99% to 100% glass or 99% to 100% glass and inert components that do not bind the glass fibers together. 12. The use of claim 7, wherein the glass fibers used to form the binderless fabric have never been compressed for packaging or shipping. 13. The use of claim 7, wherein the glass fibers are mechanically intertwined by needling. 14. The use of any of claims 7 to 13, wherein the heated appliance is an oven, a stove or a water heater.