Thin rotary-fiberized glass insulation and process for producing same

Abstract

A rotary fiberglass needled glass insulation product is provided. The formation of the needled insulation product may be conducted in a continuous in-line process in which the fibers are rotary formed, a binder is sprayed onto the hot fibers, the fibers are collected onto a conveyor and formed into a fiberglass pack, the fiberglass pack is passed through the oven, and the cured insulation blanket is passed through the needling apparatus. The needled insulation product may have a thickness of less than about 0.75 inches. The reduction in thickness and increased density caused by the needling process permits the production of lower thickness and higher density final insulation products. Thin insulation products made in accordance with the present invention can be manufactured using current manufacturing lines, thereby saving time and money. The needled insulation product may be utilized in household appliances, water heaters, and HVAC equipment.

Description

TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION [0001] The present invention relates generally to rotary fiberglass insulation and more particularly to a needled, bindered rotary-fiberized glass insulation product that has a reduced thickness. BACKGROUND OF THE INVENTION [0002] Conventional fibers are useful in a variety of applications including reinforcements, textiles, and acoustical and thermal insulation materials. The fibers can be formed from molten organic materials such as polymers or inorganic materials such as glass. Short, straight fibers typical of conventional thermal and acoustical insulation materials are made by rotary fiberizing techniques and are interconnected by binders. In such techniques, a molten glass material is delivered to a spinner. Fibers produced by the rotating spinner are drawn downwardly towards a conveyor by a blower. As the fibers move downward, binder is sprayed onto the fibers and the fibers are collected into a high loft, continuo...

AI Technical Summary

Benefits of technology

[0017] It is also an advantage of the invention that the thin insulation products made in accordance with the present invention can be manufactured using current manufacturing lines, thereby saving time and money.

[0018] It is another advantage of the invention that by needling the glass fiber insulation product a softer feel is provided.

[0019] It is a further advantage of the present invention that the needled insulation product has a low k value that is equivalent to or less than conventional thick rotary fiberized glass insulation blankets.

[0020] It is also an advantage of the present invention that the needled insulation product is easy to work due with to its reduced thickness and flexibility.

Problems solved by technology

However, in some circumstances, flammable liquids such as gasoline, kerosene, organic solvent based paint and cleaning supplies may be located near the gas water heater.

Vapors from these combustible liquids may accumulate on the floor of the room and some vapors may be drawn into the combustion chamber and ignited by the pilot flame or the flame within the combustion chamber, causing a backflash.

Not only does such equipment raise the overall cost of the water heater, but it also creates a water heater that requires a larger amount of storage space.

In these particular applications, rotary formed fiberglass is typically not used because without expensive modifications to the rotary fiberizing manufacturing line, the rotary fiberglass insulation blanket cannot be controlled to a thickness below one inch.

However, needling a carded or air-laid blanket of rotary glass fibers is difficult because the carding or air-laid process breaks the fibers into short lengths that are insufficient for mechanical bonding.

These additional fibers add significant cost to the final product as the second fiber is more expensive than the rotary glass fibers.

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