WO2001023655A1 - Fabrication de produit d'isolation fibreux a base de fibre de liaison polymere multicomposant - Google Patents

Fabrication de produit d'isolation fibreux a base de fibre de liaison polymere multicomposant Download PDF

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Publication number
WO2001023655A1
WO2001023655A1 PCT/US2000/026477 US0026477W WO0123655A1 WO 2001023655 A1 WO2001023655 A1 WO 2001023655A1 US 0026477 W US0026477 W US 0026477W WO 0123655 A1 WO0123655 A1 WO 0123655A1
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WO
WIPO (PCT)
Prior art keywords
fibers
component
insulation product
binder
polymer
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Application number
PCT/US2000/026477
Other languages
English (en)
Inventor
Qingyu Zeng
Kurt G. Melia
Original Assignee
Owens Corning
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Owens Corning filed Critical Owens Corning
Priority to AU77197/00A priority Critical patent/AU7719700A/en
Publication of WO2001023655A1 publication Critical patent/WO2001023655A1/fr

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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B1/78—Heat insulating elements
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/60—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in dry state, e.g. thermo-activatable agents in solid or molten state, and heat being applied subsequently
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
    • D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
    • D04H1/732—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged by fluid current, e.g. air-lay
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H5/00—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
    • D04H5/02—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by mechanical methods, e.g. needling
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B1/7654—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only comprising an insulating layer, disposed between two longitudinal supporting elements, e.g. to insulate ceilings
    • E04B1/7658—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only comprising an insulating layer, disposed between two longitudinal supporting elements, e.g. to insulate ceilings comprising fiber insulation, e.g. as panels or loose filled fibres
    • E04B1/7662—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only comprising an insulating layer, disposed between two longitudinal supporting elements, e.g. to insulate ceilings comprising fiber insulation, e.g. as panels or loose filled fibres comprising fiber blankets or batts
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B2001/7687—Crumble resistant fibrous blankets or panels using adhesives or meltable fibres

Definitions

  • This invention relates to fibrous insulation products and methods of manufacturing fibrous insulation products. More particularly, this invention pertains to making a fibrous insulation product having a binder material for connecting the primary insulation fibers to one another to impart structural integrity to the insulation product, and to enable the insulation product to have good insulating qualities.
  • Fibrous insulation is commonly formed by fiberizing molten material and depositing the fibers on a collecting conveyor.
  • Some fibrous insulation products are made by transporting fibrous material through various secondary processes, such as wet processes, air laid processes, reorienting, carding, blending of different types of fibers, or other processes for forming a blanket of fibrous material.
  • the fibers for insulation products are mineral fibers, such as glass fibers, although some insulation products are made of organic fibers, such as polyester.
  • Most fibrous insulation products contain a binder material to bond the fibers together where the fibers contact each other.
  • a typical binder material for glass fiber insulation is a thermosetting urea phenol- formaldehyde binder that is applied to the glass fibers before they are collected on the collecting conveyor.
  • the binder is cured by passing the hindered insulation product through an oven.
  • the binder gives the insulation product resiliency for recovery after packaging.
  • the binder provides stiffness and handleability so that the product can be handled and applied as needed in the insulation cavities of buildings, and in various other insulation applications, such as in appliances and heating, ventilating and air conditioning (HVAC) equipment, and in industrial applications.
  • HVAC heating, ventilating and air conditioning
  • the binder also enables the insulation material to be molded into various shapes as needed.
  • An important product attribute of such insulation products is good acoustical and thermal performance. Attempts have been made to improve upon the urea phenol-formaldehyde binder used in conventional fiberglass insulation products.
  • Insulation products having conventional binder must be cured in an oven typically at a temperature of about 450°F (232°C). Such a binder is water based, and curing the binder can only occur after driving off all the water. This requires a large amount of energy. Before the curing stage, the binder flows along the fibers to the fiber-to-fiber intersections. After the binder in a conventional product is cured, a significant percentage of the urea phenol-formaldehyde binder is in the form of lumps or pieces (beads) of solid material at the fiber-to-fiber intersections rather than in a fine surface coating or a fine connection from fiber to fiber.
  • non-fibrous lumps or pieces have a very low surface-area-to-mass ratio, and therefore this material fails to contribute significantly to blocking heat transfer through the insulation product by radiation.
  • the non- fibrous lumps do not provide any significant acoustical advantage. It would be advantageous if there could be developed an insulation product that provided a smaller portion of the binder material in non- fibrous form, thereby maximizing the surface area of the material for both acoustical and thermal benefits.
  • the process can be used to form a tow, which is a linear collection of intermingled fibers similar to twine or rope.
  • Marzocchi's process involves directing the binder fibers, which are of lesser diameter than the primary fibers, into contact with the primary glass fibers.
  • the Marzocchi product is not intended for use as an insulation product.
  • U.S. Patent Nos. 5,490,961 and 5,736,475 to Bakhshi et al. disclose coaxial spinners for simultaneously forming glass fibers and polymer fibers.
  • the Bakhshi patents also teach that some of the fibrous polymer material is heated in the fiber forming region to the extent that some of the polymer material softens but remains attached to the glass fibers as non- fibrous material, while some of the polymer material remains as fibers. Attempts to make commercially viable insulation products using the Bakhshi process have not been successful because, in part, of the extreme variability of the process due to the complex flow and temperature patterns of the fiber forming region.
  • U.S. Patent No. 4,237,180, to Jaskowski discloses a wet process for making a thermal and acoustical insulation product that includes a blend of glass wool and mono- component polymer fibers. A liquid binder is applied. In a subsequent manufacturing step the blend of glass wool and polymers is subjected to heat to shrink the polymer fibers in order to interlock the polymer fibers with the glass wool fibers. The interlocking can also be accomplished by needling.
  • U.S. Patent No. 5,316,601 to Hebbard at al. discloses a fiber blending system for making a mat or paper towel of blended cellulose fibers (that is, wood) and polymer fibers. The polymer fibers can be bicomponent fibers.
  • thermobonding process causes at least one of the organic components to fuse the mat and form a core product.
  • a fiber opening machine of opening and fluffing the polymer fibers All of the fiber opening machines are positioned serially so that the output from any of the fiber opening machines is delivered into each of the downstream opening machines.
  • This product is primarily aimed at hygiene applications because of the good moisture absorption of the cellulose fibers. There is no suggestion that this process can be used for insulation products having good thermal values.
  • U.S. Patent No. 5,298,694 to Thompson et al discloses an acoustical insulation product adapted to be applied to the panel of an inner door.
  • the acoustical product comprises fine staple polymers mixed with bicomponent thermally activated binder fibers.
  • the fibrous mixture is air laid to form the acoustical insulation product.
  • the above objects as well as other objects not specifically enumerated are achieved by a method of making a fibrous insulation product comprising intermingling primary mineral fibers and multi-component polymer fibers.
  • the multi-component polymer fibers have a principal polymer component and a binder polymer component.
  • the binder component has a softening point lower than the softening point of the principal component so that the insulation product can be heated to a temperature that is insufficient to soften the principal component but sufficient to soften the binder component to bond the multi-component polymer fibers and the primary fibers to themselves and to each other.
  • a method of making a fibrous insulation product comprising subjecting multi-component polymer fibers to an opening process to open and separate the fibers for further processing.
  • the multi-component polymer fibers have a principal polymer component and a binder polymer component.
  • the binder component has a softening point lower than the softening point of the principal component.
  • the primary glass fibers are subjected to an opening process having a lesser amount of opening power than the opening process used for the multi-component polymer fibers.
  • the primary glass fibers and multi-component polymer fibers are intermingled, thereby forming an insulation product of primary glass fibers and multi-component polymer fibers.
  • a method of making a fibrous insulation product comprising providing two fiber opening devices for opening and separating fibers for further processing.
  • the two fiber opening devices are arranged in a parallel arrangement.
  • the bi-component polymer fibers are subjected to at least one of the two fiber opening devices to open and separate the bicomponent fibers.
  • the bicomponent polymer fibers having a principal polymer component and a binder polymer component, with the binder component having a softening point lower than the softening point of the principal component.
  • the primary glass fibers are subjected to an additional opening device having a lesser amount of opening power than either of the first two opening devices.
  • the primary glass fibers and bi-component polymer fibers are intermingled, thereby forming an insulation product of primary glass fibers and bi- component polymer fibers.
  • Figure 1 is a schematic view in perspective of an insulation product according to the present invention.
  • Figure 2 is a schematic view more detailed view of a portion of the fibers of the insulation product of Fig. 1.
  • Figure 3 is a schematic view in elevation of the fiber opening portion of apparatus for making another insulation product according to the present invention.
  • Figure 4 is a cross-sectional view in elevation of the apparatus of Fig. 3, taken along line 4-4.
  • Figure 5 is a cross-sectional view in elevation of the apparatus of Fig. 3, taken along line 5-5.
  • Figure 6 is a cross-sectional view in elevation of the apparatus of Fig. 3, taken along line 6-6.
  • Figure 7 is a schematic view in elevation of sheet forming and fabrication apparatus, complementary to that shown in Fig. 3, for completing the insulation product of the invention.
  • Figure 8 is a schematic view of a different apparatus for interjecting bicomponent polymer fibers into a moving stream of glass fibers to form an untreated insulation product according to the present invention.
  • the insulation product of the invention is comprised of fibers 12.
  • the insulation product 10 may or may not be in the form of a molded product.
  • a facing, not shown, or encapsulation material 14, can optionally be placed on the product.
  • the facing material can be any suitable material, such as a film, a foil or an open web such as a scrim.
  • the fibers 12 comprise primary fibers 16 and multicomponent fibers, in the form of bicomponent polymer fibers 20. It is to be understood that although bicomponent fibers are illustrated, other multicomponent fibers, such as tricomponent fibers, can be used with the invention.
  • the bicomponent polymer fibers 20 are shown in cross-section, while the primary fibers 16 are not.
  • the bicomponent polymer fibers 20 are comprised of a principal polymer component 22 and a binder polymer component 24.
  • the bicomponent polymer fibers 20 are shown as having been formed as sheath-core fibers, with the principal polymer component 22 forming a core material and the binder polymer component 24 forming a sheath around the core. It is to be understood that the bicomponent polymer fibers 20 can be formed in other arrangements, such as in a side by side arrangement, not shown. It can be seen that the binder polymer component 24 binds the bicomponent polymer fibers 20 and the primary fibers 16 to themselves and to each other.
  • the primary fibers 16 can be any type of fibers suitable for providing good structural qualities as well as good acoustical and thermal properties.
  • Preferred fibers for use as the primary fibers 16 are wool glass fibers. It is to be understood that the primary fibers can specifically be any mineral fibers such as fibers made of rock, slag and basalt, as well as glass fibers. Wool glass fibers are well known in the art, and are usually made by the rotary process, typically having a diameter within the range of from about 3 to about 30 microns. If wool glass fibers are used, they can be generally straight conventional fibers, or they can be irregular fibers such as Miraflex® fibers from Owens Corning.
  • PET polyethylene terephthalate
  • the primary fibers are preferably present in an amount that is within the range of from about 30 to about 95 percent by weight of the whole insulation product, exclusive of facings, and the bicomponent fibers are preferably present in an amount within the range of from about 20 to about 60 percent by weight.
  • the primary fibers are glass fibers that are present in an amount that is within the range of from about 40 to about 80 percent by weight of the whole insulation product, exclusive of facings, and the bicomponent fibers are present in an amount within the range of from about 20 to about 60 percent by weight.
  • the introduction of the bicomponent polymer fibers 20 into the primary fibers serves two purposes. First the binder polymer component 24 supplies the binder necessary to bond the insulation product 10 together. Second, the bicomponent fibers are integrated as additional insulating fibers within the insulation product 10 to provide additional insulative value beyond that of the primary fibers 16. This additional acoustical and thermal insulative value is mainly derived from the additional fiber surface area of the bicomponent fibers which serves to block heat transfer by radiation through the insulation product, and also acts as a sound barrier and/or absorber. The addition of the bicomponent fibers adds not only the bonding capability, but also increases the strength of the product.
  • the binder polymer component 24 of the bicomponent polymer fibers 20 has a softening point lower than the softening point of the principal polymer component 22 so that upon heating the insulation product, the two materials will respond differently. More specifically, the insulation product 10 can be heated to a temperature that is above the softening point of the binder polymer component 24, but is below the softening temperature of the principal polymer component 22. This will cause the binder component to soften and become sticky, thereby bonding the various bicomponent polymer fibers 20 to themselves where they are in contact. Also, the softening of the binder polymer component 24 will bond the primary fibers 16 to themselves, and will bond the bicomponent polymer fibers 20 to the primary fibers 16.
  • a particular advantage in using a binder polymer component 24 that is merely raised to its softening point is that the polymer binder material will not exhibit a significant flow during the heating process.
  • the benefit of a non- flowing binder system is that there will be an absence of the undesirable binder particles or beads that are typically formed at the fiber-to-fiber intersections of prior art insulation products, particularly those prior art products using urea phenol-formaldehyde binder systems of the prior art.
  • the result is a lower product K value or an increased resistance to flow of heat through the insulation product.
  • Another result is higher surface area and air resistively for good acoustic performance.
  • bicomponent polymer fibers 20 can be made so that it has a softening point within the range of from about 150°F (65°C) to about 400°F (204°C), and more preferably within the range of from about 170°F (77°C) to about 300°F (149°C).
  • the binder polymer component 24 is a thermoplastic material, which for purposes of this invention is defined as an organic heat-softenable plastic material, so that it can be subjected to multiple molding processes if desired.
  • the principal polymer component 22 has a higher softening point, preferably above about 300°F, and most preferably above about 350°F.
  • the bale openers 30 and 32 mechanically and/or pneumatically decouple the clustered fibrous masses of the input stock so that fiber contact becomes fiber-to-fiber rather than bundle-to-bundle. This increases the surface area of the total fiber collection, thereby increasing the thermal and acoustical properties of the ultimate insulation product.
  • the pneumatic conveyor 34 can be powered by any suitable means, such as by a fan 36. It is to be understood that a mechanical conveyor or any other type of conveyor could also be used. The use of a closed conveyour system reduces the proliferation of dust into the plant environemnt.
  • the two bale openers 30 and 32 can be different or can be substantially identical. For purposes of illustration, bale opener 32 is shown in more detail in Fig. 4.
  • the bale opener 32 includes a generally vertical lattice board conveyor 38, beater rolls 40 for opening or separating the fibers, and lickering drums 42 for further breaking up concentrations of the fibers.
  • Lickering drums include a rotating spiral wrap in a sawtooth arrangement, and such apparatus is well known in the art.
  • the bale opener 32 separates and untangles the fibers from each other, thereby producing an output of fibrous material that can be more easily mixed and homogenized with other fibers to ultimately make a uniformly blended insulation product. Any fiber opening device can be used for the bale opener as long as it is capable of opening and separating the fibers for further processing.
  • bale openers are available from numerous sources, including Arcatex Inc., Spartanburg, SC, American Truetzchler Inc., Charlotte, NC, Fleissner GmbH & Company, Egelsbach, Germany, Hollingsworth, Greenville, SC, Rando Machine Corporation, Ard, NY, Rieter Corporation, Spartanburg, SC, N. Schlumberger (USA) inc., Fort Mill, SC, Schott & Meissner Maschinen, Blaufelden, Germany, Sigma Corporation, Simpsonville, SC, and Spezialmaschinen DOA GmbH & Co. KG, Wels, Austria.
  • One of the advantages of using bale openers in making the insulation product 10 is that scrap wool glass fibers can be recycled and added to the fibrous mix.
  • bale openers 30 and 32 are positioned in parallel, rather than in series, so that each can be configured to develop its own stream of opened fibers, and to supply those fibers to the pneumatic conveyor 34 in the desired blend ratio.
  • bale opener 30 can be set up to handle the primary fibers, and bale opener 32 can be arranged to handle the PET/PET bicomponent polymer fibers.
  • the output from the bale openers 30 and 32 is conveyed via the pneumatic conveyor 34 to the consolidation apparatus 48, also shown in Fig. 6.
  • the consolidation apparatus includes a volumetric feeder 50 having condenser rolls 52 and a vertical accumulator 54 that collects the fibers from condenser rolls 52 and feeds the fibers to another set of lickering drums 56.
  • the purpose of the consolidation apparatus 48 is to collect fibers from the bale openers 30 and 32, blend them together, and open the blended fiber mixture further for good fiber-to-fiber intermingling.
  • the additional opening power provided by the two parallel bale openers may necessitate additional blending power, such as the blending capability of the consolidation apparatus 48.
  • Typical sheet formers cannot successfully handle fibers below about 3.0 denier at economically viable throughputs, but the use of the consolidator 48 enables fibers having a denier as low as about 1.5 to be processed.
  • the output from the consolidation apparatus 48 is conveyed by pneumatic conveyor 58 downstream for further processing. Any suitable fiber consolidation apparatus can be used, such as, for example, machinery available from the manufacturers listed above.
  • a supplemental fiber opening device is positioned to add additional fibers to the pneumatic conveyor 58.
  • the opening device 64 differs from the bale openers 30 and 32 in that there are a reduced number of lickering drums 66, in contrast to the number of lickering drums 42 in the bale opener 32.
  • the opening device 64 is specifically adapted to work with fibers that do not require as much opening, or with brittle fibers, and therefore the opening device has a lesser amount of opening power than the bale openers 30 and 32.
  • the opening device 64 opens and untangles the fibers with a minimum of stress on the fibers.
  • the opening device 64 includes a generally vertical conveyor 68 to draw the glass fibers from an accumulation 70 of glass fibers, and a collection of beater rolls 72 for further opening the fibers.
  • the opening device 64 is ideally suited for use with glass fibers. Since the output of the opening device 64 is directed into the pneumatic conveyor 58, the glass fibers from the opening device 64 are not required to pass through either of the bale openers 30 and 32, or through the consolidation apparatus 48. Therefore, the opening device 64 is not arranged serially with the other bale openers 30, 32 and 48, but rather is in a parallel relationship. In bypassing the three openers, 30, 32 and 48, the glass fibers can be maintained at a reasonable length, and will not be broken into undesirably short fibers. Any supplemental fiber opening device suitable for use with glass fibers can be used, such as, for example, the manufacturers listed above, as well as from other manufacturers.
  • bale openers 30 and 32 Another advantage gained by providing the supplemental opening device 64 in addition to bale openers 30 and 32 is that there are three entry points for fibers to be introduced into the ultimate fiber stream. This allows improved flexibility, boosts production, and enables the insulation products of the invention to be manufactured with great efficiency. With three fiber input devices, three different type of fibers, each having different characteristics, can be treated differently and separately introduced to make up the desired fiber mix needed for the insulation product.
  • Each of the opening machines, 30, 32 and 64 can be configured and adapted to provide the type of opening suitable for the input fiber being processed through the machine. Since fibers introduced into the fibrous collection through bale openers 30 and 32 are subsequently passed through the consolidation device 48, there is more opening power for fibers introduced through bale openers 30 and 32.
  • the primary fiber is a fine polymer fiber
  • the main condenser unit 78 includes a volumetric feeder 80 and an accumulator 82.
  • the fibers from supplemental fiber opening device 64 blend with the fibers from bale openers 30 and 32 in the main condenser unit 78.
  • the purpose of the sheet former is to provide opening, blending and sheet forming functions.
  • Suitable sheet formers are well known in the art, and are available from several different manufacturers, such as the manufacturers listed above.
  • the use of binder fibers rather than a water-based liquid binder enables the first sheet former 86 to be operated in a dry condition. This allows the messiness and environmental problems associated with wet process systems to be avoided.
  • a second sheet former 90 similar to the first sheet former 86, is positioned to reform the fibers into a modified blanket 92.
  • the second sheet former 90 can be bypassed via a bypass conveyor 94 where the characteristics of the desired end product are achieved by using just the first sheet former 86.
  • the necessity of using both sheet formers 86 and 90 will depend in part on the type of input fibers and on the end product requirements.
  • the modified blanket 92 can be processed in any of several ways, such as, for example, by passing the modified blanket through a needier 96 which mechanically interlocks the fibers, thereby setting the density and thickness of the modified blanket 92.
  • the needier 96 can be bypassed using bypass conveyor 98 if desired.
  • Other mechanical bonding or handling processes could be applied to the modified blanket.
  • the binder component of the fibers can be eliminated because the product integrity will be imparted by the mechanical bonding of the needling process.
  • the modified blanket can then, if desired, be processed through an oven 100 to give the modified blanket greater product integrity.
  • the modified blanket can be subjected to hot gases to raise the temperature of the binder component 24 of the bicomponent polymer fibers 20 so that the binder component will soften to bond the bicomponent polymer fibers 20 and the primary fibers 16 to themselves and to each other to form the insulation product 10.
  • the oven 100 can be also configured so that it can mold the modified blanket 92 into desired end products, such as duct board, ceiling board and pipe insulation, none of which are shown. If the ultimate product from the sheet forming process is to be a fibrous molding media, such as molding media 102 shown in Fig.
  • the purpose of the oven is to soften the binder polymer component 24 only slightly, just enough to give the molding media 102 sufficient integrity for further handling.
  • the molding media 102 can be rolled up into a roll 104 by any suitable means, such as rollup apparatus 106.
  • the rolls 104 can be shipped in bags or other packaging material, not shown, to customers, who can use the molding media 102 to mold such products as automobile headliners, appliance insulation, interior panels, and duct products.
  • typical densities for the insulation products will be within the range of from about 0.5 to about 6 pounds per cubic foot (pcf) (about 8.0 kilograms per cubic meter (kg/m 3 ) to about 96.06 kg/m 3 ).
  • the insulation product of the invention can also be made using a rotary process in which glass fibers 110 are formed using a rotating spinner 112.
  • the glass fibers are maintained in an attenuable condition by an annular burner 114, and are further attenuated by a blower, not shown.
  • Bicomponent polymer fibers 116 similar to the bicomponent polymer fibers shown in Fig. 2, can be formed using a polymer fiber die 118.
  • the die 118 can be supplied with two different molten polymer materials, a principal polymer component and a binder polymer component, by conduits 120 and 122.
  • the bicomponent polymer fibers 116 are mixed in with the glass fibers 110, and collected to form an insulation product of the invention, not shown.
  • bicomponent PET/PET (2.0 denier) fibers having a diameter of about 14.3 microns were introduced to, and processed through a fiber opening process.
  • the bicomponent fibers were in a core/sheath arrangement.
  • the core had a melting temperature of about 490°F (254°C) and the sheath became soft and sticky at a temperature of about 235°F (113°C).
  • the glass wool primary fibers constituted about 70 percent by weight of the total blanket, and the PET/PET bicomponent fibers constituted about 30 percent.
  • the resulting blanket was subsequently subjected to a heat bonding process in an oven to soften the binder polymer component and bond the primary glass wool fibers and the bicomponent fibers to themselves and to each other. After bonding, both the primary glass wool fibers and the bicomponent PET/PET polymer fibers retained their fibrous shape.
  • the blanket had a density of about 1.0 pcf (16.01 kg/m 3 ) at a thickness of about 1.0 inches (2.54 centimeters).
  • the resulting product exhibited a smoother feel than conventional glass wool products, thereby generating less irritation when handled.
  • the process was a completely dry process, and consequently environmental problems were minimal or nonexistent. Since there was no liquid based binder and no curing process, there was no requirement for drying, and no odor or smoke was generated.
  • the product had a uniform color.
  • An insulation product was made in the same manner as that of the insulation product in Example 1 above with about 70 percent by weight glass wool fibers and about 30 percent by weight bicomponent PET/PET polymer fibers.
  • a one inch thick sample of the insulation product of Example 2 was tested for thermal properties using a K-tester, according to ASTM C-518. K value is measured in Btu-in/hr-ft 2 -°F.
  • the K-value of the product of Example 1 was about 0.264, whereas the expected K-value of an equivalent one inch thick 100 percent glass wool product (7 micron, 1.0 pcf density, 5 percent by weight urea phenol-formaldehyde binder) would be about 0.271. Therefore, the lower K- value of the product of Example 2 provides a better thermal insulation value what would be expected from an all glass wool product.
  • Example 1 Several insulation products were made according to the method disclosed in Example 1. The K- values for these products were tested and compared with equivalent 100 percent glass wool products having the same glass fiber diameter (7 microns) and the same density. In the glass fiber/polymer fiber products the polymer fibers were bicomponent core/sheath fibers. The results are shown in Table 1.
  • An experimental insulation product was made according to the method of the invention, as disclosed in Example 1.
  • the insulation product comprised 70 percent by weight irregular glass wool fibers (7 micron) and 30 percent by weight PET/PET core/sheath bicomponent fibers, having a diameter of about 14.32 microns.
  • the acoustical (sound absorption) properties of the experimental insulation product were measured according to ASTM E-1050 and compared with a control insulation product comprising 100 percent by weight irregular glass wool fibers (7 micron) having 5 percent by weight urea-phenol/formaldehyde binder.
  • Both the experimental insulation product and the control were maintained at a thickness of about 1.0 inches (2.54 centimeters) and at a density of about 1.0 pcf (16.01 kg/m 3 ).
  • the results of the acoustical testing are shown in TABLE 2 below.
  • the experimental insulation product of the present invention exhibited enhanced sound absorption properties over all the frequencies tested when compared with an equivalent all glass fiber acoustical insulation product of the same glass fiber diameter and density.
  • the noise reduction coefficient of the product of the invention had a noise reduction coefficient of 0.300 when compared with a noise reduction coefficient of 0.272 for the control product.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Architecture (AREA)
  • Acoustics & Sound (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

La présente invention concerne un procédé de fabrication de produit (10) d'isolation fibreux, qui consiste à entremêler des fibres de verre (16) primaires et des fibres polymères multicomposant (20). Ces fibres polymères multicomposant possèdent un composant polymère principal (22) et un composant polymère de liaison (24). Ce composant de liaison possède un point de ramollissement moins élevé que celui du composant principal de façon que ce produit d'isolation puisse être chauffé à une température insuffisante pour ramollir le principal composant mais suffisante pour ramollir le composant de liaison afin de lier les unes avec les autres les fibres polymères multicomposant et les fibres primaires et lier entre eux ces deux éléments.
PCT/US2000/026477 1999-09-27 2000-09-27 Fabrication de produit d'isolation fibreux a base de fibre de liaison polymere multicomposant WO2001023655A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU77197/00A AU7719700A (en) 1999-09-27 2000-09-27 Making a fibrous insulation product using a multicomponent polymer binder fiber

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US15625699P 1999-09-27 1999-09-27
US15618299P 1999-09-27 1999-09-27
US60/156,182 1999-09-27
US60/156,256 1999-09-27
US42993899A 1999-10-29 1999-10-29
US09/429,938 1999-10-29

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Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1300511A2 (fr) * 2001-09-20 2003-04-09 Armstrong World Industries, Inc. Panneau acoustique thermoformable
FR2844816A1 (fr) * 2002-09-25 2004-03-26 Nap Tural Materiau d'isolation pour le batiment
US7704603B2 (en) * 2002-07-25 2010-04-27 Saint Gobain Isover Aqueous solution of phenolic compound-formaldehyde-aminoalcohol resin, preparation method, mineral fiber sizing compositions containing said resin and resulting products
CN103290933A (zh) * 2013-07-01 2013-09-11 中材金晶玻纤有限公司 一种保温板专用玻璃纤维薄毡及其制备方法
EP1718896B2 (fr) † 2004-02-19 2013-10-23 Saint-Gobain Isover Doublure de conduit sans formaldehyde
WO2014184237A1 (fr) * 2013-05-14 2014-11-20 TRüTZSCHLER GMBH & CO. KG Installation et procédé de fabrication d'un matériau textile en bande
EP2889406A1 (fr) * 2013-12-24 2015-07-01 Armstrong World Industries, Inc. Panneaux acoustiques à faible densité
US10066342B2 (en) 2014-12-18 2018-09-04 Lydall, Inc. Wet-laid nonwoven including thermoplastic fiber
US11813833B2 (en) 2019-12-09 2023-11-14 Owens Corning Intellectual Capital, Llc Fiberglass insulation product

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3453355A (en) * 1965-10-15 1969-07-01 Bernard Rudloff Process for pneumatically tearing and parting fiber flocks
US4840832A (en) * 1987-06-23 1989-06-20 Collins & Aikman Corporation Molded automobile headliner
US4946738A (en) * 1987-05-22 1990-08-07 Guardian Industries Corp. Non-woven fibrous product
WO1995029882A1 (fr) * 1994-05-02 1995-11-09 Owens Corning Panier centrifugeur de production de fibres a deux composants
US5879802A (en) * 1996-09-12 1999-03-09 Prince Corporation Vehicle panel material

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3453355A (en) * 1965-10-15 1969-07-01 Bernard Rudloff Process for pneumatically tearing and parting fiber flocks
US4946738A (en) * 1987-05-22 1990-08-07 Guardian Industries Corp. Non-woven fibrous product
US4840832A (en) * 1987-06-23 1989-06-20 Collins & Aikman Corporation Molded automobile headliner
WO1995029882A1 (fr) * 1994-05-02 1995-11-09 Owens Corning Panier centrifugeur de production de fibres a deux composants
US5879802A (en) * 1996-09-12 1999-03-09 Prince Corporation Vehicle panel material

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1300511A2 (fr) * 2001-09-20 2003-04-09 Armstrong World Industries, Inc. Panneau acoustique thermoformable
EP1300511A3 (fr) * 2001-09-20 2005-02-09 Armstrong World Industries, Inc. Panneau acoustique thermoformable
US7704603B2 (en) * 2002-07-25 2010-04-27 Saint Gobain Isover Aqueous solution of phenolic compound-formaldehyde-aminoalcohol resin, preparation method, mineral fiber sizing compositions containing said resin and resulting products
FR2844816A1 (fr) * 2002-09-25 2004-03-26 Nap Tural Materiau d'isolation pour le batiment
EP1718896B2 (fr) † 2004-02-19 2013-10-23 Saint-Gobain Isover Doublure de conduit sans formaldehyde
WO2014184237A1 (fr) * 2013-05-14 2014-11-20 TRüTZSCHLER GMBH & CO. KG Installation et procédé de fabrication d'un matériau textile en bande
CN103290933A (zh) * 2013-07-01 2013-09-11 中材金晶玻纤有限公司 一种保温板专用玻璃纤维薄毡及其制备方法
CN103290933B (zh) * 2013-07-01 2016-01-06 中材金晶玻纤有限公司 一种保温板专用玻璃纤维薄毡及其制备方法
EP2889406A1 (fr) * 2013-12-24 2015-07-01 Armstrong World Industries, Inc. Panneaux acoustiques à faible densité
US9279250B2 (en) 2013-12-24 2016-03-08 Awi Licensing Company Low density acoustical panels
US10066342B2 (en) 2014-12-18 2018-09-04 Lydall, Inc. Wet-laid nonwoven including thermoplastic fiber
US11813833B2 (en) 2019-12-09 2023-11-14 Owens Corning Intellectual Capital, Llc Fiberglass insulation product

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