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WO2025128116A1 - Fibres de verre formées par rotation - Google Patents

Fibres de verre formées par rotation Download PDF

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Publication number
WO2025128116A1
WO2025128116A1 PCT/US2023/084218 US2023084218W WO2025128116A1 WO 2025128116 A1 WO2025128116 A1 WO 2025128116A1 US 2023084218 W US2023084218 W US 2023084218W WO 2025128116 A1 WO2025128116 A1 WO 2025128116A1
Authority
WO
WIPO (PCT)
Prior art keywords
fibers
woven mat
less
fiber diameter
sizing composition
Prior art date
Legal status (The legal status 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 status listed.)
Pending
Application number
PCT/US2023/084218
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English (en)
Inventor
Matthew Daniel Gawryla
Hitesh Khandelwal
Sander Christiaan Hagens
Leeanne Regina TAYLOR
Christian LUGTENBURG
Srinath Subramanian
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Owens Corning Intellectual Capital LLC
Original Assignee
Owens Corning Intellectual Capital LLC
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 Intellectual Capital LLC filed Critical Owens Corning Intellectual Capital LLC
Priority to PCT/US2023/084218 priority Critical patent/WO2025128116A1/fr
Priority to PCT/US2024/060014 priority patent/WO2025128983A1/fr
Priority to PCT/US2024/060008 priority patent/WO2025128979A1/fr
Publication of WO2025128116A1 publication Critical patent/WO2025128116A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B37/00—Manufacture or treatment of flakes, fibres, or filaments from softened glass, minerals, or slags
    • C03B37/01—Manufacture of glass fibres or filaments
    • C03B37/04—Manufacture of glass fibres or filaments by using centrifugal force, e.g. spinning through radial orifices; Construction of the spinner cups therefor
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B37/00—Manufacture or treatment of flakes, fibres, or filaments from softened glass, minerals, or slags
    • C03B37/01—Manufacture of glass fibres or filaments
    • C03B37/04—Manufacture of glass fibres or filaments by using centrifugal force, e.g. spinning through radial orifices; Construction of the spinner cups therefor
    • C03B37/045—Construction of the spinner cups
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B37/00—Manufacture or treatment of flakes, fibres, or filaments from softened glass, minerals, or slags
    • C03B37/01—Manufacture of glass fibres or filaments
    • C03B37/04—Manufacture of glass fibres or filaments by using centrifugal force, e.g. spinning through radial orifices; Construction of the spinner cups therefor
    • C03B37/048—Means for attenuating the spun fibres, e.g. blowers for spinner cups

Definitions

  • the general inventive concepts relate to an apparatus and a method of fiberizing mineral fibers, such as glass fibers, from molten mineral material using a rotary process, as well as to the fibers themselves and articles incorporating the fibers.
  • the flow generated by the blower attenuates the molten glass streams into a finer diameter, and the streams are cooled to form glass fibers.
  • An annular burner is also positioned around the spinner, and combustion gases and heat from the burner are directed downward to provide a fiber attenuating environment suitable for allowing the initial streams of glass to be attenuated to the desired final diameter.
  • the downward annular flow of hot gases facilitates attenuation of the streams of molten mineral material into mineral fibers by the blower, and also maintains the spinner at a temperature suitable for fiberizing.
  • a fiber manufacturing apparatus or fiberizer 10 includes a centrifuge or spinner 12 fixed to a rotatable hollow shaft or spindle 14.
  • the spinner 12 is fixed to a hub 54 of a quill 64 at the lower end of the rotatable shaft or spindle 14.
  • Rotating the spinner 12 by rotating spindle 14 is known in the art.
  • the spinner 12 includes a base 16 extending from hub 54 to the peripheral wall 18. Disposed around the outer periphery of the peripheral wall 18 is a plurality of orifices 20 for centrifuging fibers 22 of a molten material, for example, glass.
  • the spinner 12 is supplied with a stream 78 of a molten glass.
  • Conventional supply equipment 82 can be used to supply stream 78 of molten glass.
  • Such molten glass supply equipment is well known in the industry and, therefore, will not be discussed in detail herein.
  • the glass in stream 78 drops into the chamber 42 of spinner 12 and through centripetal force is directed against the peripheral wall 18 and flows outwardly to form a build-up or head 90 of glass.
  • the glass then flows through the orifices 20 to form primary fibers 22, which are heated and stretched by burners 24 and annular blower 28.
  • the rotation of the spinner 12 centrifuges molten glass through orifices 20 in spinner peripheral wall 18 to form primary fibers 22.
  • the primary fibers 22 are maintained in a soft, attainable condition by the heat of an annular burner 24.
  • the annular blower 28 uses induced air through passage 30 to pull primary fibers 22 and further attenuate them into secondary fibers 32 suitable for use in a product, such as wool insulating materials.
  • the secondary fibers 32 are then collected on a conveyor (not shown) for formation into a product, such as a glass wool pack.
  • Peak Index refers to the peak identifier from left to right, with the peaks being shown with dashed lines; “Peak Type” refers to the type of model used to fit the data; “Area Intg” refers to the integrated area of the fit peak; “Area IntgP” refers to the percentage of total integrated area for each fit peak; “Center Grvty” refers to the center of the fit peak; “Max Height” refers to the maximum value of the fit peak; and “FWHM” refers to the width of the peak at half of its maximum height. [0012] In the graph 210 of FIG. 2 A, the rotary fibers were produced with a target diameter of about 3.1 pm, as measured using the known air flow method.
  • the graph 210 represents the fiber diameter distribution when measured using an ISO 13322-2 compliant method and plotted by fiber volume %.
  • the (Camsizer) data measured according to the ISO 13322-2 compliant approach was analyzed using the Peak Deconvolution App (v2.00) with OriginPro 2023 (constant baseline; fit until converged to obtain displayed results), which is data analysis software sold by OriginLab Corp, of Northampton, Massachusetts.
  • FIG. 2B a graph 220 of the fiber diameter distribution for another commercially available unbonded loosefill (ULF) fiberglass material is shown.
  • ULF fibers are rotary- formed fibers that are not typically held together by a binder. ULF fibers are commonly used for building insulation applications.
  • the rotary fibers were measured as having an effective fiber diameter between 2.8 pm and 3 pm, as measured using the known air flow method.
  • the graph 220 represents the fiber diameter distribution when measured using an ISO 13322-2 compliant method and plotted by fiber volume %.
  • the (Camsizer) data measured according to the ISO 13322-2 compliant approach was analyzed using the Peak Deconvolution App (v2.00) with OriginPro 2023 (constant baseline; fit until converged to obtain displayed results), which is data analysis software sold by OriginLab Corp, of Northampton, Massachusetts.
  • FIG. 2C a graph 230 of the fiber diameter distribution for another commercially available unbonded loosefill (ULF) fiberglass material is shown.
  • ULF fibers are rotary- formed fibers that are not typically held together by a binder. ULF fibers are commonly used for building insulation applications.
  • Peak Index refers to the peak identifier from left to right, with the peaks being shown with dashed lines; “Peak Type” refers to the type of model used to fit the data; “Area Intg” refers to the integrated area of the fit peak; “Area IntgP” refers to the percentage of total integrated area for each fit peak; “Center Grvty” refers to the center of the fit peak; “Max Height” refers to the maximum value of the fit peak; and “FWHM” refers to the width of the peak at half of its maximum height.
  • the rotary fibers were measured as having an effective fiber diameter between 2.8 pm and 3 pm, as measured using the known air flow method.
  • the graph 230 represents the fiber diameter distribution when measured using an ISO 13322-2 compliant method and plotted by fiber volume %.
  • the (Camsizer) data measured according to the ISO 13322-2 compliant approach was analyzed using the Peak Deconvolution App (v2.00) with OriginPro 2023 (constant baseline; fit until converged to obtain displayed results), which is data analysis software sold by OriginLab Corp, of Northampton, Massachusetts.
  • FIG. 2D a graph 240 of the fiber diameter distribution for a commercially available specialty material, in the form of chopped glass microfibers, is shown. These specialty glass fibers are rotary-formed fibers that are chopped to shorten their length. The specialty glass fibers are not held together by a binder. These specialty glass fibers can be used as a reinforcing agent or filler material.
  • Peak Index refers to the peak identifier from left to right, with the peaks being shown with dashed lines; “Peak Type” refers to the type of model used to fit the data; “Area Intg” refers to the integrated area of the fit peak; “Area IntgP” refers to the percentage of total integrated area for each fit peak; “Center Grvty” refers to the center of the fit peak; “Max Height” refers to the maximum value of the fit peak; and “FWHM” refers to the width of the peak at half of its maximum height.
  • the rotary fibers were marketed as having an effective fiber diameter of about 3.2 pm.
  • the graph 240 represents the fiber diameter distribution when measured using an ISO 13322-2 compliant method and plotted by fiber volume %.
  • the (Camsizer) data measured according to the ISO 13322-2 compliant approach was analyzed using the Peak Deconvolution App (v2.00) with OriginPro 2023 (constant baseline; fit until converged to obtain displayed results), which is data analysis software sold by OriginLab Corp, of Northampton, Massachusetts.
  • modifications to a rotary fiber forming process allows for the production of fibers having a more uniform fiber diameter and/or length distribution.
  • the general inventive concepts encompass this new method of producing rotary fibers, the new rotary fibers themselves, a sizing formulation suitable for use on the new rotary fibers, a package of the rotary fibers (e.g., having the improved fiber distribution), a non-woven mat made from the new rotary fibers, and downstream applications for the mat (e.g., a facer for a ceiling tile).
  • the hot gases from the annular burner are directed toward the spinner and the streams of molten mineral material at a rate of about 240 cubic feet per minute to about 300 cubic feet per minute.
  • the fibers have an average formed length greater than 2 inches. In some exemplary embodiments, the fibers have an average formed length in the range of about 3 inches to about 12 inches. [0046] In some exemplary embodiments, an average aspect ratio of the fibers is in the range of 850 to 5,000. In some exemplary embodiments, an average aspect ratio of the fibers is in the range of 850 to 2,000.
  • x is less than a median fiber diameter of the fibers.
  • the fibers have a curvature greater than 0.043.
  • the fibers have a curvature of at least 0.055.
  • the fibers have a curvature in the range of 0.050 to 0.060.
  • the fibers are glass fibers.
  • the mineral fibers comprise at least 10,000 distinct fibers; wherein the mineral fibers have a fiber diameter distribution with a first Gaussian peak and a second Gaussian peak; and wherein the first Gaussian peak and the second Gaussian peak represent > 85% of a volume of the mineral fibers.
  • > 40% of the volume of the mineral fibers is represented by the first Gaussian peak, which corresponds to the smallest diameter of the mineral fibers.
  • the fibers include a sizing composition applied to a surface of the fibers; and the sizing composition is an aqueous composition comprising water, a silane coupling agent, at least one organic acid, and a cationic surfactant.
  • the fibers include a sizing composition applied to a surface of the fibers; and the sizing composition is an aqueous composition consisting essentially of or consisting of water, a silane coupling agent, at least one organic acid, and a cationic surfactant.
  • the sizing composition is free of a film former. [0058] In some exemplary embodiments, the sizing composition has less than 5% active solids content.
  • the sizing composition is substantially color-free with an AL* value of -5 to +5.
  • the at least one organic acid is selected from the group consisting of acetic acid, succinic acid, citric acid, and combinations thereof.
  • an amount of the sizing composition applied to the fibers is from about 0.05 wt.% to about 2 wt.% based on the total weight of the sized fibers.
  • a sizing composition for application to rotary- formed glass fibers comprises, consists essentially of, or consists of water, a silane coupling agent, at least one organic acid, and a cationic surfactant.
  • the at least one organic acid is selected from the group consisting of acetic acid, succinic acid, citric acid, and combinations thereof.
  • the sizing composition has a pH in the range of about 3.0 to about 7.5. In some exemplary embodiments, the sizing composition has a pH in the range of about 4.5 to about 5.5.
  • the sizing composition has less than 5% active solids content.
  • the cationic surfactant comprises from about 25 wt.% to about 90 wt.% of the dry solids of the sizing composition.
  • the silane coupling agent comprises from about 15 wt.% to about 45 wt.% solids of the sizing composition; wherein the organic acid comprises from about 1 wt.% to about 20 wt.% solids of the sizing composition; and wherein the cationic surfactant comprises from about 35 wt.% to about 75 wt.% solids of the sizing composition.
  • the water comprises about 80 wt.% to about 99.9 wt.% of the sizing composition.
  • a non-woven mat is disclosed.
  • the non-woven mat comprises: a plurality of first fibers; a plurality of second fibers; and a binder holding the first fibers and second fibers together in an interspersed arrangement; wherein the first fibers have an average fiber diameter greater than about 7 pm; wherein the second fibers have a mean fiber diameter x that is less than about 6 pm; and wherein a fiber diameter distribution of the second fibers has a standard deviation from x of less than 3.5 pm.
  • the standard deviation from x is less than 3.0 pm. In some exemplary embodiments, the standard deviation from x is less than 2.5 pm.
  • the second fibers have an average diameter of less than 5 pm. In some exemplary embodiments, the second fibers have an average diameter of less than 4 pm. In some exemplary embodiments, the second fibers have an average diameter of less than 3 pm.
  • the second fibers have an average formed length greater than 2 inches.
  • the second fibers have an average formed length in the range of about 3 inches to about 12 inches.
  • x is less than a median fiber diameter of the second fibers.
  • 90% of the second fibers have a diameter ⁇ 1.525x.
  • the second fibers have a curvature greater than 0.043.
  • the second fibers have a curvature of at least 0.055.
  • the second fibers have a curvature in the range of 0.050 to 0.060.
  • the first fibers are glass fibers.
  • the second fibers are glass fibers.
  • the second fibers are rotary -formed fibers.
  • the non-woven mat comprises at least 1 wt.% of the second fibers based on the weight of the non-woven mat. In some exemplary embodiments, the non-woven mat comprises at least 10 wt.% of the second fibers based on the weight of the non-woven mat. In some exemplary embodiments, the non-woven mat comprises at least 20 wt.% of the second fibers based on the weight of the non-woven mat.
  • an amount of the sizing composition applied to the second fibers is from about 0.05 wt.% to about 2 wt.% based on the total weight of the sized second fibers.
  • the binder includes polyvinyl alcohol.
  • the non-woven mat further comprises an inorganic filler.
  • the average fiber diameter of the first fibers is in the range of about 10 pm to about 11 pm; and the average fiber diameter of the second fibers is in the range of about 3 pm to about 4 pm.
  • the second fibers are free of any fibers having a diameter greater than 22 pm. In some exemplary embodiments, the second fibers are free of any fibers having a diameter greater than 20 pm. In some exemplary embodiments, the second fibers are free of any fibers having a diameter greater than 16 pm. In some exemplary embodiments, the second fibers are free of any fibers having a diameter greater than 15 pm. In some exemplary embodiments, the second fibers are free of any fibers having a diameter greater than 14 pm. [0089] In some exemplary embodiments, the non-woven mat has a first surface and a second surface opposite the first surface, and each surface comprises less than about 100 flocs per 1,000 m 2 of the non-woven mat.
  • each surface of the non-woven mat has less than about 50 flocs per 1,000 m 2 of the non-woven mat. In some exemplary embodiments, each surface of the non-woven mat has less than about 25 flocs per 1,000 m 2 of the non-woven mat. In some exemplary embodiments, each surface of the nonwoven mat has less than about 15 flocs per 1,000 m 2 of the non-woven mat.
  • the average fiber diameter of the first fibers is in the range of about 8 pm to about 13 pm.
  • the average fiber diameter of the second fibers is in the range of about 3 pm to about 3. 5 pm.
  • the first fibers comprise about 10% w/w to about 50% w/w of the total weight of the first and second fibers; and the second fibers comprise about 50% w/w to about 90% w/w of the total weight of the first and second fibers.
  • the non-woven mat includes more of the first fibers than the second fibers by wt.% based on the total weight of the first and second fibers.
  • a ceiling tile incudes a facer on at least one major face thereof, the facer comprising a non-woven mat, wherein the non-woven mat comprises: a plurality of first fibers; a plurality of second fibers; and a binder holding the first fibers and second fibers together in an interspersed arrangement; wherein the first fibers have an average fiber diameter greater than about 7 pm; wherein the second fibers have a mean fiber diameter x that is less than about 6 pm; and wherein a fiber diameter distribution of the second fibers has a standard deviation from x of less than 3.5 pm.
  • a method of manufacturing a non-woven fibrous mat comprises: (i) dispersing a plurality of first fibers in a first aqueous solution to form a first slurry; (ii) dispersing a plurality of second fibers in a second aqueous solution to form a second slurry; (iii) mixing the first slurry, the second slurry, and a water- soluble or water-dispersible binder to form a third slurry; (iv) depositing the third slurry to form a wet-laid web made up of the first fibers, the second fibers, and the binder; and (v) drying the wet-laid web to form the non-woven fibrous mat, wherein the first fibers have an average fiber diameter in the range of about 6.5 gm to about 15 gm; wherein the second fibers have a mean fiber diameter x that is less than 6.0 gm; wherein a fiber
  • the binder is added to the first slurry.
  • the binder is added to the second slurry.
  • a non-woven mat for use as a facer for a ceiling tile comprises: a plurality of first fibers; a plurality of second fibers; and a binder holding the first fibers and second fibers together in an interspersed arrangement; wherein the first fibers have an average fiber diameter greater than about 6 pm; wherein the second fibers have a mean fiber diameter x that is less than about 4 gm; wherein the second fibers constitute y wt.% of the mat; wherein y/x ⁇ 10; and wherein the mat has a cloudiness rating of 15 or less within the range of 19 mm to 42 mm, when measured with the cloud runner device.
  • a ceiling tile incudes a facer on at least one major face thereof, the facer comprising a non-woven mat, wherein the non-woven mat comprises: a plurality of first fibers; a plurality of second fibers; and a binder holding the first fibers and second fibers together in an interspersed arrangement; wherein the first fibers have an average fiber diameter greater than about 6 gm; wherein the second fibers have a mean fiber diameter x that is less than about 4 gm; wherein the second fibers constitute y wt.% of the mat; wherein y/x ⁇ 10; and wherein the mat has a cloudiness rating of 15 or less within the range of 19 mm to 42 mm, when measured with the cloud runner device.
  • Figure 1 is a partial cross-sectional view of a rotary fiber forming apparatus to illustrate various aspects of a conventional rotary fiber production method.
  • Figure 2A is a graph illustrating the fiber diameter distribution for a volume of glass fibers produced by one conventional rotary fiber production method.
  • Figure 2B is a graph illustrating the fiber diameter distribution for a volume of glass fibers produced by another conventional rotary fiber production method.
  • Figure 2C is a graph illustrating the fiber diameter distribution for a volume of glass fibers produced by yet another conventional rotary fiber production method.
  • Figure 2D is a graph illustrating the fiber diameter distribution for a volume of glass fibers produced by still another conventional rotary fiber production method.
  • Figure 3 is a partial cross-sectional view of a rotary fiber forming apparatus to illustrate various aspects of a rotary fiber production method, according to one exemplary embodiment.
  • Figure 4 is a graph illustrating the fiber diameter distribution for a volume of glass fibers produced by the rotary fiber production method of FIG. 3.
  • Figure 5 is a graph illustrating the zeta potential (relative to pH) of several glass sizing formulations.
  • Figure 6 is a diagram illustrating the three different simulated viewing angles by the cloud runner device.
  • Figure 7 is a graph illustrating cloud size measurements for ceiling tile facers comprising different types and percentages of fine fibers.
  • Figure 8 is a graph illustrating cloud size measurements for ceiling tile facers comprising different percentages and diameters of fine rotary fibers.
  • Figure 9A is a graph illustrating cloud size measurements for ceiling tile facers comprising different 6.5 pm WUCS glass fibers and 3.5 pm inventive rotary glass fibers.
  • Figure 9B is a graph illustrating cloud size measurements for ceiling tile facers comprising different 6.5 pm WUCS glass fibers and 6.5 pm inventive rotary glass fibers.
  • Figure 10 is a diagram showing illustrative non-woven mat portions with and without flocs therein.
  • Figure 11 is a graph showing the “conversion value” between measuring fibers diameter of various WUCS fibers having different fiber diameters using an SEM microscopy based approach and the ISO 13322-2 compliant approach described herein.
  • Figure 12 is a diagram illustrating exemplary processing of the inventive rotary fibers prior to being mixed with other fibers in a wet-laid process.
  • Figures 13A-13C are scanning electron microscopy (SEM) images of exemplary non-woven mats made from fiber blends in which fiber curvature was measured.
  • modifications to a rotary fiber forming process allows for the production of fibers having a more uniform fiber diameter and/or length distribution.
  • the general inventive concepts encompass this new method of producing rotary fibers, the new rotary fibers themselves, a sizing formulation suitable for use on the new rotary fibers, a package of the rotary fibers (e.g., having the improved fiber distribution), a non-woven mat made from the new rotary fibers, and downstream applications for the mat (e.g., a facer for a ceiling tile).
  • non-woven materials from glass fibers.
  • composite materials comprised of reinforcing glass fiber mats (known as, e.g., veils, webs, facers) are utilized in a variety of applications.
  • One approach to forming glass fibers involves passing molten glass through orifices in the bottom of a stationary bushing, wherein the streams of molten glass attenuate into fibers as they cool. See, e.g., U.S. 3,653,860; U.S. 3,972,702; and U.S. 4,207,086.
  • Another approach to forming glass fibers involves passing molten glass through orifices in the outer wall of a spinner (via centrifugal force), wherein the streams of molten glass attenuate into fibers as they cool. See, e.g., U.S. 5,582,841.
  • heated air can be used to draw the fibers downward, which helps with attenuation and collection of the fibers.
  • the bushing-formed glass fibers can subsequently be chopped to form wet-use chopped strand (WUCS) fibers having a relatively consistent average fiber diameter and average fiber length.
  • WUCS wet-use chopped strand
  • bushing-formed glass fibers are usually limited to fiber diameters of 6.5 pm or larger, due to health concerns relating to their non-biosolubility.
  • bushing-formed glass fibers can be relatively more expensive to produce compared to rotary- formed glass fibers.
  • rotary-formed glass fibers are used instead of or in addition to bushing-formed glass fibers.
  • the rotary-formed glass fibers can have fiber diameters well below 6.5 pm owing to their biosoluble formulations. These so called “microfibers” can provide improved properties at lower add-on weights compared to WUCS fibers.
  • One approach to measuring average fiber diameter involves: (1) subjecting the samples to sufficient heat to burn off any surface chemistry without impacting the underlying fiber morphology; and (2) determining the average fiber diameter for a given quantity of the fibers by measuring an airflow/pressure drop across the quantity of fibers, as commonly performed in the insulation and fiber industries (e.g., Micronaire). Instrumentation used for measuring fiber diameter via airflow resistance are based on theories by Darcy, Les Fontaines Publiques de la Ville de Dijon (1856); Kozeny, Uber Kapillaretechnisch des Wassers im Boden (1927); and Carman, Flow of Gases Through Porous Media (1956) among others.
  • the instruments work by measuring the airflow resistance through a known mass of material; as the fiber diameter decreases, the specific surface area increases, which increases the resistance to airflow.
  • the higher the airflow resistance the smaller the effective fiber diameter, representing the fiber diameter that would be expected to produce the same resistance, if all fibers were the same diameter.
  • This is the primary technique (referred to as the airflow resistance approach) to obtaining the effective fiber diameter values presented herein (as an estimate of the average fiber diameter), including in the claims, unless otherwise noted.
  • the aforementioned airflow resistance approach is not suitable for determining the distribution of individual fibers (e.g., fibers with different diameters) from a quantity of fibers or values calculated from the distribution (e.g., mean, median, standard deviation).
  • another approach to measuring fiber diameter in the context of the overall fiber distribution involves (1) subjecting the samples to sufficient heat to burn off any surface chemistry without impacting the underlying fiber morphology; (2) dispersing the plain fibers in water using a high-speed blender; (3) diluting the fibers dispersed in the water to an acceptable concentration suitable for image analysis; and (4) measuring the fiber diameter distribution using image analysis (e.g., in compliance with ISO 13322-2).
  • the image analysis can be performed by an apparatus wherein particles (i.e., the dispersed fibers) pass through the focal planes of two cameras, the apparatus having an image rate of 300 images per second and a resolution of 0.8 pm per pixel.
  • the apparatus used to obtain the data described herein is the Camsizer X2 with the X-Flow Module, which is manufactured by Microtrac MRB of Osaka, Japan.
  • the measured data can be filtered to remove non-fibrous particles (e.g., particles having an aspect ratio (L/D) of less than 5). In general, a minimum of 10,000 fibers are measured to ensure a proper distribution assessment.
  • average fiber diameter encompasses both the effective fiber diameter and the mean fiber diameter for a sample, unless the context indicates otherwise.
  • the modified rotary fiber forming process 300 will be described with reference to a conventional fiber manufacturing apparatus or fiberizer, such as the fiberizer 10 of FIG. 1 (albeit with the radiation shield 52 disclosed therein being an optional component).
  • the rotary fiber forming process 300 includes multiple aspects A-E that can be modified to produce the fibers having a more uniform fiber diameter and/or length distribution.
  • the general inventive concepts encompass a modified rotary fiber forming process 300 that uses any one or more of these aspects A-E to obtain a quantity of fibers (produced together) having a more uniform fiber diameter and/or length distribution.
  • the general inventive concepts encompass any combination of these aspects (e.g., A, A+B, A+C, A+B+C, A+D, A+B+D, A+B+C+D, A+E, etc.). Furthermore, the general inventive concepts are not necessarily limited to these aspects and other features of the invention, such as the sizing formulation(s) described herein, may also contribute to the improved fiber diameter and/or length distribution, in some exemplary embodiments.
  • a surface of a quill pan 67 of the fiberizer 10 can get hot enough to melt fibers that come into contact with the quill pan 67.
  • the amount of cooling air introduced through the hollow quill 64 is increased, which reduces the temperature of the quill pan 67.
  • a conventional rotary fiber forming process will use approximately 5-15 cubic feet per minute (CFM) of air flow to cool the quill pan 67 to a temperature temp con v.
  • the inventive rotary fiber forming process (e.g., the process 300) uses approximately 30-60 CFM of air flow to cool the quill plan 67 to a temperature tempinv.
  • temp con v is typically much higher than 1,100 °F (e.g., > 1,200 °F)
  • tempinv is kept under 1,100 °F.
  • fibers being formed that come into contact with the quill pan 67 are less likely to be fused thereto (or with other fibers fused thereto) in a manner likely to damage the fibers or lead to agglomeration of fibers (e.g., flocs), both of which can distort the intended fiber diameter and/or length distribution.
  • a rotational speed of the spinner 12 (via the rotating spindle 14) is decreased, which reduces the likelihood of the fibers contacting a surface of the blower 28.
  • a conventional rotary fiber forming process will cause the spinner 12 to run at 2,500 revolutions per minute (rpm) to 3,000 rpm, while the inventive rotary fiber forming process (e.g., the process 300) will cause the same spinner 12 to run at 1,800 rpm to 2,400 rpm.
  • these ranges might shift, but the reduction in rotational speed in the modified rotary fiber forming process versus a conventional rotary fiber forming process will hold.
  • the fibers being formed are less likely to be fused thereto (or with other fibers fused thereto) in a manner likely to damage the fibers or lead to agglomeration of fibers (e.g., flocs), both of which can distort the intended fiber diameter and/or length distribution.
  • fibers e.g., flocs
  • the modified rotary fiber forming process 300 may have a lower limit on its ability to produce smaller diameter and/or length fibers.
  • the lower limit of effective fiber diameter (using the air flow method) would be in the range of 2.5 pm to 3.0 pm, with this lower limit being restricted by the ability to maintain sufficient temperature to attenuate the molten glass into fibers.
  • an amount of air induced through passage 30 by blower 28 is controlled to promote improved attenuation of the primary fibers 22 into the secondary fibers 32.
  • the blower 28 outputs approximately 410 cubic feet per minute (CFM) of air, which in turn leads to the “induced air” flowing through the passage 30.
  • CFM cubic feet per minute
  • “improved attenuation” can be considered achieving a reduction in the occurrence of fused fibers and other defects (e.g., shot, flocs), as described herein.
  • this improved attenuation is evidenced by an improved fiber diameter and/or length distribution, such as shown in the graph 400 of FIG. 4.
  • the above aspects A-D are particularly important with respect to aspect E of the modified rotary fiber forming process 300, which represents the “attenuation zone” for the secondary fibers 32.
  • the attenuation zone E is an area around the fiberizer 10 where the temperatures are hot enough to fuse the fibers 32.
  • the modified rotary fiber forming process 300 attempts to minimize collisions between two separate fibers 32 and/or between a fiber 32 and a piece of the fiber forming equipment until after the fibers 32 have cooled below their glass transition temperature T g and, thus, are less likely to fuse. For example, for glass fibers having a Tg in the range of 1,000 °F to 1,250 °F, the modified rotary fiber forming process 300 would attempt to minimize fiber collisions until after the fibers have cooled to a temperature below 1,100 °F.
  • the modified rotary fiber forming process 300 produces a quantity of fibers with an improved overall quality (e.g., longer length), as compared to conventional rotary fibers.
  • the fibers produced by the modified rotary fiber forming process 300 can be further processed downstream of the process 300, such as by milling/cutting/chopping the fibers into easier to process lengths.
  • the fibers can be milled to have a reduced length in the range of 1/8 inch (3.25 mm) to 1 inch (25.4 mm), which facilitates the use of the fibers in a wet-laid process.
  • other applications/processes might benefit from the fibers having a longer length.
  • the fibers produced by the modified rotary fiber forming process 300 have a longer initial (formed) length than conventional rotary -formed fibers, the fibers are more likely to start at a length greater than a target length, which in turn provides more flexibility in reducing the fibers to the target (processed) length and more uniformity in products made from such fibers.
  • the inventive rotary fibers can be processed to have an average aspect ratio in the range of 850 to 5,000 or in the range of 850 to 2,000.
  • the combined average aspect ratio of the fiber blend is less than about 1,000.
  • the average aspect ratio of the fibers when used to form a non-woven mat, as described herein will typically be lower (e.g., in the range of 150 to 500) due to breakage in the non-woven forming process.
  • FIG. 4 a graph 400 of the fiber diameter distribution for a fiberglass material, according to one exemplary embodiment, is shown.
  • the fiberglass material comprises rotary- formed fibers that are not held together by a binder.
  • the fiberglass material was formed by a modified rotary fiber forming process (e.g., the process 300).
  • Peak Index refers to the peak identifier from left to right, with the peaks being shown with dashed lines; “Peak Type” refers to the type of model used to fit the data; “Area Intg” refers to the integrated area of the fit peak; “Area IntgP” refers to the percentage of total integrated area for each fit peak; “Center Grvty” refers to the center of the fit peak; “Max Height” refers to the maximum value of the fit peak; and “FWHM” refers to the width of the peak at half of its maximum height.
  • the rotary fibers were produced with a target diameter of about 3.5 pm, as measured using the known air flow method.
  • the graph 400 represents the fiber diameter distribution when measured using an ISO 13322-2 compliant method and plotted by fiber volume %.
  • the (Camsizer) data measured according to the ISO 13322-2 compliant approach was analyzed using the Peak Deconvolution App (v2.00) with OriginPro 2023 (constant baseline; fit until converged to obtain displayed results), which is data analysis software sold by OriginLab Corp, of Northampton, Massachusetts.
  • rotary fiber production is a complex process with many variables, only some of which can be controlled.
  • a modified rotary fiber forming process e.g., the process 300
  • the rotary fibers shown in the graph 400 have a more pronounced bi-modal distribution, as compared to the conventional rotary fibers shown in the graphs of FIGS. 2A- 2D.
  • two distinct peaks are shown, with each peak having an apex higher than 15 %/pm within the distribution.
  • the fiber diameter distribution i.e., the area under the graph
  • this narrower variance in fiber diameters (e.g., about 1.5 pm to about 13.5 pm), with a majority of the fibers having a fiber diameter less than 6 pm, is closer to the ideal than that achieved by conventional rotary fibers.
  • the inventive rotary fibers could result in improved products/applications.
  • dlO means that 10% of all particles in the sample are smaller than or equal to the dlO value
  • d50 means that 50% of all particles in the sample are smaller than or equal to the d50 value (also known as the median particle size)
  • d90 means that 90% of all particles in the sample are smaller than or equal to the d90 value
  • Sample Mean refers to the mean particle size for the sample
  • Standard Deviation refers to the standard deviation from the mean.
  • the inventive rotary-formed glass fibers do not have a lower median fiber diameter (d50) than all of the sampled conventional rotary-formed glass fibers, the inventive rotary-formed glass fibers do have a lower mean value than all of the sampled conventional rotary-formed glass fibers.
  • the smaller standard deviation value also indicates that the inventive rotary-formed glass fibers have a more uniform fiber diameter distribution, as described herein.
  • the inventive rotary fibers are produced with an increased fiber length relative to conventional rotary fibers.
  • a conventional rotary fiber forming process will produce rotary fibers (from the fiberizer 10) having a length of approximately 0.5 inches (12.7 mm) to 2 inches (50.8 mm), while the inventive rotary fiber forming process (e.g., the process 300) will produce rotary fibers (from the fiberizer 10) having a length of approximately 3 inches (76.2 mm) to 12 inches (304.8 mm).
  • This longer fiber length provides for increased flexibility in downstream processing of the fibers, as well as more control over final product properties.
  • the inventive rotary fibers contain fewer fused fibers, clumps (e.g., flocs), or strings, thus enabling a more uniform dispersion of the fibers when producing nonwoven products, as described herein.
  • the term “floc” refers to a loosely clumped mass of fibers which is visible to the naked eye.
  • a sample portion of a non-woven mat 1010 is substantially free of any flocs 1002 on one side 1012 thereof and/or on the side (not shown) opposite the side 1012, while a sample portion of another non-woven mat 1020 includes several flocs 1002 on one side 1022 thereof and/or on the side (not shown) opposite the side 1022.
  • the rotary fibers have an average fiber diameter of less than 6.5 pm. In some exemplary embodiments, the rotary fibers have an average fiber diameter of less than 5.5 pm. In some exemplary embodiments, the rotary fibers have an average fiber diameter of less than 4.5 pm.
  • the rotary fibers have a fiber diameter distribution with one or two Gaussian peaks that represent > 85% of the fiber volume/mass, with > 40% of the volume/mass being in the peak representing the smallest diameter fibers.
  • the rotary fibers are substantially free of any fibers having a diameter larger than 15 pm.
  • the rotary fibers upon formation thereof (e.g., exiting the fiberizer 10), are substantially free of or have a substantial reduction in any unfiberized or poorly fiberized material (generally referred to as “shot”), fused fibers, agglomerated fibers (e.g., flocs), and/or other forms of defective fibers, which can contribute to the improved fiber diameter distribution described herein.
  • shots unfiberized or poorly fiberized material
  • agglomerated fibers e.g., flocs
  • the rotary fibers are made from a bio-soluble composition.
  • non-rotary fibers e.g., WUCS fibers
  • rotary fibers generally have a curvature due to the glass fibers cooling in a less controlled environment. This curvature can also impart benefits to products made from the inventive rotary fibers, for example, reducing visual defects (e.g., clouds/mottling; directionality) in ceiling tiles due to more random scattering of light and the inability of the fibers to align with one another.
  • visual defects e.g., clouds/mottling; directionality
  • FIGS. 13A-13C several sample non-woven mats were made using a wet-laid process that combined blends of fibers comprising 11 pm diameter, 6 mm long WUCS fibers as first fibers (Fiber 1) and (i) 6.5 pm diameter, 6 mm long WUCS fibers as second fibers (Fiber 2) in FIG. 13 A; (ii) the conventional ULF fibers shown in FIG. 2C as second fibers (Fiber 2) in FIG. 13B; and (iii) the inventive rotary fibers described herein and shown in FIG. 4 as second fibers (Fiber 2) in FIG. 13C.
  • FIG. 13A includes an SEM image of a non-woven mat 1300 made by a wet-laid process from a combination of 85% first WUCS fibers (Fiber 1) having an average fiber diameter of 11 pm and a processed length of 6 mm and 15% second WUCS fibers (Fiber 2) having an average fiber diameter of 6.5 pm and a processed length of 6 mm, by weight of the glass fibers.
  • FIG. 1 first WUCS fibers
  • Fiber 2 having an average fiber diameter of 6.5 pm and a processed length of 6 mm
  • 13B includes an SEM image of a non-woven mat 1302 made by a wet-laid process from a combination of 85% first WUCS fibers (Fiber 1) having an average fiber diameter of 11 pm and a processed length of 6 mm and 15% second ULF fibers (Fiber 2) having an average fiber diameter in the range of 2.8 pm to 3 pm and a processed length in the range of 1 mm to 6 mm, by weight of the glass fibers.
  • FIG. 1 first WUCS fibers
  • Fiber 2 second ULF fibers
  • 13C includes an SEM image of a non-woven mat 1304 made by a wet-laid process from a combination of 85% first WUCS fibers (Fiber 1) having an average fiber diameter of 11 pm and a processed length of 6 mm and 15% second inventive rotary fibers (Fiber 2) having an average fiber diameter of 3.5 pm and a processed length in the range of 1 mm to 6 mm, by weight of the glass fibers.
  • the mats 1300, 1302, and 1304 were imaged using scanning electron microscopy to create the SEM images shown in FIGS. 13A-13C, respectively. These SEM images were analyzed using Imaged version 1.54f open-source software, with the Kappa Curvature Analysis plug-in (Gary Brouhard, 2016) to approximate the curvature of the second fibers (Fiber 2) in each of the mats 1300, 1302, 1304.
  • the WUCS fibers (Fiber 2) in the mat 1300 were found to have a curvature of 0.004.
  • the ULF fibers (Fiber 2) in the mat 1302 were found to have a curvature of about 0.043.
  • the inventive rotary fibers (Fiber 2) in the mat 1304 were found to have a curvature of about 0.055.
  • the rotary fibers which are all produced by one or more fiberizers having essentially the same operating parameters (and, perhaps, at essentially the same time), are packaged together.
  • the rotary fibers may undergo processing (e.g., milling to reduce length (to a “processed length”)) prior to packaging.
  • the rotary fibers in the package may include a sizing composition applied thereto, as described herein.
  • the package of rotary fibers will have an improved fiber diameter and/or length distribution, as described herein.
  • an aqueous sizing composition can be applied thereto.
  • the sizing composition could be sprayed on the fibers using an annular ring with nozzles surrounding the curtain of fibers being directed downward.
  • the surface chemistry imparted to the rotary fibers by the sizing composition can act to protect the fibers and promote downstream processing thereof.
  • a sizing composition comprises water, a silane coupling agent, at least one organic acid, and a cationic surfactant, wherein the sizing composition has less than 5% active solids content and is substantially “color-free.”
  • the subject sizing composition which includes a reduced number of components compared to conventional sizing compositions (e.g., conventional sizing compositions used with WUCS fibers), is particularly useful with the inventive fibers.
  • various exemplary aspects of the sizing composition disclosed herein are free of a film former.
  • the reduced number of components results in a sizing composition that is more cationic than conventional sizing compositions, which provides improved dispersion of the sized fibers in the whitewater solution during formation of mats made from the inventive rotary fibers.
  • the exemplary sizing composition includes, at a minimum, a silane coupling agent, at least one organic acid, and a cationic surfactant.
  • the sizing composition may consist essentially of, or consist of a silane coupling agent, at least one organic acid, and a cationic surfactant.
  • the silane coupling agent may be in a partially or a fully hydrolyzed state or in a non-hydrolyzed state.
  • the silane coupling agent may also be in monomeric, oligomeric, or polymeric form prior to, during, or after its use.
  • Suitable silane coupling agents used in the sizing compositions disclosed herein are organosilanes that have silanol functional groups (e.g., after hydrolysis of the alkoxy groups) that bond well with glass.
  • the silane coupling agent also functions to aid in processability, such as by reducing the level of broken fiber filaments during subsequent processing.
  • Silane coupling agents which may be used in the present sizing composition may be characterized by the functional groups amino, methacrylate, epoxy, azido, vinyl, methacryloxy, ureido, and isocyanato.
  • the organosilane has a functional group that is linked through non-hydrolyzable bonds to a silicon atom.
  • Organosilanes for use in the sizing composition include monosilanes containing the structure Si(OR)s, where R is an organic group such as an alkyl group. Lower alkyl groups such as methyl, ethyl, and isopropyl are preferred.
  • silane coupling agents suitable for use in the sizing composition include, but are not limited to, gammaaminopropyltriethoxysilane (A-1100), gamma-ureidopropyltrimethoxysilane (A-1524), 3- aminopropyltriethoxysilane (KBE-903), y-glycidoxypropyltrimethoxysilane (A-187), y- methacryloxypropyltrimethoxysilane (A- 174), n-Paminoethyl-y-aminopropyltrimethoxysilane (A-1120), methyl-trichlorosilane (A-154), methyltrimethoxysilane (A-163), y- mercaptopropyl-trimethoxy-silane (A- 189), y-chloropropyl-trimethoxy-silane (A- 143), vinyl- triethoxy-silane (A
  • silane coupling agents listed herein are commercially available as SilquestTM products from Momentive Performance Materials, Inc. (Waterford, New York).
  • the silane coupling agent is selected from the group consisting of gamma-aminopropyltriethoxysilane, gamma- ureidopropyltrimethoxysilane, 3 -aminopropyltri ethoxy silane, and combinations thereof.
  • the sizing composition comprises Silquest® Y- 9669, available from Momentive, which is a N-phenyl-gamma-aminopropltrimethoxy silane, with a solids content of 82% and Silquest® A-1120, which is N(beta-aminoethyl)gamma- aminopropyltrimethoxy-silane, with a solids content of 81%.
  • An exemplary methacrylate- functional silane for use in the sizing compositions disclosed herein is Gamma- methacryloxypropltrimethoxysilane (A-174), which is available commercially from Momentive Performance Materials, Inc. of Waterford, New York.
  • the silane coupling agent component of the sizing compositions of the present disclosure comprises Silquest® Y-9669 and A-174.
  • the sizing composition includes a silane coupling agent in an amount such that the silane coupling agent comprises from 1 wt.% to 60 wt.% of the solids content of the sizing composition.
  • the silane coupling agent comprises from 5 wt.% to 50 wt.% solids, based on the total solids content of the sizing composition, including, for example, from 15 wt.% to 45 wt.%, and also including from 25 wt.% to 35 wt.% of the solids.
  • the silane coupling agent has an active solids content of 25-80%, including from 40-70%, and 60- 65 %.
  • the exemplary sizing compositions disclosed herein include at least one organic acid.
  • the organic acid is used to adjust the pH to enable the hydrolysis of the silane coupling agent.
  • the organic acid disclosed herein comprises at least one weak acid.
  • suitable weak acids that can be used in the sizing compositions disclosed herein include, but are not limited to, acetic acid, succinic acid, citric acid, and combinations thereof.
  • the weak acid component comprises or consists of acetic acid.
  • the sizing compositions disclosed herein have a pH of from about 3.0 to about 7.5, preferably from about 4.5 to about 5.5.
  • the sizing composition includes an organic acid in an amount such that the organic acid comprises from 0.01 wt.% to 50 wt.% of the solids content of the sizing composition.
  • the organic acid comprises from 0.05 wt.% to 40 wt.% of the solids content of the sizing composition, including from 0.1 wt.% to 30 wt.%, from 0.5 wt.% to 25 wt.%, from 0.75 wt.% to 22 wt.%, from 1.0 wt.% to 20 wt.%, from 1.5 wt.% to 18 wt.%, and from 2.0 wt.% to 15 wt.%, based on the total solids of the sizing composition.
  • the organic acid has an active solids content of 25-99%, including from 40-90%, and 70-85%.
  • the organic acid has an active solids content of about 80% +/-
  • the exemplary sizing compositions disclosed herein further include a cationic surfactant.
  • the cationic surfactant acts as a “wet lubricant” and serves to increase dispersion of the glass fibers in the white-water solution during formation of mats made from the inventive rotary fibers.
  • Suitable examples of cationic surfactants include, but are not limited to, imidazoline and alkyl imidazoline derivatives, amino ethyl imidazolines, a stearic ethanolamide such as Lubesize K-12 (Alpha/Owens Coming (Ontario, Canada), polyamides of acetic acid, of C5-C9 carboxylic acids and of diethylenetriamine-ethyleneimine, commercially available as Katax® 6760L (Pulcra Chemicals).
  • a preferred cationic softener is the acetic acid salt of the reaction product of tetraethylene pentamine and stearic acid converted in about 91 % imidazoline groups, commercially available as LUBESIZE K-12.
  • Imidazolines are thermally stable organic nitrogenous bases. Unneutralized imidazolines, being lipophilic, are generally soluble in non-polar solvents and mineral oil but tend to only be dispersible in aqueous systems. The ability of imidazolines to form cations renders them strongly adsorbed onto the negatively charged surface of metals, fibers, plastics, glass and minerals, thereby converting these hydrophilic surfaces to hydrophobic surfaces. Imidazoline salts tend to be much more hydrophilic than their bases and function as acid stable detergents with good wetting agents. The compatibility of imidazolines in aqueous systems may be improved through the use of suitable solubilizers.
  • the sizing composition includes a cationic surfactant in an amount such that the cationic surfactant comprises from 25 wt.% to 90 wt.% of the total solids content of the sizing composition.
  • the cationic surfactant comprises from 30 wt.% to 80 wt.% solids, based on the total solids content of the sizing composition, including, for example, from 35 wt.% to 75 wt.%, from 37 wt.% to 72 wt.%, and from 40 wt.% to 70 wt.% solids, including all endpoints and subranges therebetween.
  • the cationic surfactant has an active solids content of 0.5-20%, including from 1-15%, and 5-10%. In certain exemplary embodiments, the cationic surfactant has an active solids content of about 9% +/- 3%.
  • the sizing compositions disclosed herein may be formed without the presence of a film former material, which may comprise a polymer material, such as, for example, an amide-based polymer, acrylic-based polymer, polyester-based polymer, epoxy-based polymer, and the like.
  • a film former material such as, for example, an amide-based polymer, acrylic-based polymer, polyester-based polymer, epoxy-based polymer, and the like.
  • film formers are included to coalesce and form a film on a fiber when the sizing composition has been dried.
  • the film former functions to protect the fibers from damage during processing and imparts compatibility of the fibers with other end use materials.
  • the sizing compositions disclosed herein are formed using a reduced amount of chemicals and provides sufficient fiber protection without the use of a film former. Nonetheless, the various aspects of the exemplary sizing compositions disclosed herein may optionally include a film former.
  • the exemplary sizing compositions disclosed herein also include water.
  • the sizing composition contains an amount of water sufficient to dilute the solids of the sizing composition to a viscosity that is suitable for application to rotary fibers.
  • the sizing composition comprises water in an amount of from 80 wt.% to 99.9 wt.%, based on the total weight of the sizing composition, including, for example, from 85 wt.% to 98 wt.%, or from 90 wt.% to 99.5 wt.%.
  • the total solids content of the sizing composition may be from 0.5 wt.% to about 20 wt.%, including from 2 wt.% to 10 wt.%.
  • the sizing composition has a total solids content of 3 wt.% to 6 wt.%, and more preferably of about 5 wt.%.
  • the sizing composition comprises, consists essentially of, or consists of a silane coupling agent in an amount of from 25 wt.% to 35 wt.% solids, an organic acid in an amount of about 2-20 wt.% solids, and a cationic surfactant in an amount of from 50 wt.% to 70 wt.% solids, based on the total solids content of the sizing composition.
  • the sizing composition may comprise or consist of a y-aminopropyltriethoxysilane coupling agent in an amount of from 25 wt.% to 35 wt.% solids, based on the total solids content of the sizing composition, acetic acid in an amount of from 2 wt.% to 20 wt.% solids, based on the total solid content of the sizing composition, and an imidazoline derivative coupling agent in an amount of from 50 wt.% to 70 wt.% solids, based on the total solids content of the sizing composition.
  • the exemplary sizing compositions disclosed herein may also include other components that are conventionally used in sizing compositions.
  • the sizing compositions may optionally include wetting agents, surfactants, lubricants, antioxidants, dyes, oils, fillers, thermal stabilizers, antifoaming agents, dust suppression agents, antimicrobial agents, antistatic agents, fungicides, biocides, film forming agents, chopping aids, thickeners and/or other conventional additives.
  • the amount of the foregoing optional components in the sizing composition may range from 0 wt.% to 90 wt.% based on the dry solids content of the sizing composition, including, for example, 0 wt.% to 50 wt.%, or 0 wt.% to 30 wt.%.
  • the exemplary sizing compositions disclosed herein may be prepared by combining the ingredients thereof according to any method known to one of ordinary skill in the art.
  • the viscosity of the white water at room temperature is preferably greater than 2.0 cps, and more preferably between 2.0 and 5 cps, and still more preferably about 3.0-3.5 cps.
  • Exemplary sizing compositional ranges are provided below in Table 7. It should be appreciated that any of the disclosed ranges of Sizing Compositions A-C in Table 7 may be used in combination with any other disclosed compositional range herein and is not limited to the particular combination of ranges provided therein.
  • the sizing composition is substantially cationic in nature.
  • the charge of the sizing composition may be described in terms of its zeta potential over a range of pH values.
  • the zeta potential is the charge that develops at the interface between a solid surface (such as a particulate material) and its liquid medium.
  • the sizing composition of the subject inventive concepts has a zeta potential with an absolute value that is at least 20 greater than the pH.
  • the sizing composition has a zeta potential with an absolute value of greater than 30 at a pH range between 2 and 4.
  • the sizing composition has a zeta potential with an absolute value of greater than 20 at a pH range between 2 and 6.
  • an inventive sizing formulation (IF) formed in accordance with the present inventive concepts and with about 70 wt.% solids of a cationic surfactant was compared to a first conventional reference sizing formulation (RF-1) applied to an equivalent fiber and a second conventional reference sizing formulation (RF-2) applied to another equivalent fiber.
  • the particular size formulation was applied using a roll coating technique on conventional WUCS fibers at the same or lower wt.%.
  • a graph 500 of the zeta potential of each formulation is plotted relative to the pH. In general, the greater the magnitude of the zeta potential, the more cationic the formulation.
  • the greater zeta potential of the IF at both high and low pH indicates that the sized fiber exhibits amphoteric behavior, meaning it can act as an acid or a base. This property indicates that fibers sized with the IF disperses well in both acidic and basic environments. To achieve a suitable dispersion, it is generally desirable to have a zeta potential with an absolute value greater than 20 at a pH between 2 and 6.
  • the overall composition of the size chemistry (e.g., IF) contains more cationic lubricant, about 70 wt.% solids, than traditional size chemistries (e.g., RF-1, RF-2) which typically range from 0-40 wt.% solids.
  • the exemplary sizing compositions disclosed herein may be substantially “color- free,” as compared to traditional sizing compositions.
  • the sizing compositions disclosed herein exhibit an AL* value of -5 to +5.
  • the sizing compositions disclosed herein exhibit an AL* value of 0 to +2.5, including an AL* value of +2.
  • the sizing compositions disclosed herein exhibit an Aa* value of -10 to +10.
  • the sizing compositions disclosed herein exhibit an Aa* value of -8 to +2, including an Aa* value of about -6.
  • the sizing compositions disclosed herein exhibit an Ab* value of -10 to +10.
  • the sizing compositions disclosed herein exhibit an Ab* value of -5 to +5, including an Ab* value of about 0.
  • the sizing composition may be applied to the fibers such that the sizing composition is present on the fibers in an amount of from 0.05 wt.% to 2 wt.%, based on the total weight of the sized fibers.
  • the amount of sizing composition present on the fibers is also referred to as “strand solids content.”
  • the sizing composition is present on the fibers in an amount of from 0.08 wt.% to 1.0 wt.% based on the total weight of the sized fibers, including from 0.1 wt.% to 0.8 wt.%, from 0.2 wt.% to 0.6 wt.%, and also including from 0.35 wt.% to 0.55 wt.%, based on the total weight of the sized fibers.
  • LOI loss on ignition
  • inventive sizing composition further may be applied at lower levels when evaluated based on surface area of the fiber.
  • inventive rotary fibers described herein may have less than about 4 mg/cm 2 of strand solids applied thereon, including, for example, 0.5 mg/cm 2 - 3.8 mg/cm 2 , 0.75 mg/cm 2 - 3.4 mg/cm 2 , 1 mg/cm 2 - 3 mg/cm 2 , or 1.15 mg/cm 2 - 2.5 mg/cm 2 , while traditional WUCS fibers might have from 4-24 mg/cm 2 of strand solids applied thereon.
  • the moisture content of the sized fiber has a final moisture content of less than 10%, including less than 7%, less than 6%, and less than or equal to 5%.
  • the reduction in final moisture content i.e., increased dryness of the fibers
  • benefits such as reduced shipping costs, while reducing/avoiding the need for antimicrobial agents in the sizing composition.
  • the inventive rotary fibers can be used to form other materials, such as a nonwoven mat.
  • the fibrous mat can be formed by known processes, such as a wet-laid process.
  • a wet-laid process discrete fibers are dispersed in a water slurry that contains surfactants, thickeners, defoaming agents, and/or other chemical agents.
  • the water and chemical components are often referred to as a “white water” solution.
  • the slurry containing the fibers is then agitated in a mixing tank so that the fibers become dispersed throughout the slurry.
  • the slurry containing the dispersed fibers is deposited onto a moving screen, wherein a substantial portion of the water is removed to form a web of randomly oriented fibers.
  • a binder is applied to the collection of fibers, which then passes through an oven to dry (i.e., remove any residual water from) the fibers and cure the binder to form the mat.
  • the binder could also be applied in a dry (powered) form.
  • a swellable polyvinyl alcohol (PVA) powder could be added to the fiber mix, wherein the PVA binder effectively binds the fibers as they pass through the oven/dryer.
  • the uniformity of the arrangement of the fibers in the non-woven, sheet-like mat of fibers contributes to the strength of the mat and to the ultimate end product. Other benefits, such as improved aesthetics, can also result from increased uniformity of the arrangement of the fibers.
  • One problem that exists in preparing a uniform mat of fibers from an aqueous dispersion is that the fibers (e.g., glass fibers) are not easily dispersed in aqueous media. This difficulty in dispersing the fibers occurs initially upon adding the fibers to water. The dispersibility is further complicated by the tendency of the fibers that are scattered somewhat in the aqueous medium, to reagglomerate to some degree. The reagglomerated fibers are very difficult to redisperse.
  • the adequate dispersion of the aqueous mixture may be obtained by any suitable means provided a uniform or substantially uniform distribution of the two (or more) groups of different glass fibers in the aqueous medium is produced. In some exemplary embodiments, a uniform distribution of two groups of different glass fibers is produced. In some exemplary embodiments, a substantially uniform distribution of the two groups of glass fibers is produced.
  • the dispersion may be obtained by a high shear mixing apparatus, such as a rotor/stator mixer.
  • a significant portion (e.g., at least 10% by weight), but not all, of the fibers used to the form the non-woven mat are the inventive rotary fibers described herein.
  • the non-woven mat is formed from a blend of first fibers and second fibers (i.e., the inventive rotary fibers), wherein the first fibers have an average diameter > 6.5 pm and the second fibers have an average diameter ⁇ 6.5 pm.
  • the first fibers have an average diameter in the range of about 6.5 pm to about 15 pm.
  • the second fibers have an average diameter in the range of about 1 gm to about 6 gm.
  • the first fibers and the second fibers are both glass fibers.
  • the first fibers are not rotary -formed fibers.
  • the inventive rotary fibers are subject to preprocessing before being introduced into a mixing tank (with other fibers) of a wet-laid process.
  • the pre-processing may serve to convert the fibers from a stored (e.g., compressed) form to a form more suitable for wet-laid processing, may serve to condition the fibers (e.g., to promote dispersibility) for wet-laid processing, may serve to evaluate the fibers for defects (e.g., remove flocs or potential flocs), etc.
  • inventive rotary fibers are ultimately mixed with the WUCS in a slurry, wherein a percentage of the rotary fibers in the total blend of glass fibers can vary between 1% to 99% w/w%.
  • the rotary fibers Prior to using this mix of the two glass-based fibers in a wet-laid process to produce a non-woven veil, the rotary fibers are wetted and dispersed in a separate process before being mixed with the WUCS.
  • a quantity of the rotary fibers are loaded onto a conveyer to be fed into a mixing tank.
  • a next step 1204 the rotary fibers are fed into the mixing tank, which contains an aqueous solution of surfactants, viscosity modifiers, polymeric binders, and other process chemical aids.
  • the rotary fibers are added gradually into the mixing tank to ensure wetting of individual fibers with the aqueous solution.
  • the agitator and shape of the tank are designed such that there is adequate shear energy input and volume displacement rate while also breaking any continuous vortices formed.
  • the rotary fibers, with their large surface area to mass ratio are wetted thoroughly with the aqueous solution.
  • the dosage level of the rotary fibers in the mixing tank varies between 5-50 g/L.
  • a next step 1206 after sufficient dispersion, the rotary fiber aqueous suspension is pumped through a screening unit to remove any possible large impurities in the raw material.
  • the screening device can be modified according to the required fineness of the rotary fiber suspension.
  • the rotary fiber raw material may contain agglomerations of fibers which are difficult to wet and disperse thoroughly with the initial mixing process (step 1204). These agglomerations can manifest as defects (e.g., “flocs”) in the non-woven mat.
  • a device such as a high shear mixer may be employed to break up these fiber flocs.
  • the fiber suspension passes through a slotted rotor/stator system which homogenizes the fiber suspension, thereby aiding in the breaking up of fiber flocs.
  • step 1210 the pre-processed rotary fibers are delivered to a mixing tank of a wet-laid process, wherein the rotary fibers can be more effectively dispersed in a white water solution with other fibers.
  • the method comprises dispersing the rotary fibers in a first white water solution and then adding the dispersed rotary fibers to a second white water solution containing non-rotary fibers.
  • the non-rotary fibers are WUCS fibers.
  • the non-rotary fibers have a larger average fiber diameter than the rotary fibers.
  • separate aqueous mixtures of the first and second groups of glass fibers are respectively prepared, and are then combined with agitation (e.g., high intensity mixing) to provide a uniform or nearly uniform dispersion of the fiber blend.
  • agitation e.g., high intensity mixing
  • the first and second groups of glass fibers are combined to form a dry mixture of glass fibers.
  • the dry mixture is then formed into an aqueous mixture with agitation (e.g., high intensity mixing) to provide a uniform or substantially uniform dispersion of the fiber blend.
  • inventive rotary fibers e.g., made by the process 300 or a similar process
  • inventive rotary fibers can be substantially free of or have a substantial reduction in any unfiberized or poorly fiberized material (generally referred to as “shot”), fused fibers, agglomerated fibers (e.g., flocs), and/or other forms of defective fibers
  • a non-woven mat e.g., the non-woven mat including the portion 1010 made from the inventive rotary fibers can likewise have fewer defects and, thus, improved properties (e.g., surface smoothness, surface appearance).
  • a non-woven mat has a first surface 1012 and a second surface (not shown) opposite the first surface 1012.
  • at least one surface of the non-woven mat has less than about 100 flocs per 1,000 m 2 of the non-woven mat.
  • each surface of the non-woven mat has less than about 100 flocs per 1,000 m 2 of the non-woven mat.
  • at least one surface of the non-woven mat has less than about 50 flocs per 1,000 m 2 of the non-woven mat.
  • each surface of the non-woven mat has less than about 50 flocs per 1,000 m 2 of the non-woven mat.
  • At least one surface of the non-woven mat has less than about 25 flocs per 1,000 m 2 of the non-woven mat. In some exemplary embodiments, each surface of the non-woven mat has less than about 25 flocs per 1,000 m 2 of the non-woven mat. In some exemplary embodiments, at least one surface of the non-woven mat has less than about 15 flocs per 1,000 m 2 of the non-woven mat. In some exemplary embodiments, each surface of the non-woven mat has less than about 15 flocs per 1,000 m 2 of the non-woven mat.
  • At least one surface of the non-woven mat is substantially free of any flocs per 1,000 m 2 of the non-woven mat. In some exemplary embodiments, each surface of the non-woven is substantially free of any flocs per 1,000 m 2 of the non-woven mat.
  • the non-woven mat is designed to have sufficient strength to withstand the processing steps and speeds required to produce the non-woven mat for application in various end uses.
  • the strength of the non-woven mat must be sufficient to permit the mat to be stored in any desirable form, possibly for an extended period of time, without loss of its cohesive properties.
  • the improved fiber diameter and/or fiber length distribution of the inventive rotary fibers is expected to enhance the structure and homogeneity or uniformity of the arrangement of the glass fibers in the non-woven mat, which should lead to more consistent and defined strength properties for the mat.
  • One such application is as a facing material (“facer”) for a ceiling tile.
  • the facer is intended to be bonded to or otherwise interfaced with a core substrate (e.g., gypsum board, polyiso board, mineral wool insulation board). Further processing of the faced substrate (e.g., by painting) forms the ceiling tile.
  • a core substrate e.g., gypsum board, polyiso board, mineral wool insulation board.
  • the non-woven mat (as a “base mat”) will be impregnated with an inorganic filler (e.g., calcium carbonate (CaCCh) alumina tri-hydrate (ATH), kaolin) and a secondary binder to form an “impregnated mat.”
  • an inorganic filler e.g., calcium carbonate (CaCCh) alumina tri-hydrate (ATH), kaolin
  • Selection and application of the filler are controlled to achieve the desired aesthetic properties (e.g., color, smoothness) while still maintaining the necessary acoustic insulative properties (e.g., porosity).
  • a base mat and/or an impregnated mat is formed using the inventive rotary fibers described herein.
  • a blend of WUCS glass fibers (as first fibers) and rotary glass fibers (as second fibers) are used to form the base mat and/or the impregnated mat.
  • the average diameter of the second fibers is smaller than the average diameter of the first fibers and the average (processed, e.g., milled) length of the second fibers is smaller than the average (processed, e.g., chopped) length of the first fibers.
  • the mean fiber diameter distribution and/or the mean fiber length distribution of the inventive rotary fibers is much more compact (by volume) around a target fiber diameter and/or a target fiber length than with conventional rotary fibers.
  • the average fiber diameter of the first fibers is in the range of 10 pm to 11 pm; and the average fiber diameter of the second fibers is in the range of 3 pm to 4 pm.
  • the average processed fiber length of the first fibers is approximately 6 mm; and the average processed fiber length of the second fibers is in the range of 1 mm to 6 mm.
  • a conventional rotary fiber forming process will produce rotary fibers (from the fiberizer 10) having a formed length of approximately 0.5 inches (12.7 mm) to 2 inches (50.8 mm), while the inventive rotary fiber forming process (e.g., the process 300) will produce rotary fibers (from the fiberizer 10) having a formed length of approximately 3 inches (76.2 mm) to 12 inches (304.8 mm).
  • This longer fiber length provides for increased flexibility in downstream processing of the fibers, as well as more control over final product properties.
  • the first fibers and the second fibers are bound together by a polyvinyl alcohol (PVOH) binder.
  • PVOH polyvinyl alcohol
  • the inventive non-woven mat may or may not include a coating (i.e., impregnation) that penetrates into the mat.
  • the coating can be considered a combination of an inorganic mineral filler (e.g., alumina trihydrate and/or calcium carbonate), a secondary binder (i.e., PVOH and/or acrylic emulsion), and other additives (e.g., defoamer, dispersant, repellant).
  • the non-woven mat is an unfilled product that comprises the first fibers (average diameter in the range of 10 pm to 11 pm and average processed length of about 6 mm), the second fibers (average diameter in the range of 3 pm to 4 pm and average processed length in the range of 1 mm to 6 mm), and the PVOH binder, as described above, without having any coating/impregnation applied thereto.
  • the mat includes approximately 64 wt.% of the first fibers, approximately 21 wt.% of the second fibers, and approximately 15 wt.% of the binder.
  • the non-woven mat is a low-filled product that comprises the first fibers (average diameter in the range of 10 pm to 11 pm and average processed length of about 6 mm), the second fibers (average diameter in the range of 3 pm to 4 pm and average processed length in the range of 1 mm to 6 mm), and the PVOH binder, as described above, with a coating/impregnation applied thereto.
  • the mat includes approximately 32 wt.% of the first fibers, approximately 11 wt.% of the second fibers, and approximately 7 wt.% of the primary PVOH binder, as well as approximately 50 wt.% of the coating (i.e., 47 wt.% inorganic filler and approximately 3 wt.% of the secondary binder).
  • the non-woven mat is a high-filled product that comprises the first fibers (average diameter in the range of 10 pm to 11 pm and average processed length of about 6 mm), the second fibers (average diameter in the range of 3 pm to 4 pm and average processed length in the range of 1 mm to 6 mm), and the PVOH binder, as described above, with a coating/impregnation applied thereto.
  • the mat includes approximately 13 wt.% of the first fibers, approximately 4 wt.% of the second fibers, and approximately 3 wt.% of the primary PVOH binder, as well as approximately 80 wt.% of the coating (i.e., 75 wt.% inorganic filler and approximately 5 wt.% of the secondary binder).
  • inventive base mat or impregnated mat is as a ceiling tile facer. It is expected that the inventive mat (at least by virtue of inclusion of the inventive rotary fibers) will contribute to properties that are important to the functionality of and/or the customer acceptance of finished ceiling tiles. These properties can include reduced cloudiness, increased opacity, and improved directionality. Directionality refers to the phenomenon of a ceiling tile having a different perceived visual effect when rotated 90 degrees. Furthermore, the inventive mat may have a smoother surface, which can reduce the amount of coating needed to obtain a desired aesthetic. Further still, the inventive mat may have a desired surface porosity, such that the ceiling tile exhibits acceptable acoustical performance.
  • the cloud-runner Mottling Meter Control of Paint Mottling (the “cloud runner” device), manufactured by BYK-Gardner GmbH of Geretsried, Germany was used.
  • the cloud runner device is typically marketed to the automotive industry for measurement of paint mottling (e.g., spots, blotches, clouds) of automotive finishes.
  • the cloud runner device can measure irregular lightness variations by simulating visual evaluation under three different observing angles, as shown in the diagram 600 of FIG. 6, and characterizes clouds/mottles by their size and visibility. In this manner, the cloud runner device proved to be an effective tool for quantifying and ranking the cloudiness of ceiling tile surfaces.
  • the cloud runner device is able to measure different size “clouds” (i.e., color variations/deviations) and provide a numerical rating/value indicative of the cloudiness of the sample. As shown in Table 8, each range of clouds need a minimum scan length to be measured.
  • the cloud runner device supports scan lengths of 10 cm to 100 cm, selectable in 1 cm steps.
  • clouds within the Md, Me, Mf, and Mg were measured.
  • the data was gathered using the cloud runner device with a scan length set at 23 cm. Five passes at this scan length were done over the width or length of an A3 (297 mm x 420 mm) or A4 (210 mm x 297 mm) sized sample to obtain 1 measurement.
  • the unpainted and unfilled sample sheets were measured over a black background.
  • samples including 6.5 pm non-rotary WUCS glass fibers were compared to samples including 3.5 pm inventive rotary-formed glass fibers at different loading percentages (%) and across all three viewing angles (15°, 45°, and 60°) for the cloud runner device.
  • the inclusion of the 3.5 pm inventive rotary fibers reduced the cloudiness rating for both smaller (9 mm to 13 mm and 11 mm to 24 mm) and larger (19 mm to 42 mm and 33 mm to 72 mm) clouds more effectively than the 6.5 pm WUCS fibers.
  • the 3.5 pm inventive rotary fibers reduced the cloudiness rating for both the smaller and larger clouds, the 6.5 pm WUCS fibers did not have much effect on the larger clouds.
  • the 3.5 pm inventive rotary fibers showed a much steeper reduction in the cloudiness rating versus the loading level (%), as compared to the 6.5 pm WUCS fibers.
  • the 3.5 pm inventive rotary fibers showed approximately a 35% reduction in the cloudiness rating for 9 mm to 13 mm clouds, while the 6.5 pm WUCS fibers at the same loading % only showed a reduction of approximately 18% with respect to the cloudiness rating for clouds within this size range.
  • the 3.5 pm inventive rotary fibers showed approximately a 45% reduction in the cloudiness rating for 33 mm to 72 mm clouds, while the 6.5 pm WUCS fibers at the same loading % showed no significant reduction (0%) with respect to clouds within this size range.
  • a ceiling tile with acceptable aesthetic properties can be achieved at a lower fiber loading of the 3.5 pm inventive rotary fibers, as compared to the 6.5 pm WUCS fibers.
  • each of the smaller, medium, and larger diameter inventive rotary glass fibers were added to the 10 pm to 11 pm WUCS glass fibers at different loading percentages (%) to create ceiling tile facer samples that were measured across all three viewing angles (15°, 45°, and 60°) for the cloud runner device.
  • the inventive rotary fibers are more efficient than other microfibers at reducing large clouds. From the above measurements, it was determined that 13.54 wt.% of the mat per pm of the conventional microfibers would be needed to achieve the target, while 8.96 wt.% of the mat per pm of the inventive microfibers would be needed to achieve the target. Thus, if the conventional microfiber and the inventive microfiber were made to have the same average fiber diameter, the inventive rotary fibers would require less material to impart the same cloudiness reduction.
  • any particular element recited as relating to a particularly disclosed embodiment should be interpreted as available for use with all disclosed embodiments, unless incorporation of the particular element would be contradictory to the express terms of the embodiment.
  • the scope of the general inventive concepts presented herein are not intended to be limited to the particular exemplary embodiments shown and described herein. From the disclosure given, those skilled in the art will not only understand the general inventive concepts and their attendant advantages, but will also find apparent various changes and modifications thereto. For example, notwithstanding the illustrative embodiments often disclosing the use of glass fibers, the general inventive concepts may encompass fibers made of materials other than glass, such as mineral wool or stone wool. It is sought, therefore, to cover all such changes and modifications as fall within the spirit and scope of the general inventive concepts, as described and/or claimed herein, and any equivalents thereof.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

Est divulgué un procédé de formation de fibres par rotation (par exemple, des fibres de verre) qui ont une répartition des diamètres et/ou des longueurs de la fibre plus uniforme ou limitée. Les fibres formées par rotation ayant la/les distribution(s) de propriétés améliorée(s) favorisent la formation de mats fibreux non tissés améliorés et de produits formés à partir des mats (par exemple, un revêtement pour une dalle de plafond). Du fait que le mat non tissé est plus uniforme/cohérent, le revêtement de dalle de plafond peut avoir moins de défauts visuels.
PCT/US2023/084218 2023-12-15 2023-12-15 Fibres de verre formées par rotation Pending WO2025128116A1 (fr)

Priority Applications (3)

Application Number Priority Date Filing Date Title
PCT/US2023/084218 WO2025128116A1 (fr) 2023-12-15 2023-12-15 Fibres de verre formées par rotation
PCT/US2024/060014 WO2025128983A1 (fr) 2023-12-15 2024-12-13 Parement de dalle de plafond
PCT/US2024/060008 WO2025128979A1 (fr) 2023-12-15 2024-12-13 Fibres de verre formées par rotation

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PCT/US2024/060014 Pending WO2025128983A1 (fr) 2023-12-15 2024-12-13 Parement de dalle de plafond
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US3972702A (en) 1973-07-30 1976-08-03 Owens-Corning Fiberglas Corporation Method and apparatus for producing fibers from heat-softenable materials
GB1469501A (en) * 1974-05-28 1977-04-06 Owens Corning Fiberglass Corp Method and apparatus for producing glass fibres
US4207086A (en) 1977-12-23 1980-06-10 Owens-Corning Fiberglas Corporation Stream feeder apparatus
US5582841A (en) 1995-05-04 1996-12-10 Owens Corning Fiberglas Technology, Inc. Fiber manufacturing spinner and fiberizer
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US20050191590A1 (en) * 2002-02-13 2005-09-01 Saint Gobain Isover Internal combustion burner, particularly for drawing mineral fibers
US20070000286A1 (en) * 2005-07-01 2007-01-04 Gavin Patrick M Fiberizing spinner for the manufacture of low diameter, high quality fibers
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US8250884B2 (en) 2007-03-21 2012-08-28 Owens Corning Intellectual Capital, Llc Rotary fiberizer
US20190241460A1 (en) * 2008-02-28 2019-08-08 Saint-Gobain Isover Product based on mineral fibers and process for obtaining it
US20230227724A1 (en) * 2020-09-24 2023-07-20 Unifrax I Llc Insulation material including inorganic fibers and endothermic material

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US9267238B2 (en) * 2012-07-25 2016-02-23 Johns Manville Glass fiber reinforced facer mat
WO2015057763A1 (fr) * 2013-10-16 2015-04-23 Ocv Intellectual Capital, Llc Mat non-tissé souple
KR20220024473A (ko) * 2019-06-13 2022-03-03 오웬스 코닝 인텔렉츄얼 캐피탈 엘엘씨 지붕 단열을 위한 보행용 페이서 매트

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Publication number Priority date Publication date Assignee Title
US3653860A (en) 1970-05-25 1972-04-04 Owens Corning Fiberglass Corp Apparatus for processing a plurality of strand-like materials
US3972702A (en) 1973-07-30 1976-08-03 Owens-Corning Fiberglas Corporation Method and apparatus for producing fibers from heat-softenable materials
GB1469501A (en) * 1974-05-28 1977-04-06 Owens Corning Fiberglass Corp Method and apparatus for producing glass fibres
US4207086A (en) 1977-12-23 1980-06-10 Owens-Corning Fiberglas Corporation Stream feeder apparatus
US5582841A (en) 1995-05-04 1996-12-10 Owens Corning Fiberglas Technology, Inc. Fiber manufacturing spinner and fiberizer
US5968645A (en) * 1996-07-11 1999-10-19 Isover Saint-Gobain Inorganic fibre material
US20050191590A1 (en) * 2002-02-13 2005-09-01 Saint Gobain Isover Internal combustion burner, particularly for drawing mineral fibers
US20070000286A1 (en) * 2005-07-01 2007-01-04 Gavin Patrick M Fiberizing spinner for the manufacture of low diameter, high quality fibers
US7856853B2 (en) 2006-02-01 2010-12-28 Owens Corning Intellectual Capital, Llc Rotary process for making mineral fiber insulation material
US7469570B2 (en) * 2006-04-11 2008-12-30 Owens Corning Intellectual Capital, Llc Calibrating system for measuring sprayed materials
US8087265B2 (en) 2006-12-28 2012-01-03 Owens Corning Intellectual Captial, Llc Fiberizing spinner including a radiation shield for the manufacture of high quality fibers
US8250884B2 (en) 2007-03-21 2012-08-28 Owens Corning Intellectual Capital, Llc Rotary fiberizer
US20190241460A1 (en) * 2008-02-28 2019-08-08 Saint-Gobain Isover Product based on mineral fibers and process for obtaining it
US20230227724A1 (en) * 2020-09-24 2023-07-20 Unifrax I Llc Insulation material including inorganic fibers and endothermic material

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WO2025128979A9 (fr) 2025-08-28
WO2025128979A1 (fr) 2025-06-19

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