Abstract:
Fibrous insulation products have an aqueous binder composition that includes a carbohydrate and a crosslinking agent. In exemplary embodiments, the carbohydrate-based binder composition may also include a catalyst, a coupling agent, a process aid, a crosslinking density enhancer, an extender, a moisture resistant agent, a dedusting oil, a colorant, a corrosion inhibitor, a surfactant, a pH adjuster, and combinations thereof. The carbohydrate may be natural in origin and derived from renewable resources. Additionally, the carbohydrate polymer may have a dextrose equivalent (DE) number from 2 to 20. In at least one exemplary embodiment, the carbohydrate is a water-soluble polysaccharide such as dextrin or maltodextrin and the crosslinking agent is citric acid. Advantageously, the carbohydrates have a low viscosity and cure at moderate temperatures. The environmentally friendly, formaldehyde-free binder may be used in the formation of insulation materials and non-woven chopped strand mats. A method of making fibrous insulation products is also provided.
Abstract:
Systems, devices and methods for applying solution to a filament include an applicator for applying at least a partial coating of a solution to a filament, comprising: an applicator surface operable to at least partially coat a filament with a solution; a first container operable to supply the solution to the applicator surface, a volume of the solution in the first container corresponding to a solution level in the first container; a second container operable to contain a supply of solution in fluid communication with the solution in the first container such that the solution in the second container has a solution level indicative of the solution level of the solution in the first container; and a detector for determining the solution level within the second container, the detector operable to control an adjustment of the volume of the solution in the first container such that the solution level in the first container is maintained within a predetermined range of levels.
Abstract:
Systems, devices and methods for applying solution to a filament include an applicator for applying at least a partial coating of a solution to a filament, comprising: an applicator surface operable to at least partially coat a filament with a solution; a first container operable to supply the solution to the applicator surface, a volume of the solution in the first container corresponding to a solution level in the first container; a second container operable to contain a supply of solution in fluid communication with the solution in the first container such that the solution in the second container has a solution level indicative of the solution level of the solution in the first container; and a detector for determining the solution level within the second container, the detector operable to control an adjustment of the volume of the solution in the first container such that the solution level in the first container is maintained within a predetermined range of levels.
Abstract:
A roll for applying a sizing composition to a fan of one or more fibers, providing a shaft having a curved central axis and a sleeve covering at least a portion of the shaft, the sleeve being rotatable relative to the shaft. Each fiber of the fan of one or more fibers contacts the sleeve at an axial location of the sleeve such that each fiber of the fan of one or more fibers lies substantially in a plane perpendicular to the curved central axis of the shaft at the axial location.
Abstract:
A process for manufacturing a continuous yarn, which entails the steps of: a) continously impregnating a mat of mechanically held-together fibers with a mixture of anhydrous size in a liquid state; b) continuosly taking up at least some of the mixture of the anhydrous size by a sizing roller in contact with the mat such that a liquid film having an almost constant thickness of less than 8 &mgr;m is formed thereon; and c) depositing the mixture of the anhydrous size, using the sizing roller, on a surface of at least some of a multiplicity of continuous filaments which are formed by mechanical drawing of at least a multiplicity of streams containing molten glass flowing out of orifices of at least one device.
Abstract:
An applicator is disclosed for applying binder and/or size to glass filaments. The applicator is designed to both apply the binder and/or size to the filaments and gather the filaments into a unified strand. Due to its unique design, the applicator directs the moving strand in a direction such that the air flowing downwardly with the filaments as they are formed expels binder and/or size from the filaments and the applicator recovers this material for recirculation. This is accomplished without the need to divert the air flowing downwardly with the filaments from its normal path and without the use of any external deflector shields or other means for diverting airflow.
Abstract:
An apparatus for producing glass fibers is disclosed. The apparatus includes means associated with an applicator for moving the glass filaments from the surface of the applicator when waste filaments are being produced such that the glass filaments are brought into contact with the application surface for coating the filaments with a binder and/or size only when production quality strand is being produced. This substantially reduces binder and/or size consumption and prevents the operator of the forming position from coming into physical contact with the binder and/or size coated strand.
Abstract:
An apparatus for producing glass fibers is disclosed. The apparatus includes means associated with a cover means for an applicator for moving the glass filaments from the surface of the applicator when waste filaments are being produced such that the glass filaments are brought into contact with the application surface for coating the filaments with a binder and/or size only when production quality strand is being produced. This substantially reduces binder and/or size consumption and prevents the operator of the forming position from coming into physical contact with the binder and/or size coated strand.
Abstract:
An apparatus and method are provided for movably supporting a binder applicator assembly of a glass fiber forming apparatus to position the applicator assembly remote from the glass fiber forming apparatus for servicing of the applicator assembly and to return the applicator assembly to its operation position. The apparatus for movably supporting the applicator assembly comprises a stationary support frame, a movable block on which the applicator is mounted, and a hydraulically-actuated device for lowering and raising the movable block and the applicator assembly.