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US 12,767,581 B2Granted
Method of forming a web from fibrous materials
AssigneeOwens Corning Intellectual Capital, LLC
InventorsGlenn Haley, David J. Gaul, Michael T. Pellegrin
Life of this patent
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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.
Claims10
A layered web of glass fibers comprising:
- a first web of glass fibers having a density of 0.2 lb/ft3 to 0.6 lb/ft3 and a thickness of 0.1 to 0.5 inches and comprising a dry binder penetrating the first web of glass fibers and holding the fibers of the first web together;
- at least one additional web of glass fibers having a density of 0.2 lb/ft3 to 0.6 lb/ft3 and a thickness of 0.1 to 0.5 inches and comprising the dry binder, the dry binder penetrating the at least one additional web of glass fibers and holding the fibers of the at least one additional web together, and disposed on the first web of glass fibers;
- wherein the dry binder holds said first web and said at least one additional web together to form a pack, said dry binder comprising substantially 100% solids,
- wherein the dry binder is selected from the group consisting of polymeric thermoset resins, ethylene-vinyl acetate copolymer, low density polyethylene, high density polyethylene, polybutene-1, polyamide, and combinations thereof;
- wherein all the glass fibers of the layered web have a diameter range of 16 HT to 17 HT;
- wherein all the glass fibers of the layered web have a length of about 3 inches;
- wherein the layered web of glass fibers has a tensile strength to weight ratio of 40 lbf/lbm to 140 lbf/lbm;
- wherein the layered web has a thickness of about 0.5 inches to about 1.75 inches.
5 more elements
A layered web of glass fibers formed from individual web layers, the layered web consisting of:
- a first web of glass fibers having a density of 0.2 lb/ft3 to 0.6 lb/ft3 and a thickness of 0.1 to 0.5 inches and comprising a dry binder penetrating the first web of glass fibers and holding the fibers of the first web together;
- at least one additional web of glass fibers having a density of 0.2 lb/ft3 to 0.6 lb/ft3 and a thickness of 0.1 to 0.5 inches and comprising the dry binder, the dry binder penetrating the at least one additional web of glass fibers and holding the fibers of the at least one additional web together, the at least one additional web disposed on the first web of fibers;
- wherein the layered web made up of the first web of glass fibers and the at least one additional web of glass fibers comprises from four to eight web layers in total;
- the dry binder holding said first web and said at least one additional web together to form a pack, said dry binder comprising substantially 100% solids,
- wherein the dry binder is selected from the group consisting of ethylene-vinyl acetate copolymer, low density polyethylene, high density polyethylene, polybutene-1, polyamide, and combinations thereof;
- wherein the dry binder is the only binder in the layered web of glass fibers;
- wherein all the glass fibers of the layered web have a diameter range of 16 HT to 17 HT;
- wherein all the glass fibers of the layered web have a length of 1 inch to 5 inches.
5 more elements
A layered web of glass fibers formed from individual web layers, the layered web comprising:
- a first web of fibers having a density of 0.2 lb/ft3 to 0.6 lb/ft3 and a thickness of 0.1 to 0.5 inches and comprising a dry binder penetrating the first web of fibers and holding the fibers of the first web together;
- at least one additional web of fibers having a density of 0.2 lb/ft3 to 0.6 lb/ft3 and a thickness of 0.1 to 0.5 inches and comprising the dry binder, the dry binder penetrating the at least one additional web of fibers and holding the fibers of the at least one additional web together, the at least one additional web disposed on the first web of fibers;
- wherein the layered web made up of the first web of fibers and the at least one additional web of fibers consists of at least four layers;
- wherein the fibers of the first web and the fibers of the at least one additional web consist of glass fibers;
- the dry binder holding said first web and said at least one additional web together to form a pack, said dry binder comprising substantially 100% solids,
- wherein the dry binder is selected from the group consisting of ethylene-vinyl acetate copolymer, low density polyethylene, high density polyethylene, polybutene-1, and combinations thereof;
- wherein all the glass fibers of the layered web have a diameter range of 16 HT to 17 HT;
- wherein the layered web has a thickness of about 0.5 inches to about 1.75 inches.
5 more elements
Dependencies are inferred from the claim text.