Continuous nonwoven polyester fiber and fiberglass thread hybrid mat
AssigneeTAMKO Building Products, Inc.
InventorsJames Gregory Powell, Chris Freeborg, Jonathan Marta, Kyle Davis
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Abstract
Disclosed are methods and devices for forming a combined polyester and fiberglass mat, in which separate polyester and fiberglass layers can be formed or polyester filaments and fiberglass threads can be mixed together by a disperser to form a polyester and fiberglass web. The polyester filaments and the fiberglass threads can be dispersed by separate dispersers on a web forming belt to form separate layers of polyester filaments and fiberglass threads, or can be dispersed by a single disperser to at least, somewhat evenly disperse, the fiberglass threads and polyester filaments.
Claims43
A method of forming a fire resistant synthetic fiber and mineral fiber mat comprising:
- heating a plastic to a liquid state to create liquid plastic;
- extruding said liquid plastic through a first extruder to create a plurality of first continuous synthetic fiber filaments;
- drawing said first continuous synthetic fiber filaments through a first vacuum venturi tube;
- drawing a plurality of continuous mineral fiber threads through a second vacuum venturi tube;
- randomly dispersing said plurality of continuous mineral fiber threads and said continuous synthetic fiber filaments so that said plurality of continuous mineral fiber threads and said continuous synthetic fiber filaments are mixed and dispersed across a web forming belt to thereby create said fire resistant synthetic fiber and mineral fiber mat.
A method of forming a combined, fire resistant, synthetic fiber and mineral fiber mat comprising:
- heating a synthetic polymer to a liquid state to create a liquid synthetic polymer;
- extruding said liquid synthetic polymer through a first extruder to create a plurality of first polymer fiber filaments;
- drawing said polymer filaments through a vacuum venturi tube;
- supplying said polymer filaments and a plurality of mineral fiber threads to a disperser that disperses and mixes said polymer filaments and said plurality of mineral fiber threads in a random order to create said combined, fire resistant, synthetic fiber and mineral fiber mat.
A method of forming a combined synthetic fiber and mineral fiber mat that is fire resistant comprising:
- generating continuous synthetic fiber filaments;
- generating a plurality of continuous mineral fiber threads;
- dispersing said continuous synthetic fiber filaments and said plurality of continuous mineral fiber threads which creates a mixture of said continuous synthetic fiber filaments and said plurality of continuous mineral fiber threads on a web forming belt;
- entangling said mixture of continuous synthetic fiber filaments and said plurality of continuous mineral fiber threads to create an entangled mixed web of said continuous synthetic fiber filaments and said plurality of continuous mineral fiber threads;
- bonding said entangled mixed web of said continuous synthetic fiber filaments and said plurality of continuous mineral fiber threads to form said combined synthetic fiber and mineral fiber mat.
A method of forming a fire resistant mat using entangled, continuous synthetic polymer filaments and continuous mineral fiber threads comprising:
- supplying said continuous synthetic polymer filaments and said continuous mineral fiber threads to a disperser that randomly disperses said continuous synthetic polymer filaments and said continuous mineral fiber threads so that said continuous synthetic polymer filaments and said continuous mineral fiber threads are mixed to form a web of continuous synthetic polymer filaments and continuous mineral fiber threads;
- entangling said web of continuous synthetic polymer filaments and said continuous mineral fiber threads to form an entangled synthetic polymer filament and mineral fiber thread layer;
- bonding said entangled synthetic polymer filaments and mineral fiber threads to create said fire resistant mat.
Dependencies are inferred from the claim text.