Method of forming a web from fibrous material

Patent metadata

Field	Value
Publication number	US-10703668-B2
Application number	US-201314101680-A
Country	US
Kind code	B2
Filing date	Dec 10, 2013
Priority date	Sep 30, 2011
Publication date	Jul 7, 2020
Grant date	Jul 7, 2020

Abstract

Fibrous material webs and methods of making the fibrous material webs. Binderless webs can be formed in a continuous process where fiber material, such as glass is melted and formed into fibers. The fibers are formed into a web of binderless glass fibers or a web with a dry binder. The binderless web or the web with dry binder can be layered and/or the fibers that make up the web can be mechanically entangled, for example, by needling.

First claim

The invention claimed is:

1. An insulation system for a thermal appliance, the insulation system comprising:
a cabinet having a plurality of interior surfaces;
a liner positioned within the cabinet, the liner including an outer surface; and
a fibrous insulation material disposed between the outer surface of the liner and one or more of the interior surfaces of the cabinet; wherein the fibrous insulation material comprises a layered binderless web of glass fibers comprising:
a first web of glass fibers; and
at least one additional web of glass fibers formed by cross-lapping the first web of glass fibers;

wherein the glass fibers of the first web are mechanically entangled with the glass fibers of the at least one additional web;
wherein the entangled web has a thickness of 0.1 inches to 2.0 inches and a density of 0.9 lbs/ft 3 and to 4.2 lbs/ft 3 , wherein the entangled web has a k-value of 0.333 to 0.203 at 75° F., and wherein the entangled web has a k-value of 0.387 at 500° F. when the density is 0.9 lbs/ft 3 ,
and wherein the glass fibers of the first web and the at least one additional web have an average diameter in a range of 15 HT to 19 HT and an average length of 0.25 inches to 10 inches.

2. The insulation system of claim 1 , wherein the glass fibers used to form the layered binderless web have never been compressed for packaging or shipping.

3. The insulation system of claim 1 , wherein the glass fibers of the first web and the at least one additional web are mechanically entangled by needling.

4. The insulation system of claim 1 , wherein the thermal appliance is an oven.

5. An insulation system for a thermal appliance, the insulation system comprising:
a cabinet having a plurality of interior surfaces:
a liner positioned within the outer cabinet, the liner including an outer surface; and
a fibrous insulation material disposed between the outer surface of the liner and one or more of the interior surfaces of the cabinet;
wherein the fibrous insulation material is formed from at least one layered binderless web of glass fibers, the layered binderless web comprising:
a first web of glass fibers;
at least one additional web of glass fibers formed by cross-lapping the first web of glass fibers;
wherein the glass fibers of the first web are mechanically entangled with the glass fibers of the at least one additional web; and
wherein the entangled web has a thickness of 0.1 inches to 2.0 inches, and a density of 0.9 lbs/ft 3 and to 4.2 lbs/ft 3 , wherein the entangled web has a k-value of 0.387 at 500° F. when the density is 0.9 lbs/ft 3 ,
and wherein the glass fibers of the first web and the at least one additional web have an average diameter in a range of 15 HT to 19 HT.

6. The insulation system of claim 5 , wherein the at least one layered binderless web of glass fibers comprises 99 percent to 100 percent glass.

7. The insulation system of claim 6 , wherein the glass fibers used to form the layered binderless web have never been compressed for packaging or shipping.

8. The insulation system of claim 6 , wherein the glass fibers of the first web and the at least one additional web are mechanically entangled by needling.

9. The insulation system of claim 1 , wherein the layered binderless web of glass fibers comprises 99 percent to 100 percent by weight glass.

Assignees

• Owens Corning Intellectual Capital Llc

Inventors

• Haley Glenn
• Gaul David J
• Pellegrin Michael T

Classifications

• C03C25/1095 Primary

  to obtain coated fabrics · CPC title

• D04H1/60

  the bonding agent being applied in dry state, e.g. thermo-activatable agents in solid or molten state, and heat being applied subsequently · CPC title

• D04H1/4374

  using different kinds of webs, e.g. by layering webs · CPC title

• D04H1/46

  by needling or like operations to cause entanglement of fibres (D04H1/45 takes precedence; needling machines D04H18/00) · CPC title

• D04H3/08

  characterised by the method of strengthening or consolidating · CPC title