Method for forming a web from fibrous material

Abstract

To provide a web of a fibrous material and a method for manufacturing the web of the fibrous material.SOLUTION: A binderless web can be formed in a continuous process in which a fibrous material such as glass is molten and is molded into a fiber. The fiber is molded into a web of a binderless / glass fiber or a web containing a dry type binder. The binderless webs or webs containing the dry type binders can be laminated and / or fibers composing the webs can be mechanically entangled by needling, for instance.SELECTED DRAWING: Figure 3E

Description

[Technical Field] 【0001】 Related applications This application is a continuation-in-part application of U.S. Patent Application No. 13 / 632,895, filed on October 1, 2012, entitled "Method of Forming a Pack from Fibrous Materials," claiming priority to U.S. Provisional Patent Application No. 61 / 541,162, filed on September 30, 2011, entitled "Method of Forming a Pack from Fibrous Materials." U.S. Patent Application No. 13 / 632,895 and U.S. Provisional Patent Application No. 61 / 541,162 are incorporated herein by reference in their entirety. [Background technology] 【0002】 Fibrous materials can be molded into a variety of products, including webs, packs, batts, and blankets. Packs of fibrous materials can be used in many applications, including insulation and soundproofing for buildings, building components, electrical appliances, and aircraft, which are not limited examples. Packs of fibrous materials are typically formed by a process that includes a fiberizer, a molding hood, a furnace, trimming, and packaging machinery. Typical processes also include the use of a wet binder, binder recovery water, and a wash water system. [Prior art documents] [Patent Documents] 【0003】 [Patent Document 1] U.S. Patent Application Publication No. 2010 / 0151223 [Patent Document 2] U.S. Patent No. 6,527,014 [Patent Document 3] U.S. Patent No. 5,932,499 [Patent Document 4] U.S. Patent No. 5,523,264 [Patent Document 5] U.S. Patent No. 5,055,428 [Patent Document 6] U.S. Patent No. 4,266,960 [Patent Document 7] U.S. Patent No. 5,603,743 [Patent Document 8] U.S. Patent No. 4,263,033 [Patent Document 9] International Publication No. 95 / 30036 [Patent Document 10] U.S. Patent Application Publication No. 2008 / 0246379 [Patent Document 11] U.S. Patent No. 3,092,529 [Patent Document 12] International Publication No. 2010 / 002958 [Patent Document 13] U.S. Patent No. 7,329,456 [Patent Document 14] U.S. Patent No. 7,294,218 [Overview of the project] 【0004】 This application discloses numerous exemplary embodiments of fibrous material webs and methods for manufacturing fibrous material webs. A binderless web or a web containing a dry binder can be formed in a continuous process in which a fibrous material such as glass is melted and formed into fibers. The fibers are formed into a binderless glass fiber web or a web containing a dry binder. The binderless web or the web containing a dry binder can be laminated, and / or the fibers constituting the web can be mechanically entangled, for example, by needling. 【0005】 The advantages of the web, the bat, and other methods for manufacturing the web and the bat will become apparent to those skilled in the art upon reading the following detailed description in consideration of the attached drawings. [Brief explanation of the drawing] 【0006】 [Figure 1A]A flowchart of an exemplary embodiment of a method for forming a binderless laminated web or pack of glass fibers. [Figure 1B] A flowchart of an exemplary embodiment of a method for forming a binderless entangled web of glass fibers. [Figure 1C] A flowchart of an exemplary embodiment of a method for forming a binderless laminated and entangled web or pack of glass fibers. [Figure 2A] A flowchart of an exemplary embodiment of a method for forming a laminated web or pack of glass fibers including a dry binder. [Figure 2B] A flowchart of an exemplary embodiment of a method for forming a binderless entangled web of glass fibers including a dry binder. [Figure 2C] A flowchart of an exemplary embodiment of a method for forming a binderless laminated and entangled web or pack of glass fibers including a dry binder. [Figure 2D] A flowchart of an exemplary embodiment of a method for forming a binderless laminated and entangled web or pack of glass fibers including a dry binder. [Figure 3A] A schematic diagram of an exemplary apparatus for forming a binderless laminated web or pack of glass fibers. [Figure 3B] A schematic diagram of an exemplary apparatus for forming a binderless entangled web of glass fibers. [Figure 3C] A schematic diagram of an exemplary apparatus for forming a binderless laminated and entangled web or pack of glass fibers. [Figure 3D] A schematic diagram of an exemplary apparatus for forming a binderless laminated and entangled web or pack of glass fibers. [Figure 3E] A schematic diagram of an exemplary storage configuration. [Figure 3F] A schematic diagram of an exemplary diverting configuration. [Figure 4] A schematic diagram of a forming apparatus for forming a web of glass fibers. [Figure 5]This is a schematic diagram of an exemplary apparatus for forming a web or pack of glass fibers including a dry binder. [Figure 5A] This is a schematic diagram of an exemplary apparatus for forming a web or pack of glass fibers including a dry binder. [Figure 5B] This is a schematic diagram of an exemplary apparatus for forming a web or pack of glass fibers including a dry binder. [Figure 6] This is a schematic elevation view of the process for forming a pack of fibrous material. [Figure 7] This is a schematic plan view of the process of forming a pack from fibrous material. [Figure 8] This is a schematic diagram of an exemplary apparatus for forming a web or pack of glass fibers including a dry binder. [Figure 9A] This is a cross-sectional view drawn along line 9A-9A in Figure 8. [Figure 9B] This is a cross-sectional view drawn along line 9A-9A in Figure 8. [Figure 10A] This is a schematic diagram of an exemplary embodiment of an insulating product. [Figure 10B] This is a schematic diagram of an exemplary embodiment of an insulating product. [Figure 10C] This is a schematic diagram of an exemplary embodiment of an insulating product. [Figure 10D] This is a schematic diagram of an exemplary embodiment of an insulating product. [Figure 10E] This is a schematic diagram of an exemplary embodiment of an insulating product. [Figure 10F] This is a schematic diagram of an exemplary embodiment of an insulating product. [Figure 10G] This is a schematic diagram of an exemplary embodiment of an insulating bat or pack. [Figure 10H] This is a schematic diagram of an exemplary embodiment of an insulating bat or pack. [Figure 10I] This is a schematic diagram of an exemplary embodiment of an insulating bat or pack. [Figure 11] This is a schematic diagram of the structure used to manufacture staple fibers. [Figure 12] This is a perspective view of a cooking range. [Figure 12A] This is a perspective view of a cooking range. [Figure 13] This is a front cross-sectional view showing an exemplary embodiment of a fiberglass insulator in a range. [Figure 13A] This is a front cross-sectional view showing an exemplary embodiment of a fiberglass insulator in a range. [Figure 14] This is a side cross-sectional view showing an exemplary embodiment of a fiberglass insulator in a range. [Figure 14A] This is a side cross-sectional view showing an exemplary embodiment of a fiberglass insulator in a range. [Figure 15A] This document illustrates an exemplary embodiment of a method for producing compression-molded fiberglass products from binderless or dry-binder type fiberglass vats. [Figure 15B] This document illustrates an exemplary embodiment of a method for producing compression-molded fiberglass products from binderless or dry-binder type fiberglass vats. [Figure 15C] This document illustrates an exemplary embodiment of a method for producing compression-molded fiberglass products from binderless or dry-binder type fiberglass vats. [Figure 16A] This document illustrates an exemplary embodiment of a method for producing vacuum-formed fiberglass products from binderless or dry-binder fiberglass vats. [Figure 16B] This document illustrates an exemplary embodiment of a method for producing vacuum-formed fiberglass products from binderless or dry-binder fiberglass vats. [Figure 16C] This document illustrates an exemplary embodiment of a method for producing vacuum-formed fiberglass products from binderless or dry-binder fiberglass vats. [Modes for carrying out the invention] 【0007】 Next, the present invention will be described with reference from time to time to specific exemplary embodiments. However, the present invention can be embodied in a variety of different forms and should not be considered as being limited to the embodiments described herein. Rather, these embodiments are provided so as to make this disclosure thorough and complete and to fully convey the scope of the invention to those skilled in the art. 【0008】 Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art in which the invention pertains. The terms used herein in describing the invention are for the purpose of describing specific embodiments only and are not intended to limit the invention. Where used in the description of the invention and in the appended claims, the singular forms "a," "an," and "the" are similarly intended to include the plural form unless the context expressly indicates otherwise. 【0009】 Unless otherwise specified, all numbers used herein and in the claims to represent dimensional quantities such as length, width, and height should be understood to be modified in all cases by the term "about." Therefore, unless otherwise specified, the numerical characteristics described herein and in the claims are approximations that may vary depending on the desired characteristics sought in the embodiments of the present invention. Although the numerical ranges and parameters describing the broad scope of the present invention are approximations, the numerical values ​​described in specific examples are reported as accurately as possible. However, each numerical value inherently contains certain errors that inevitably arise from the errors found in their respective measurements. 【0010】 The description and drawings disclose an improved method for forming packs from fibrous material. Generally, the improved continuous method replaces the traditional method of applying a wet binder to a spun material with a novel method for producing a fibrous bat or pack without using any binder (i.e., a material that binds the fibers together) and / or a novel method for producing a fibrous bat or pack using a dry binder. 【0011】 The term "fibrous material" as used herein is defined to mean any material formed by stretching or thinning a molten material. The term "pack" as used herein is defined to mean any product formed of fibrous materials joined together by adhesives and / or mechanical entanglement. 【0012】 Figures 1A and 3A show a first exemplary embodiment of a continuous process or method 100 for forming a pack 300 (see Figure 3A) from a fibrous material. The dashed lines 101 surrounding the steps of method 100 indicate that this method is a continuous method, as will be described in more detail below. Although the method and pack are described in relation to glass fibers, the method and pack are equally applicable to the production of fibrous products formed from other mineral materials such as rocks, slags, and basalts, which are non-limiting examples. 【0013】 Referring to Figure 1A, the glass is melted (102). For example, Figure 3A schematically shows a melting apparatus 314. The melting apparatus 314 can supply the molten glass 312 to the fore hearth 316. The melting apparatus and fore hearth are known in the art and will not be described here. The molten glass 312 can be formed from various raw materials combined in proportions that give a desired chemical composition. 【0014】 Referring again to Figure 1A, the molten glass 312 is processed to form glass fibers 322 (104). The molten glass 312 can be processed in various different ways to form the fibers 322. For example, in the example shown in Figure 3A, the molten glass 312 flows from the fore hearth 316 to one or more rotary spinning machines 318. The rotary spinning machine 18 receives the molten glass 312 and then forms a veil 320 of glass fibers 322. As will be described in more detail later, the glass fibers 322 formed by the rotary spinning machine 318 are long and thin. Therefore, any desired rotary or other type of spinning machine can be used as long as it is sufficient to form long and thin glass fibers 322. Although the embodiment shown in Figure 3A shows one rotary spinning machine 318, it should be noted that any desired number of rotary spinning machines 318 can be used. 【0015】 Long, thin fibers can take on a variety of different forms. In exemplary embodiments, long, thin fibers have lengths ranging from about 0.25 inches to about 10.0 inches and diameters ranging from about 9HT to about 35HT. HT represents one hundred-thousandth of an inch. In exemplary embodiments, fiber 322 has lengths ranging from about 1.0 inch to about 5.0 inches and diameters ranging from about 14HT to about 25HT. In exemplary embodiments, fiber 322 has a length of about 3 inches and an average diameter of about 16-17HT. While not constrained by theory, the use of relatively long, thin fibers is thought to offer advantages such as superior heat and sound insulation performance, as well as superior strength properties such as higher tensile strength and / or higher adhesive strength, compared to packs of similar size with shorter, thicker fibers. 【0016】 In exemplary embodiments where the fibers are glass fibers, the term "binderless" means that the fibrous material, web, and / or pack includes only 99% or 100% glass, or 99% or 100% glass with an inert component added. The inert component is any material that does not bind the glass fibers together. For example, in the exemplary binderless embodiments described herein, the glass fibers 322 may optionally be coated or partially coated with a lubricant after the glass fibers have been formed. For example, the glass fibers 322 may be coated with any lubricating material that does not bind the glass fibers together. In exemplary embodiments, the lubricant may be a silicone compound such as siloxane, dimethylsiloxane, and / or silane. The lubricant may also be other materials or combinations of materials such as oil or oil emulsion. The oil or oil emulsion may be mineral oil or mineral oil emulsion and / or vegetable oil or vegetable oil emulsion. 【0017】 Glass fibers can be coated or partially coated with a lubricant in a variety of different ways. For example, the lubricant can be sprayed onto the glass fibers 322. In exemplary embodiments, the lubricant is configured to prevent damage to the glass fibers 322 as they move through the manufacturing process and come into contact with various devices and other glass fibers. The lubricant may also be useful in reducing dust in the manufacturing process. The application of optional lubricants can be precisely controlled by any desired structure, mechanism, or device. 【0018】 Referring to Figure 1A, a web 321 of fibers is formed (106) without a binder or other material that binds the fibers together. The web 321 can be formed in a variety of different ways. In the example shown in Figure 3A, glass fibers 322 are collected by an optional collecting member 324. The collecting member 324 is shaped and sized to receive the glass fibers 322. The collecting member 324 is configured to divert the glass fibers 322 to a duct 330 for transport to a downstream processing station, such as a molding device 332, which forms the web 321. In other embodiments, the glass fibers 322 can be collected on a transport mechanism (not shown) to form the web. 【0019】 The molding apparatus 332 can be configured to form a continuous dry web 321 of fibrous material having a desired thickness. In one exemplary embodiment, the dry web 321 disclosed in this application has a thickness ranging from about 0.25 inches to about 4 inches and a thickness of about 0.2 lb / ft 3 From approximately 0.6 lb / ft 3 It can have densities in the range of up to . In one exemplary embodiment, the dry web 321 disclosed in this application has a thickness ranging from about 1 inch to about 3 inches and about 0.3 lb / ft 3 From approximately 0.5 lb / ft 3 It can have densities in the range of up to . In one exemplary embodiment, the dry web 321 disclosed in this application has a thickness of about 1.5 inches and a density of about 0.4 b / ft 3It can have a density. The forming device 332 can take a variety of different forms. Any configuration for forming the dry web 321 of glass fibers can be used. 【0020】 In one exemplary embodiment, the forming device 332 includes a rotating drum having a forming surface and areas of higher or lower pressure. Referring to FIG. 4, the pressure P1 on the side 460 of the forming surface 462 where the fibers 322 are collected is higher than the pressure P2 on the opposite side 464. This pressure loss ΔP collects the fibers 322 on the forming surface 462 to form the dry web 321. In one exemplary embodiment, the pressure loss ΔP across the forming surface 462 is controlled to be a low pressure, and a web with a low weight per unit area is produced. For example, the pressure loss ΔP can be from about 0.5 inches of water to 30 inches of water. The velocity V of the air moving through the web being formed, which results in this low pressure loss ΔP, can be up to 1,000 feet per minute. 【0021】 The low weight per unit area web 321 has a weight per unit area of from about 5 to about 50 grams per square foot. The low weight per unit area web can have the above density and thickness ranges. The low weight per unit area web can have a thickness in the range from about 2.5 inches to about 4 inches, a thickness in the range from about 1 inch to about 3 inches, or a thickness of about 1.5 inches. The low weight per unit area web has a density in the range from about 0.2 lb / ft 3 to about 0.6 lb / ft 3 a density in the range from about 0.3 lb / ft 3 to about 0.5 lb / ft 3 or a density of about 0.4 lb / ft 3It can have a density of . Referring to Figure 3A, the dry web 321 comes out of the molding apparatus 332. In one exemplary embodiment, a web 321 with a low weight per unit area has a measured coefficient of variation of weight distribution per unit area = sigma(1 standard deviation) / mean(mean) × 100% = between 0% and 40%. In an exemplary embodiment, the coefficient of variation of weight distribution is less than 30%, less than 20%, or less than 10%. In one exemplary embodiment, the coefficient of variation of weight distribution is between 25% and 30%, for example, about 28%. In one exemplary embodiment, the coefficient of variation of weight distribution is about 28%. The coefficient of variation of weight distribution is obtained by measuring multiple, small, e.g., 2-inch" × 2" sample area sizes of a large, e.g., 6ft × 10ft sample using a light table. 【0022】 In the example shown in Figure 1A, the web 321 or multiple webs are stacked (108). For example, a single web 321 can be folded in the direction of the machine or cross-lapped at a 90-degree angle to the direction of the machine to form a stacked web 350. In another embodiment, the web can be cut into sections and these sections can be stacked on top of each other to form a stacked web. In yet another exemplary embodiment, one or more double spinning machines 318 and forming apparatus 332 can be mounted so that two or more webs are produced in parallel and continuously. The parallel webs are then stacked on top of each other to form a stacked web. 【0023】 In one exemplary embodiment, the stacking mechanism 332 is a folding mechanism or cross-folding mechanism that functions in conjunction with a conveyor 336. The conveyor 336 is configured to move in the machine direction indicated by arrow D1. The folding mechanism or cross-folding mechanism is configured to receive a continuous web 321 and stack alternating layers of the continuous web on the first conveyor 336 when the first conveyor is moving in direction D1. In the stacking process, the folding mechanism 334 will form alternating layers in the machine direction indicated by arrow D1, or the cross-folding mechanism 334 will form alternating layers in the machine cross direction. Additional webs 321 can be formed, and folding or cross-folding can be performed by additional folding or cross-folding mechanisms to increase the number of layers and processing capacity. 【0024】 In one exemplary embodiment, the cross-folding mechanism is configured to precisely control the movement of the continuous web 321 so as not to damage the continuous web, thereby accumulating the continuous web on the conveyor 336. The cross-folding mechanism can include any desired structure and can be configured to operate in any desired manner. In one exemplary embodiment, the cross-folding mechanism includes a head (not shown) configured to move back and forth at 90 degrees with respect to the machine direction D1. In this embodiment, the speed of the movable head is adjusted so that the movement of the head in both directions of the machine cross direction is substantially the same, thereby resulting in uniformity of the resulting fibrous body layer. In an exemplary embodiment, the cross-folding mechanism includes a vertical conveyor (not shown) configured to be centered on the centerline of the conveyor 336. The vertical conveyor is further configured to swing above the conveyor 336 by a pivot mechanism to accumulate the continuous web on the conveyor 336. While several examples of cross-folding mechanisms have been described above, it should be recognized that the cross-folding mechanism can be other structures, mechanisms, or devices or combinations thereof. 【0025】 The laminated web 350 can have any desired thickness. The thickness of the laminated web is a function of several variables. Firstly, the thickness of the laminated web 350 is a function of the thickness of the continuous web 321 formed by the forming apparatus 332. Secondly, the thickness of the laminated web 350 is a function of the rate at which the lamination mechanism 334 deposits the continuous web 321 onto the conveyor 336. Thirdly, the thickness of the laminated web 334 is a function of the speed of the conveyor 336. In the illustrated embodiment, the laminated web 350 has a thickness ranging from about 0.1 inches to about 20.0 inches. In an exemplary embodiment, the cross-folding mechanism 334 can form a laminated web 350 having 1 to 60 layers. Optionally, the cross-folding mechanism can be made adjustable, thereby allowing the cross-folding mechanism 334 to form a pack having any desired width. In a particular embodiment, the pack can have a general width ranging from about 98.0 inches to about 236.0 inches. 【0026】 In one exemplary embodiment, the laminated web 350 is manufactured in a continuous process as shown by the dashed box 101 in Figure 1A. The fibers produced by the spinning machine 318 are fed directly to the forming machine 332 (i.e., the fibers are not collected, packaged, and then unpacked for use in a remote forming machine). The web 321 is supplied directly to the laminating machine 352 (i.e., the web is not formed, wound up, and then unwound for use in a remote laminating machine 352). In an exemplary embodiment of the continuous process, each process (forming and lamination in Figure 1A) is connected to the spinning process, so that the fibers from the spinning machine are used by the other processes without being stored for later use. In another exemplary embodiment of the continuous process, one or more spinning machines 318 may have a greater processing capacity than required by the forming machine 332 and the laminating machine 352. Therefore, the fibers do not necessarily need to be continuously supplied to the forming machine 332 by the spinning machine 318 to make the process continuous. For example, the spinning machine 318 can produce batches of fibers that are accumulated in the same factory in a continuous process and supplied to the molding machine 332, but these fibers are not compressed, shipped, or repacked in the continuous process. In another example of a continuous process, the fibers produced by the spinning machine 318 can be alternately distributed to the molding machine 332, to another molding machine, or for some other use or product. In another example of a continuous process, a portion of the fibers produced by the spinning machine 318 is continuously distributed to the molding machine 332, and the remaining portion of the fibers is distributed to another molding machine or for some other use or product. 【0027】 Figure 3E shows that in any of the examples shown in Figures 3A-3D, the fibers 322 can be collected by the accumulator 390. Arrow 392 indicates that the fibers 322 are supplied to the molding apparatus 332 by the accumulator 390 in a controlled manner. The fibers 322 can remain in the accumulator 390 for a predetermined time to cool before being supplied to the molding apparatus 332. In one exemplary embodiment, the fibers 322 are supplied to the molding apparatus 332 by the accumulator 390 at the same rate at which the fibers 322 are supplied to the accumulator 390. Therefore, in this exemplary embodiment, the time the fibers remain in the accumulator to cool is determined by the amount of fibers 322 in the accumulator. In this example, the residence time is the amount of fibers in the accumulator divided by the rate at which the fibers are supplied to the molding apparatus 332 by the accumulator. In another exemplary embodiment, the accumulator 390 can selectively start and stop the supply of fibers and / or adjust the rate at which the fibers are supplied. 【0028】 Figure 3F shows that in any of the examples shown in Figures 3A-3D, the fibers 322 can be selectively distributed between the molding station 332 and the second molding station 332' by the diverting mechanism 398. In one exemplary embodiment, the embodiment shown in Figure 3A-3D may have both a accumulator 390 and a diverting mechanism 398. 【0029】 In one exemplary embodiment, the web 321 is relatively thick and has a low weight per square foot, yet the continuous process still has high processing capacity, and all the fibers produced by the spinning machine are used to make the web. For example, a single layer of web 321 may have a weight per square foot of about 5 to about 50 grams per square foot. Webs with a low weight per square foot may have the aforementioned range of density and thickness. High-yield continuous processes can produce at yields between about 750 lbs / hr and 1500 lbs / hr, for example, at least 900 lbs / hr or at least 1250 lbs / hr. The laminated web 350 can be used for a variety of different applications. 【0030】 Figures 1B and 3B show a second exemplary embodiment of method 150 for forming a pack 300 (see Figure 3B) from a fibrous material without using a binder. The dashed lines 151 surrounding the steps of method 150 indicate that this method is a continuous method. Referring to Figure 1B, the glass is melted (102). The glass can be melted as described above with respect to Figure 3A. The molten glass 312 is processed to form glass fibers 322 (104). The molten glass 312 can be processed as described above with respect to Figure 3A to form the fibers 322. A web 321 of fibers is formed without a binder or other material that binds the fibers together (106). The web 321 can be formed as described above with respect to Figure 3A. 【0031】 Referring to Figure 1B, the fibers 322 of the web 321 are mechanically entangled (202) to form an entangled web 352 (see Figure 3B). Referring to Figure 3B, the fibers of the web 321 can be mechanically entangled by an entanglement mechanism 345, such as a needling device. The entanglement mechanism 345 is configured to entangle the individual fibers 322 of the web 321. By entangling the glass fibers, the fibers of the web are bound together. The entanglement improves the mechanical properties of the web, such as tensile strength and shear strength. In the illustrated embodiment, the entanglement mechanism 345 is a needling mechanism. In other embodiments, the entanglement mechanism 345 may include other structures, mechanisms, or devices, or combinations thereof, including, but not limited to, stitching mechanisms. 【0032】 The entangled web 352 can have any desired thickness. The thickness of the entangled web is a function of the thickness of the continuous web 321 formed by the forming apparatus 332 and the amount of compression of the continuous web 321 by the entanglement mechanism 345. In exemplary embodiments, the entangled web 352 has a thickness ranging from about 0.1 inches to about 2.0 inches. In exemplary embodiments, the entangled web 352 has a thickness ranging from about 0.5 inches to about 1.75 inches. For example, in one exemplary embodiment, the thickness of the entangled web is about 1 / 2”. 【0033】 In one exemplary embodiment, the entangled web 352 is produced in a continuous process 151. The fibers produced by the spinning machine 318 are fed directly to the forming device 332 (i.e., the fibers are not collected, packaged, and then unpacked for use in a remote forming device). The web 321 is supplied directly to the entanglement device 345 (i.e., the web is not formed, wound up, and then unwound for use in a remote entanglement device 345). The entangled web 352 can be used for a variety of different applications. In an exemplary embodiment of the continuous process, each process (forming and entanglement in Figure 1B) is connected to the spinning process, so that the fibers from the spinning machine are used by other processes without being stored for later use. In another exemplary embodiment of the continuous process, one or more spinning machines 318 may have a greater processing capacity than required by the forming device 332 and / or entanglement device 345. Therefore, the fibers do not necessarily need to be continuously supplied to the molding apparatus 332 by the spinning machine 318 in order to continue the process. For example, the spinning machine 318 can produce batches of fibers that are accumulated in the same factory and supplied to the molding apparatus 332 in a continuous process, but these fibers are not compressed, shipped, or repacked in the continuous process. In another example of a continuous process, the fibers produced by the spinning machine 318 can be alternately distributed to the molding apparatus 332, to another molding apparatus, or for some other use or product. In another example of a continuous process, a portion of the fibers produced by the spinning machine 318 is continuously distributed to the molding apparatus 332, and the remaining portion of the fibers is distributed to another molding apparatus or for some other use or product. 【0034】 Figure 3D shows an exemplary embodiment of an apparatus similar to the embodiment shown in Figure 3B for forming a single-layer high-density pack. For example, the embodiment shown in Figure 3D can produce a pack 300 with a higher density than the highest density pack produced by the embodiment shown in Figure 3B. The apparatus in Figure 3D corresponds to the embodiment in Figure 3B, but differs in that a compression mechanism 375 is provided between the forming station 332 and the entanglement mechanism 345, and / or the entanglement mechanism 345 includes a compression mechanism. The compression mechanism 375 compresses the web 321 as indicated by arrow 377 before the web 321 is sent to the entanglement mechanism 345, and / or the web 321 is compressed at the inlet of the compression mechanism. The formed entangled web 352 has high density. The compression mechanism can take a variety of different forms. Examples of the compression mechanism 345 include, but are not limited to, rollers, belts, rotary tackers, additional needling mechanisms, perforated belts with negative pressure applied to the side of the belt opposite the entangled web 352 (see a similar example shown in Figure 4), any mechanism including any combination of the listed compression mechanisms, any mechanism including any combination of any features of the listed compression mechanisms. Any configuration for compressing the web can be used. When the entanglement mechanism 345 includes a compression mechanism, the compression mechanism 375 can be omitted in the embodiment of the single-layer high-density pack 300 shown in Figure 3D. The compression performed by the compression mechanism 375 and / or the entanglement mechanism 345 can be any combination of compression and / or needling, which compresses the pack in addition to entangling the fibers. Examples of compression and needling arrangements for manufacturing high-density packs include, but are not limited to, compression with rollers followed by needling, two-step needling, compression with rollers followed by two-step needling, three-step needling, pre-needling-from-top-from-bottom needling, pre-needling-from-bottom needling-from-top needling, compression with rollers-from-top-from-bottom needling, and compression with rollers-from-bottom needling-from-top needling. 【0035】 The high-density entangled web 352 in Figure 3D can have any desired thickness. The thickness of the entangled web is a function of the thickness of the continuous web 321 formed by the forming apparatus 332 and the amount of compression of the continuous web 321 by the compression mechanism 375 and the entanglement mechanism 345. In an exemplary embodiment, the high-density entangled web 352 in Figure 3D has a thickness ranging from about 0.1 inches to about 5 inches. In an exemplary embodiment, the high-density entangled web 352 has a thickness ranging from about 0.250 inches to about 3.0 inches. In an exemplary embodiment, the high-density entangled web has a load of 0.4 lb / ft 3 From approximately 12 lb / ft 3 It has densities in the range up to . In one exemplary embodiment, the high-density entangled web 352 of Figure 3D is manufactured in a continuous process in the same manner as described with respect to Figure 3B. 【0036】 Figures 1C and 3C show another exemplary embodiment of method 170 for forming a pack 370 (see Figure 3C) from a fibrous material without using a binder. Referring to Figure 1C, the glass is melted (102). The dashed line 171 surrounding the steps of method 170 indicates that this method is a continuous method. The glass can be melted as described above with respect to Figure 3A. Referring again to Figure 1C, the molten glass 312 is processed to form glass fibers 322 (104). The molten glass 312 can be processed as described above with respect to Figure 3A to form the fibers 322. Referring to Figure 1C, a web 321 of fibers is formed without a binder or other material that binds the fibers together (106). The web 321 can be formed as described above with respect to Figure 3A. Referring to Figure 1C, the web 321 or multiple webs are laminated (108). The web 321 or multiple webs can be laminated as described above with respect to Figure 3A. Referring to Figure 1C, the fibers 322 of the laminated web 350 are mechanically entangled (302) to form an entangled pack 370 of the laminated web. 【0037】 Referring to Figure 3C, the fibers of the laminated web 350 can be mechanically entangled by an entanglement mechanism 345, such as a needling device. The entanglement mechanism 345 is configured to entangle the individual fibers 322 that form the layers of the laminated web. By entangling the glass fibers 322, the fibers of the laminated web 350 are bound together to form a pack. Mechanical entanglement improves mechanical properties such as tensile strength and shear strength. In the illustrated embodiment, the entanglement mechanism 345 is a needling mechanism. In other embodiments, the entanglement mechanism 345 may include other structures, mechanisms, or devices, or combinations thereof, including, in non-limiting examples, a stitching mechanism. 【0038】 The entangled pack 370 of the laminated web 350 can have any desired thickness. The thickness of the entangled pack is a function of several variables. Firstly, the thickness of the entangled pack is a function of the thickness of the continuous web 321 formed by the molding device 332. Secondly, the thickness of the entangled pack 370 is a function of the rate at which the folding or cross-folding mechanism 334 deposits the layers of the continuous web 321 onto the conveyor 336. Thirdly, the thickness of the entangled pack 370 is a function of the speed of the conveyor 336. Fourthly, the thickness of the entangled pack 370 is a function of the amount of compression of the laminated web 350 by the entanglement mechanism 345. The entangled pack 370 can have a thickness ranging from about 0.1 inches to about 20.0 inches. In an exemplary embodiment, the entangled pack 370 can have from 1 to 60 layers. Each entangled web layer 352 can be 0.1 to 2 inches thick. For example, each entangled web layer can be approximately 0.5 inches thick. 【0039】 In one exemplary embodiment, the entangled pack 370 is manufactured in a continuous process. The fibers produced by the spinning machine 318 are fed directly to the forming machine 332 (i.e., the fibers are not collected, packaged, and then unpacked for use in a remote forming machine). The web 321 is fed directly to the laminating machine 352 (i.e., the web is not formed, wound up, and then unwound for use in a remote laminating machine 352). The laminated web 350 is fed directly to the entanglement machine 345 (i.e., the laminated web is not formed, wound up, and then unwound for use in a remote entanglement machine 345). In the exemplary embodiment of the continuous process, each process (forming, lamination, and entanglement in Figure 1C) is connected to the spinning process, so that the fibers from the spinning machine are used by the other processes without being stored for later use. In another exemplary embodiment of the continuous process, one or more spinning machines 318 may have a greater processing capacity than required by the forming machine 332, the laminating machine 352, and / or the entanglement machine. Therefore, the fibers do not necessarily need to be continuously supplied to the forming machine 332 by the spinning machine 318 in order to continue the process. For example, the spinning machine 318 can produce batches of fibers that are accumulated in the same factory in the continuous process and supplied to the forming machine 332, but these fibers are not compressed, shipped, and repacked in the continuous process. In another example of the continuous process, the fibers produced by the spinning machine 318 can be alternately distributed to the forming machine 332 and to another forming machine, or for some other use or product. In another example of the continuous process, a portion of the fibers produced by the spinning machine 318 is continuously distributed to the forming machine 332, and the remainder of the fibers is distributed to another forming machine, or for some other use or product. 【0040】 In exemplary embodiments, the laminated web entanglement pack 370 is made from a web 321 or multiple webs that are relatively thick and have a low weight per unit area, yet the continuous process still has high processing capacity, and all fibers produced by the spinning machine are used to make the entanglement pack. For example, a single layer of web 321 may have the aforementioned weight per unit area, thickness, and density. High-yield continuous processes can produce between approximately 750 lbs / hr and 1500 lbs / hr, for example, at least 900 lbs / hr or at least 1250 lbs / hr. In exemplary embodiments, the combination of the high web processing capacity of the continuous process and mechanical entanglement such as needling is facilitated by lamination of the web 321, such as web folding or cross-folding. By laminating the web 321, the linear speed of the material moving through the laminating device is slower than the speed at which the web is formed. For example, in the continuous process, a two-layer web will move through the entanglement device 345 at half the speed at which the web is formed (one-third for a three-layer web, etc.). This reduction in speed enables a continuous process in which high-volume, low-weight-per-area webs 321 are formed and converted into multi-layer mechanically entangled packs 370. The entangled packs 370 of the laminated webs can be used for a variety of different applications. 【0041】 In exemplary embodiments, lamination and entanglement of long, thin fibers result in a strong web 370. For example, the entanglement of long, thin glass fibers described in this application results in a laminated entangled web having high tensile strength and high adhesive strength. Tensile strength is the strength of the web 370 when it is pulled in the direction of its length or width. Adhesive strength is the strength of the web when it is pulled apart in the direction of its thickness. 【0042】 Tensile strength and adhesive strength can be tested in a variety of different ways. In one exemplary embodiment, a machine such as an Instron machine pulls the web 370 at a constant speed (12 inches per second in the example described later) and measures the amount of force required to pull the web apart. The force required to pull the web apart is recorded, including the peak force applied to the web before it tears or is damaged. 【0043】 In one method of testing tensile strength, the longitudinal tensile strength is measured by fixing the ends of the web along the width of the web, pulling the web 370 along the length of the web at a constant speed (12 inches per second in the example below) using a machine, and recording the peak force applied in the longitudinal direction of the web. The widthwise tensile strength is measured by fixing the sides of the web along the width of the web, pulling the web 370 along the width of the web at a constant speed (12 inches per second in the example below), and recording the peak force applied. The tensile strength of the sample is determined by taking the average of the longitudinal tensile strength and the widthwise tensile strength. 【0044】 In one method of testing adhesive strength, a sample of a predetermined size (6"×6") is prepared. Each side of the sample is bonded to a substrate, for example, by adhesive. The substrates on both sides of the sample are pulled apart by a machine at a constant speed (12 inches per second in the example below), and the applied peak force is recorded. Dividing the applied peak force by the area of ​​the sample (6"×6") in the example below gives the adhesive strength in units of force / area. 【0045】 The following examples are presented to demonstrate the increased strength of the layered entangled web 370. In these examples, no binder is included at all; that is, neither aqueous nor dry binders are included. These examples do not limit the scope of the invention unless expressly stated in the claims. Examples of layered entangled webs having 4, 6, and 8 layers are presented. However, the layered entangled web 370 can have any number of layers. The length, width, thickness, number of folds, and weight of the layered entangled web 370 sample can be varied depending on the application of the web 370. In the dense single-layer embodiment shown in Figure 3D, the single-layer high-density pack 300 can have a weight per square foot that is higher, for example twice or more, than the examples of the same thickness in the following six paragraphs. 【0046】 In one exemplary embodiment, a 6-inch × 12-inch sample of Web 370 has multiple layers, e.g., two folds (i.e., four layers), is between 0.5 inches and 2.0 inches thick, has a weight per square foot between 0.1 lbs / sqft and 0.3 lbs / sqft, has a tensile strength greater than 3 lbf, and has a tensile strength-to-weight ratio greater than 40 lbf / lbm, e.g., about 40 to about 120 lbf / lbm. In an exemplary embodiment, the adhesive strength of this sample is greater than 0.1 lbs / sqft. In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 5 lbf. In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 7.5 lbf. In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 10 lbf. In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 12.5 lbf. In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 13.75 lbf. In exemplary embodiments, the tensile strength of the sample described in this paragraph is between 3 lbf and 15 lbf. In exemplary embodiments, the adhesive strength of the sample described in this paragraph is greater than 2 lbs / sqft. In exemplary embodiments, the adhesive strength of the sample described in this paragraph is greater than 5 lbs / sqft. In exemplary embodiments, the adhesive strength of the sample described in this paragraph is greater than 10 lbs / sqft. In exemplary embodiments, the adhesive strength of the sample described in this paragraph is greater than 15 lbs / sqft. In exemplary embodiments, the adhesive strength of the sample described in this paragraph is greater than 20 lbs / sqft. In exemplary embodiments, the tensile strength of the sample described in this paragraph is greater than 5 lbf and the adhesive strength is greater than 2 lbs / sqft. In exemplary embodiments, the tensile strength of the sample described in this paragraph is greater than 7.5 lbf and the adhesive strength is greater than 7.5 lbs / sqft. In exemplary embodiments, the tensile strength of the sample described in this paragraph is greater than 10 lbf and the adhesive strength is greater than 10 lbs / sqft. In exemplary embodiments, the tensile strength of the sample described in this paragraph is greater than 12.5 lbf, and the adhesive strength is greater than 15 lbs / sqft.In exemplary embodiments, the tensile strength of the sample described in this paragraph is greater than 13.75 lbf, and the adhesive strength is greater than 20 lbs / sqft. In exemplary embodiments, the tensile strength of the sample described in this paragraph is between 3 lbf and 15 lbf, and the adhesive strength is between 0.3 lbs / sqft and 30 lbs / sqft. 【0047】 In one exemplary embodiment, a 6-inch × 12-inch sample of Web 370 has multiple layers, e.g., two folds (i.e., four layers), is between 0.5 inches and 1.75 inches thick, has a weight per square foot between 0.12 lbs / sqft and 0.27 lbs / sqft, has a tensile strength greater than 3 lbf, a tensile strength-to-weight ratio greater than 40 lbf / lbm, e.g., about 40 to about 120 lbf / lbm, and an adhesive strength greater than 1 lb / sqft. In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 5 lbf. In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 7.5 lbf. In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 10 lbf. In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 12.5 lbf. In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 13.75 lbf. In exemplary embodiments, the tensile strength of the sample described in this paragraph is between 3 lbf and 15 lbf. In exemplary embodiments, the adhesive strength of the sample described in this paragraph is greater than 2 lbs / sqft. In exemplary embodiments, the adhesive strength of the sample described in this paragraph is greater than 5 lbs / sqft. In exemplary embodiments, the adhesive strength of the sample described in this paragraph is greater than 10 lbs / sqft. In exemplary embodiments, the adhesive strength of the sample described in this paragraph is greater than 15 lbs / sqft. In exemplary embodiments, the adhesive strength of the sample described in this paragraph is greater than 20 lbs / sqft. In exemplary embodiments, the tensile strength of the sample described in this paragraph is greater than 5 lbf and the adhesive strength is greater than 2 lbs / sqft. In exemplary embodiments, the tensile strength of the sample described in this paragraph is greater than 7.5 lbf and the adhesive strength is greater than 7.5 lbs / sqft. In exemplary embodiments, the tensile strength of the sample described in this paragraph is greater than 10 lbf and the adhesive strength is greater than 10 lbs / sqft. In exemplary embodiments, the tensile strength of the sample described in this paragraph is greater than 12.5 lbf, and the adhesive strength is greater than 15 lbs / sqft.In exemplary embodiments, the tensile strength of the sample described in this paragraph is greater than 13.75 lbf, and the adhesive strength is greater than 20 lbs / sqft. In exemplary embodiments, the tensile strength of the sample described in this paragraph is between 3 lbf and 15 lbf, and the adhesive strength is between 0.3 lbs / sqft and 30 lbs / sqft. 【0048】 In one exemplary embodiment, a 6-inch × 12-inch sample of Web 370 has multiple layers, e.g., two folds (i.e., four layers), is between 0.5 inches and 1.25 inches thick, has a weight per square foot between 0.2 lbs / sqft and 0.3 lbs / sqft, has a tensile strength greater than 10 lbf, and has a tensile strength-to-weight ratio greater than 75 lbf / lbm, e.g., about 75 to about 120 lbf / lbm. In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 12.5 lbf. In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 13.75 lbf. In an exemplary embodiment, the tensile strength of the sample described in this paragraph is between 3 lbf and 15 lbf. In an exemplary embodiment, the adhesive strength of the sample described in this paragraph is greater than 3 lbs / sqft. In an exemplary embodiment, the adhesive strength of the sample described in this paragraph is greater than 10 lbs / sqft. In exemplary embodiments, the adhesive strength of the sample described in this paragraph is greater than 15 lbs / sqft. In exemplary embodiments, the tensile strength of the sample described in this paragraph is greater than 10 lbf and the adhesive strength is greater than 3 lbs / sqft. In exemplary embodiments, the tensile strength of the sample described in this paragraph is greater than 12.5 lbf and the adhesive strength is greater than 10 lbs / sqft. In exemplary embodiments, the tensile strength of the sample described in this paragraph is greater than 13.75 lbf and the adhesive strength is greater than 15 lbs / sqft. 【0049】 In an exemplary embodiment, a 6-inch × 12-inch sample of Web 370 has multiple layers, e.g., three folds (i.e., six layers), is between 1.0 inch and 2.25 inch thick, has a weight per square foot between 0.15 lbs / sqft and 0.4 lbs / sqft, has a tensile strength greater than 5 lbf, and has a tensile strength-to-weight ratio greater than 40 lbf / lbm, e.g., about 40 to about 140 lbf / lbm. In an exemplary embodiment, the adhesive strength of this sample is greater than 0.1 lbs / sqft. In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 7.5 lbf. In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 10 lbf. In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 12.5 lbf. In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 13.75 lbf. In exemplary embodiments, the tensile strength of the sample described in this paragraph is between 5 lbf and 20 lbf. In exemplary embodiments, the adhesive strength of the sample described in this paragraph is greater than 0.5 lbs / sqft. In exemplary embodiments, the adhesive strength of the sample described in this paragraph is greater than 1.0 lbs / sqft. In exemplary embodiments, the adhesive strength of the sample described in this paragraph is greater than 1.5 lbs / sqft. In exemplary embodiments, the adhesive strength of the sample described in this paragraph is greater than 2.0 lbs / sqft. In exemplary embodiments, the adhesive strength of the sample described in this paragraph is greater than 2.5 lbs / sqft. In exemplary embodiments, the adhesive strength of the sample described in this paragraph is greater than 3.0 lbs / sqft. In exemplary embodiments, the tensile strength of the sample described in this paragraph is greater than 7.5 lbf and the adhesive strength is greater than 0.40 lbs / sqft. In exemplary embodiments, the tensile strength of the sample described in this paragraph is greater than 10 lbf and the adhesive strength is greater than 0.6 lbs / sqft. In exemplary embodiments, the tensile strength of the sample described in this paragraph is greater than 12.5 lbf, and the adhesive strength is greater than 0.9 lbs / sqft. In exemplary embodiments, the tensile strength of the sample described in this paragraph is between 5 lbf and 20 lbf, and the adhesive strength is between 0.1 lbs / sqft and 4 lbs / sqft. 【0050】 In one exemplary embodiment, a 6-inch × 12-inch sample of Web 370 has multiple layers, e.g., three folds (i.e., six layers), is between 1.0 inch and 1.50 inch thick, has a weight per square foot between 0.25 lbs / sqft and 0.4 lbs / sqft, has a tensile strength greater than 9 lbf, and has a tensile strength-to-weight ratio greater than 50 lbf / lbm, e.g., about 50 to about 140 lbf / lbm. In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 12.5 lbf. In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 13.75 lbf. In an exemplary embodiment, the tensile strength of the sample described in this paragraph is between 9 lbf and 15 lbf. In an exemplary embodiment, the adhesive strength of the sample described in this paragraph is greater than 0.5 lbs / sqft. In an exemplary embodiment, the adhesive strength of the sample described in this paragraph is greater than 1.0 lbs / sqft. In exemplary embodiments, the adhesive strength of the sample described in this paragraph is greater than 1.5 lbs / sqft. In exemplary embodiments, the adhesive strength of the sample described in this paragraph is greater than 2.0 lbs / sqft. In exemplary embodiments, the adhesive strength of the sample described in this paragraph is greater than 2.5 lbs / sqft. In exemplary embodiments, the adhesive strength of the sample described in this paragraph is greater than 3.0 lbs / sqft. In exemplary embodiments, the tensile strength of the sample described in this paragraph is greater than 9 lbf and the adhesive strength is greater than 0.5 lbs / sqft. In exemplary embodiments, the tensile strength of the sample described in this paragraph is greater than 12.5 lbf and the adhesive strength is greater than 1.0 lbs / sqft. In exemplary embodiments, the tensile strength of the sample described in this paragraph is greater than 13.75 lbf and the adhesive strength is greater than 2 lbs / sqft. 【0051】 In one exemplary embodiment, a 6-inch × 12-inch sample of web 370 has multiple layers, e.g., four folds (i.e., eight layers), is between 0.875 inches and 2.0 inches thick, has a weight per square foot between 0.15 lbs / sqft and 0.4 lbs / sqft, has a tensile strength greater than 3 lbf, and has a tensile strength-to-weight ratio greater than 40 lbf / lbm, e.g., about 40 to about 130 lbf / lbm. In an exemplary embodiment, the web has an adhesive strength greater than 0.3 lbs / sqft. In an exemplary embodiment, the adhesive strength of this sample is greater than 0.1 lbs / sqft. In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 7.5 lbf. In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 10 lbf. In an exemplary embodiment, the tensile strength of the sample described in this paragraph is between 3 lbf and 15 lbf. In exemplary embodiments, the adhesive strength of the sample described in this paragraph is greater than 0.5 lbs / sqft. In exemplary embodiments, the adhesive strength of the sample described in this paragraph is greater than 1.0 lbs / sqft. In exemplary embodiments, the adhesive strength of the sample described in this paragraph is greater than 2 lbs / sqft. In exemplary embodiments, the adhesive strength of the sample described in this paragraph is greater than 3 lbs / sqft. In exemplary embodiments, the adhesive strength of the sample described in this paragraph is greater than 4 lbs / sqft. In exemplary embodiments, the adhesive strength of the sample described in this paragraph is greater than 5 lbs / sqft. In exemplary embodiments, the adhesive strength of the sample described in this paragraph is greater than 10 lbs / sqft. In exemplary embodiments, the tensile strength of the sample described in this paragraph is greater than 7.5 lbf and the adhesive strength is greater than 0.5 lbs / sqft. In exemplary embodiments, the tensile strength of the sample described in this paragraph is greater than 10 lbf and the adhesive strength is greater than 1.0 lbs / sqft. In one exemplary embodiment, the tensile strength of the sample described in this paragraph is between 3 lbf and 15 lbf, and the adhesive strength is between 0.3 lbs / sqft and 15 lbs / sqft. 【0052】 In an exemplary embodiment, a 6-inch x 12-inch sample of Web 370 has multiple layers, for example, four folds (i.e., eight layers), is between 1.0 inch and 2.0 inch thick, has a weight per square foot between 0.1 lbs / sqft and 0.3 lbs / sqft, has a tensile strength greater than 9 lbf, and has a tensile strength-to-weight ratio greater than 70 lbf / lbm. In an exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than 10 lbf. In an exemplary embodiment, the adhesive strength of the sample described in this paragraph is greater than 0.5 lbs / sqft. In an exemplary embodiment, the adhesive strength of the sample described in this paragraph is greater than 1.0 lbs / sqft. In an exemplary embodiment, the adhesive strength of the sample described in this paragraph is greater than 2 lbs / sqft. In an exemplary embodiment, the adhesive strength of the sample described in this paragraph is greater than 3 lbs / sqft. In an exemplary embodiment, the adhesive strength of the sample described in this paragraph is greater than 4 lbs / sqft. In exemplary embodiments, the adhesive strength of the sample described in this paragraph is greater than 5 lbs / sqft. In exemplary embodiments, the adhesive strength of the sample described in this paragraph is greater than 10 lbs / sqft. In exemplary embodiments, the tensile strength of the sample described in this paragraph is greater than 10 lbf and the adhesive strength is greater than 5 lbs / sqft. 【0053】 In exemplary embodiments, the entangled webs fabricated according to Figures 1A-1C and 3A-3C have combined physical properties within the range shown in Table 1 below. 【0054】 [Table 1] 【0055】 Patent Document 1, and / or Patent Documents 2, 3, 4, and 5, are incorporated herein by reference in their entirety. In one exemplary embodiment, the fiber diameter and fiber length identified herein relate to the majority of fibers of a group of fibers provided by a spinning machine or other spinning machine but which have not undergone any further processing after fiber formation. In another exemplary embodiment, the fiber diameter and fiber length identified herein relate to a group of fibers provided by a spinning machine or other spinning machine but which have not undergone any further processing after fiber formation, wherein a small number or any number of fibers have their fiber diameter and / or fiber length. 【0056】 Figures 2A-2C are similar to the embodiments in Figures 1A-1C, except that the web 521 (see Figure 5) is formed using a dry or non-aqueous binder (260). Method 200 in Figure 2A generally corresponds to Method 100 in Figure 1A. Method 250 in Figure 2B generally corresponds to Method 150 in Figure 1B. Method 270 in Figure 2C generally corresponds to Method 170 in Figure 1C. 【0057】 Figure 2D shows a method 290 similar to method 270 in Figure 2C. In Figure 2D, the steps in the dashed boxes are optional. In the exemplary embodiment shown in Figure 2D, the dry binder may optionally be added to the web in step 292 and / or to the laminated web in step 294, instead of (or in addition to) before the web is formed. For example, if step 292 is included, the web can be formed without the dry binder, and then the dry binder is added to the web before and / or during lamination. If step 294 is included, the web can be formed and laminated without the dry binder, and then the dry binder is added to the laminated web. 【0058】 Referring to Figure 5, the dry binder (indicated by the large arrow) can be added to the fibers 322 and / or the web 521 at various different points in the process. Arrow 525 indicates that the dry binder can be added to the fibers 322 in or above the collection member. Arrow 527 indicates that the dry binder can be added to the fibers 322 in the duct 330. Arrow 529 indicates that the dry binder can be added to the fibers 322 in the molding apparatus 332. Arrow 531 indicates that the dry binder can be added to the web after the web 321 has left the molding apparatus 332. Arrow 533 indicates that the dry binder can be added to the web as the web 321 is being laminated by the laminating apparatus 334. Arrow 535 indicates that the dry binder can be added to the web after the web 321 has been laminated. Arrow 537 indicates that the dry binder can be added to the web 321 or the laminated web in the furnace 550. Referring to Figure 8, arrow 827 indicates that the dry binder can be added to the fibers 322 in the duct 330 at a position close to the spinning machine. Arrow 829 indicates that the dry binder can be added to the fibers 322 in the duct 330 at the duct elbow. Arrow 831 indicates that the dry binder can be added to the fibers in the duct 330 at the duct outlet end. Arrow 833 indicates that the dry binder can be added to the fibers 322 in a molding apparatus 332 having a drum-shaped molding surface. The dry binder can be added to the fibers 322 or web 321 in any way to form a web 521 having the dry binder. 【0059】 Figure 5A is similar to the embodiment in Figure 5, except that the fibers 322 are collected by the accumulator 590. Arrow 592 indicates that the fibers 322 are supplied to the molding apparatus 332 by the accumulator 590 in a controlled manner. The fibers 322 can remain in the accumulator 590 for a predetermined time to cool before being supplied to the molding apparatus 332. In one exemplary embodiment, the fibers 322 are supplied to the molding apparatus 322 by the accumulator 590 at the same rate at which the fibers 322 are supplied to the accumulator 590. Therefore, in this exemplary embodiment, the time the fibers remain in the accumulator to cool is determined by the amount of fibers 322 in the accumulator. In this example, the residence time is the amount of fibers in the accumulator divided by the rate at which the fibers are supplied to the molding apparatus 332 by the accumulator. In another exemplary embodiment, the accumulator 390 can selectively start and stop the supply of fibers and / or adjust the rate at which the fibers are supplied. The dry binder can be added to the fibers 322 at any of the locations shown in Figure 5. Furthermore, the dry binder can be applied to the fibers 322 in the accumulator as indicated by arrow 594, and / or when the fibers are transferred from the accumulator 590 to the molding apparatus 332 as indicated by arrow 596. 【0060】 Figure 5B is similar to the embodiment in Figure 5, except that the fibers 322 can be selectively distributed by the flow divider 598 between the molding apparatus 332 and the second molding apparatus, and / or for any other use. In one exemplary embodiment, the embodiment shown in Figure 5 may have both a storage unit 590 and a flow divider 598. The dry binder can be applied to the fibers 322 at any of the positions shown in Figure 5. Furthermore, the dry binder can be applied to the fibers 322 within the flow divider, as indicated by arrow 595, and / or as the fibers are transferred from the flow divider 598 to the molding apparatus 332, as indicated by arrow 597. 【0061】 In an exemplary embodiment, a dry binder is applied to the fiber 322 at a location considerably downstream from the spinning machine 318. For example, a dry binder can be applied to the fiber at a location where the temperature of the fiber and / or the temperature of the air surrounding the fiber is considerably lower than the temperature of the fiber and the surrounding air in the spinning machine. In one exemplary embodiment, a dry binder is applied at a location where the temperature of the fiber and / or the temperature of the air surrounding the fiber is lower than the melting temperature of the dry binder or the temperature at which the dry binder completely hardens or reacts. For example, a thermoplastic binder can be applied at a point in the production line where the temperature of the fiber 322 and / or the temperature of the air surrounding the fiber is lower than the melting point of the thermoplastic binder. A thermosetting binder can be applied at a point in the production line where the temperature of the fiber 322 and / or the temperature of the air surrounding the fiber is lower than the curing temperature of the thermosetting binder. That is, a thermosetting binder can be applied at a point where the temperature of the fiber 322 and / or the temperature of the air surrounding the fiber is lower than the temperature at which the thermosetting binder will react sufficiently or complete crosslinking of the thermosetting binder will occur. In one exemplary embodiment, a dry binder can be applied at a point in the production line where the temperature of the fiber 322 and / or the temperature of the air surrounding the fiber is lower than 300°F. In one exemplary embodiment, a dry binder can be applied at a point in the production line where the temperature of the fiber 322 and / or the temperature of the air surrounding the fiber is lower than 250°F. In one exemplary embodiment, the temperature of the fiber and / or the temperature of the air surrounding the fiber at the locations indicated by arrows 527, 529, 531, 533, and 535 in Figure 5 is lower than the temperature at which the dry binder will melt or completely harden. 【0062】 In one exemplary embodiment, the binder applicator is a sprayer configured for dry powder. The sprayer is configured to have an adjustable spray force, thereby allowing for greater or less permeation of the dry powder into the continuous web of fibrous material. Alternatively, the binder applicator can be other structures, mechanisms, or devices, or combinations thereof, such as a vacuum device sufficient to draw the dry binder into the continuous web of glass fibers 321. For example, the dry binder may include binder fibers supplied in bale form. The binder applicator includes a bale opener and a blower, which open the bale, separate the binder fibers from each other, and blow the binder fibers into a duct where the binder is mixed with the fiberglass fibers. The dry binder may include powder. The binder applicator may include a screw dispenser that delivers binder powder to an air nozzle, which delivers the binder powder into a duct where it is mixed with the fibers. Dry binders may include non-aqueous liquids. The binder applicator may include a nozzle that delivers liquid binder into a duct where the binder is mixed with the fibers. 【0063】 Figures 9, 9A, and 9B illustrate exemplary embodiments in which a binder 900, such as in the form of fibers or powder, fiber form, or non-aqueous liquid form, is applied by a modified air lapper 902. Air lappers are well known in the art. Examples of air lappers are disclosed in Patent Documents 6, 7, 8, and 9, which are incorporated herein by reference in their entirety. Any feature of the air lappers disclosed in Patent Documents 6, 7, 8, and 9 can be used in the air lapper 902 schematically shown in this patent application. One existing type of air lapper is the Air Full Veil Lapper (AFVL). The air lapper 902 shown in Figures 9, 9A, and 9B differs from conventional air lappers in that the air lapper is configured to apply the binder 900. 【0064】 Figure 8 shows a rotary spinning machine 318, an optional collection member 324, a duct 330, and a molding apparatus 332. The apparatus shown in Figure 8 typically also includes the melting apparatus 314 and fore hearth 316 shown in Figure 5. The melting apparatus 314, fore hearth, and other components shown in Figure 5 are omitted in Figure 8 for the sake of simplicity. 【0065】 Referring to Figure 8, the molding apparatus 332 can be configured to form a continuous web 321 of fibrous material having a desired thickness. The molding apparatus 332 can take on a variety of different forms. Any configuration can be used to form a web 321 of glass fibers. In the exemplary embodiment shown in Figure 8, the molding apparatus 332 includes a rotating drum 910 having a molding surface 462 and areas of higher pressure or lower pressure. The collection of fibers using a pressure loss ΔP across the surface 462 is as described with respect to Figure 4. 【0066】 Referring to Figures 9A and 9B, the air wrapper 902 includes a first blower 920 and a second blower 922. The air wrapper operates by airflow, for example, by alternating airflow from the first and second blowers 920 and 922. Blower 920 provides an airflow against the movement of fibers moving through the duct toward the molding surface 462, while blower 922 provides no airflow (see Figures 9A and 9B). After a controlled time, blower 922 provides an airflow against the movement of fibers moving through the duct toward the molding surface 462, while blower 920 provides no airflow. This alternating operation of the first and second blowers 920 and 922 results in a uniform distribution of fibers 322 collected on the molding surface 462. 【0067】 The air wrappers 902 shown in Figures 9, 9A, and 9B differ from conventional air wrappers in that each of the blowers 920 and 922 includes one or more binder introduction devices 904. The binder introduction devices 904 can take a variety of different forms. For example, the binder introduction device 904 can supply binder 900 into the interior 930 of the housing 932 of the blowers 920 and 922, as shown, or the binder introduction device can be positioned to introduce binder 900 into the airflow of the blowers 920 and 922. For example, the nozzle of the binder introduction device can supply binder into the airflow of the blowers 920 and 922. Examples of binder introduction devices include, but are not limited to, a nozzle and a blower that provides less airflow than the blowers 920 and 922. In one exemplary embodiment, the binder introduction device 904 injects the binder 900 into the interior 930 of the housing 932 when the blowers 920, 922 are not blowing air. Then, when the blowers 920, 922 are turned on, the interior 930 is pressurized and the binder 900 is carried out of the interior 930 into the fiber airflow. In the airflow, air from the air purifier moves the fibers to give a forming effect on the fiber distribution on the molding surface 462, and the air also injects the binder and mixes it with the fibers in the airflow. 【0068】 Referring to Figures 9A and 9B, the air ruffler 902 mixes the binder 900 into the fibers 332, which then gather on the molding surface 462 to form the web 321. In one exemplary embodiment, when a blower 920 provides an airflow 921 against the movement of the fibers toward the molding surface 462 within the duct, the binder introduction device 904 introduces the binder 900 into the blower 920, and the airflow 921 provided by the blower 920 mixes the binder with the fibers 322 (as shown in Figures 9A and 9B). Similarly, in this embodiment, when the blower 922 provides an airflow 921 against the movement of the fibers in the duct toward the molding surface 462, the binder introduction device 904 introduces the binder 900 to the blower 922, and the airflow 921 provided by the blower 922 mixes the binder with the fibers 322 (the airflow provided by the blower 922 is not shown, but is the same as the airflow provided by the blower 920). As a result, the binder 900 is uniformly mixed with the fibers 322. 【0069】 Dry binders can take a variety of different forms. Any non-aqueous medium can be used to hold the fibers 322 together to form the web 521. In one exemplary embodiment, the dry binder consists of substantially 100% solid when initially applied to the fibers. The term “substantially 100% solid,” as used herein, means any binder material containing a diluent, such as water, equal to or less than about 2% of the binder’s weight, preferably equal to or less than 1% (not after the binder has dried or cured). However, it should be recognized that in certain embodiments, the binder may contain any desired amount of diluent, such as water, depending on the specific application and design requirements. In one exemplary embodiment, the dry binder is a thermoplastic resin-based material that is not applied in liquid form and is not water-based. In other embodiments, the dry binder may be other materials or mixtures of other materials, including polymeric thermosetting resins, which are non-limiting examples. Dry binders can have any form or combination of forms, including, but are not limited to, powders, particles, fibers, and / or hot melts. Examples of hot melt polymers include, but are not limited to, ethylene-vinyl acetate copolymers, ethylene-acrylate copolymers, low-density polyethylene, high-density polyethylene, atactic polypropylene, polybutene-1, styrene block copolymers, polyamides, thermoplastic polyurethanes, styrene block copolymers, and polyesters. In one exemplary embodiment, the dry binder is a formaldehyde-free dry binder, meaning that the dry binder does not contain formaldehyde. However, formaldehyde may be formed when a formaldehyde-free dry binder is burned. In one exemplary embodiment, a pack of cured fibers can be compressed for packaging, storage, and shipping, but still given enough dry binder so that its thickness returns to its original state when placed in place (a process known as "loft recovery"). 【0070】 In the examples shown in Figures 2A-2D and 5, the glass fibers 322 may be optionally coated or partially coated with a lubricant before or after the dry binder is applied to the glass fibers. In exemplary embodiments, the lubricant is applied after the dry binder to enhance the adhesion of the dry binder to the glass fibers 322. The lubricant may be any of the aforementioned lubricants. 【0071】 Referring to Figure 5, the continuous web 521 containing the unreacted dry binder is transferred from the molding apparatus 332 to an optional lamination mechanism 334. The lamination mechanism can take on a variety of different forms. For example, the lamination mechanism can be a folding mechanism that laminates the web 321 in the machine direction D1, or a cross-folding mechanism that folds the web in a direction substantially perpendicular to the machine direction. The web 521 containing the unreacted dry binder can be laminated using the above-described cross-folding apparatus for laminating binderless webs 321. 【0072】 In an exemplary embodiment, the dry binder of the continuous web 521 is configured to be heat-cured in a curing furnace 550. In an exemplary embodiment, the curing furnace 550 replaces the entanglement mechanism 345 because the dry binder holds the fibers 322 together. In another exemplary embodiment, both the curing furnace 550 and the entanglement mechanism 345 are included. 【0073】 Figures 6 and 7 schematically show another exemplary embodiment of a method for forming a pack from a fibrous material, generally shown in 610. Referring to Figure 6, molten glass 612 is supplied from a melting apparatus 614 to a fore hearth 616. The molten glass 612 can be formed from various raw materials combined in proportions that give a desired chemical composition. The molten glass 612 flows from the fore hearth 616 to a plurality of rotary spinning machines 618. 【0074】 Referring to Figure 6, the rotary spinning machine 618 receives the molten glass 612 and subsequently forms a veil 620 of glass fibers 622 accompanied by a flow of high-temperature gas. As will be described in more detail later, the glass fibers 622 formed by the rotary spinning machine 618 are long and thin. Therefore, any desired rotary or other type of spinning machine can be used, sufficient to form long and thin glass fibers 22. The embodiments shown in Figures 6 and 7 show two rotary spinning machines 618, but it should be noted that any desired number of rotary spinning machines 18 can be used. 【0075】 The flow of high-temperature gas can be generated by any blowing mechanism, such as an annular blower (not shown) or an annular burner (not shown), which are non-limiting examples. Generally, the blowing mechanism is configured to direct the veil 620 of glass fibers 622 in a given direction, usually downward. It should be understood that the flow of high-temperature gas can be generated by any desired structure, mechanism, or device, or any combination thereof. 【0076】 As shown in Figure 6, an optional spray mechanism 626 can be positioned below the rotary spinning machine 618 and can be configured to spray fine droplets of water or other fluid onto the hot gas within the veil 620 to help cool the hot gas flow, protect the fibers 622 from contact damage, and / or enhance the adhesive properties of the fibers 622. The spray mechanism 626 can be any desired structure, mechanism, or device sufficient to help spray fine droplets of water onto the hot gas within the veil 620 to cool the hot gas flow, protect the fibers 622 from contact damage, and / or enhance the adhesive properties of the fibers 22. While the embodiment shown in Figure 6 illustrates the use of the spray mechanism 626, it should be noted that the use of the spray mechanism 626 is optional, and the method 610 for forming a pack from fibrous material can be carried out without using the spray mechanism 626. 【0077】 Optionally, the glass fibers 622 can be coated with a lubricant after they have been formed. In the illustrated embodiment, a plurality of nozzles 628 can be arranged around the veil 620 at a position below the rotary spinning machine 618. The nozzles 628 can be configured to supply lubricant (not shown) to the glass fibers 622 from a lubricant source (not shown). 【0078】 The application of the lubricant can be precisely controlled by any desired structure, mechanism, or device, such as a valve (not shown), which is a non-limiting example. In certain embodiments, the lubricant may be a silicone compound such as siloxane, dimethylsiloxane, and / or silane. The lubricant may also be another material or mixture of materials, such as oil or oil emulsion. The oil or oil emulsion may be mineral oil or mineral oil emulsion and / or vegetable oil or vegetable oil emulsion. In exemplary embodiments, the lubricant is applied in an amount of oil and / or silicone compound of about 1.0 percent by weight of the pack of fibrous material obtained. However, in other embodiments, the amount of lubricant may be more or less than about 1.0 weight percent of oil and / or silicone compound. 【0079】 The embodiment shown in Figure 6 illustrates the use of a nozzle 628 for supplying a lubricant (not shown) to the glass fibers 622. However, it should be noted that the use of the nozzle 628 is optional, and the method 610 for forming a pack from the fibrous material can be carried out without using the nozzle 628. 【0080】 In the illustrated embodiment, glass fibers 622 entrained in the high-temperature gas flow can be collected by an optional collection member 624. The collection member 624 is shaped and sized to easily receive the glass fibers 622 and the high-temperature gas flow. The collection member 624 is configured to distribute the glass fibers 622 and the high-temperature gas flow to a duct 630 for transport to a downstream processing station, such as a molding apparatus 632a and 632b. In other embodiments, the glass fibers 622 can be collected on a transport mechanism (not shown) to form, for example, a blanket or a bat (not shown). The bat can be transported by the transport mechanism to a further processing station (not shown). The collection member 624 and the duct 630 can have any structure having a generally hollow configuration suitable for receiving and transporting the glass fibers 622 and the high-temperature gas flow. Although the embodiment shown in Figure 6 illustrates the use of the collection member 624, it is optional to use the collection member 624 to distribute the glass fibers 622 and high-temperature gas flow to the duct 630, and it should be noted that the method 610 for forming a pack from fibrous material can be carried out without using the collection member 624. 【0081】 In the embodiments shown in Figures 6 and 7, a single spinning wheel 618 is associated with an individual duct 630, and the glass fibers 622 and hot gas flow from the single spinning wheel 618 are the sole source of glass fibers 622 and hot gas flow entering the duct 630. Alternatively, individual ducts 630 can be adapted to receive glass fibers 622 and hot gas flow from multiple spinning wheels 618 (not shown). 【0082】 Referring again to Figure 6, a header system (not shown) can optionally be placed between the molding apparatuses 632a and 632b and the spinning machines 618. The header system can be configured as a chamber in which glass fibers 622 and gas flowing from multiple spinning machines 618 can be combined while controlling the characteristics of the resulting mixed flow. In certain embodiments, the header system may include a control system (not shown) configured to combine the flows of glass fibers 622 and gas from the spinning machines 618 and to direct the resulting mixed flow towards the molding apparatuses 632a and 632b. Such a header system can enable maintenance and cleaning of a particular spinning machine 618 without having to shut down the remaining spinning machines 618. Optionally, the header system can incorporate any desired means for controlling and directing the glass fiber 22 and gas flows. 【0083】 Referring now to Figure 7, the momentum of the gas flow containing the encompassing glass fibers 622 causes the glass fibers 622 to continue flowing through the duct 630 to the molding apparatuses 632a and 632b. The molding apparatuses 632a and 632b can be configured for several functions. Firstly, the molding apparatuses 632a and 632b can be configured to separate the encompassing glass fibers 622 from the gas flow. Secondly, the molding apparatuses 632a and 632b can be configured to form a continuous, thin, dry web of fibrous material having a desired thickness. Thirdly, the molding apparatuses 632a and 632b can be configured to separate the glass fibers 622 from the gas flow in such a manner that the fibers can be oriented with any desired degree of "randomness" within the web. The term "randomness," as used herein, is defined to mean that the fibers 622 or a portion of the fibers 622 can be oriented non-preferentially in any of the X, Y, or Z dimensions. In certain cases, a high degree of randomness may be desirable. In other cases, it may be desirable to control the randomness of the fibers so that they are oriented non-randomly, in other words, so that the fibers are substantially coplanar or substantially parallel to each other. Fourth, the molding apparatuses 632a and 632b can be configured to transfer a continuous web of fibrous material to other downstream operations. 【0084】 In the embodiment shown in Figure 7, each of the molding apparatuses 632a and 632b includes a drum (not shown) configured to rotate. The drum may include a surface having any desired number of pores and areas for higher or lower pressure. Alternatively, each of the molding apparatuses 632a and 632b may be formed from other structures, mechanisms and apparatus sufficient to separate the entrained glass fibers 622 from the gas flow, form a continuous web of fibrous material having a desired thickness, and transfer the continuous web of fibrous material to other downstream operations. In the illustrative embodiment shown in Figure 7, each of the molding apparatuses 632a and 632b is the same. However, in other embodiments, each of the molding apparatuses 632a and 632b may be different from one another. 【0085】 Referring again to Figure 7, the continuous web of fibrous material is transferred from the molding apparatus 632a and 632b to an optional binder applicator 646. The binder applicator 646 is configured to apply a “dry binder” to the continuous web of fibrous material. The term “dry binder,” as used herein, is defined to mean that the binder consists of substantially 100% solid material at the time the binder is applied. The term “substantially 100% solid,” as used herein, is defined to mean any binder material having a diluent, such as water, equal to or less than about 2% of the binder’s weight, preferably equal to or less than about 1% of the binder’s weight (at the time the binder is applied, not after the binder has dried and / or cured). However, it should be noted that in certain embodiments, the binder may contain any desired amount of diluent, such as water, depending on the specific application and design requirements. The binder may be configured to be heat-cured in a curing furnace 650. In this application, the terms “cure” and “thermally set” refer to the chemical reactions and / or one or more phase changes that cause a dry binder to bond the fibers of the web together. For example, a thermosetting dry binder (or a thermosetting component of a dry binder) cures or sets as a result of chemical reactions that occur as a result of heat being applied. A thermoplastic dry binder (or a thermoplastic component of a dry binder) cures or sets as a result of being heated to soften or molten and then cooled to solid. 【0086】 In exemplary embodiments, the dry binder is a thermoplastic resin-based material that is not applied in liquid form and is not water-based. In other embodiments, the dry binder may be other materials or mixtures of other materials, including polymeric thermosetting resins, which are non-limiting examples. The dry binder may have any form or combination of forms, including powders, particles, fibers and / or hot melts, which are non-limiting examples. Examples of hot melt polymers, but not limited to them, include ethylene-vinyl acetate copolymers, ethylene-acrylate copolymers, low-density polyethylene, high-density polyethylene, atactic polypropylene, polybutene-1, styrene block copolymers, polyamides, thermoplastic polyurethanes, styrene block copolymers, and polyesters. The cured fiber packs can be compressed for packaging, storage and shipping, but sufficient dry binder is applied so that their thickness returns to its original state when placed (a process known as "bulkness recovery"). When the dry binder is applied to a continuous web of fibers, a continuous web is formed with optionally unreacted binder. 【0087】 In the embodiments shown in Figures 6 and 7, the binder applicator 646 is a sprayer configured for dry powder. The sprayer is configured to have an adjustable spray force, thereby allowing for greater or less permeation of the dry powder into the continuous web of the fibrous material. Alternatively, the binder applicator 646 can be other structures, mechanisms, or devices, or combinations thereof, such as a vacuum device sufficient to draw the "dry binder" into the continuous web of the fibrous material. 【0088】 The embodiment shown in Figure 7 illustrates a binder applicator 646 configured to apply a dry binder to a continuous web of fibrous material; however, in certain embodiments, the dry binder may not be applied to the continuous web of fibrous material, which is also within the scope of the present invention. 【0089】 Referring again to Figure 7, a continuous web containing unreacted binder is optionally transferred from the binder applicator 646 to the corresponding cross-folding mechanisms 634a and 634b. As shown in Figure 7, the molding apparatus 632a is associated with the cross-folding mechanism 634a, and the molding apparatus 632b is associated with the cross-folding mechanism 634b. The cross-folding mechanisms 634a and 634b work in conjunction with the first conveyor 636, which is configured to move in the machine direction indicated by arrow D1. The cross-folding mechanism 634a is configured to receive a continuous web containing unreacted binder optionally from the binder applicator 646, and further, as the first conveyor 636 moves in the machine direction D1, it is configured to deposit alternating layers of the continuous web containing unreacted binder optionally on the first conveyor 636, thereby forming the initial layer of the fibrous material. In this deposition process, the cross-folding mechanism 634a forms alternating layers in the machine-crossing direction indicated by arrow D2. Therefore, as the deposited continuous web, which may contain unreacted binder, moves from the cross-folding mechanism 634a in the machine direction D1, the downstream cross-folding mechanism 634b deposits additional layers on top of the fibrous material. The layers of fibrous material deposited by the cross-folding mechanisms 634a and 634b form a pack. 【0090】 In the illustrated embodiment, the cross-folding mechanisms 634a and 634b are devices configured to precisely control the movement of a continuous web containing unreacted binder, so as not to damage the continuous web containing unreacted binder, and to pile the continuous web containing unreacted binder onto the first conveyor 636. The cross-folding mechanisms 634a and 634b can include any desired structure and can be configured to operate in any desired manner. In one example, the cross-folding mechanisms 634a and 634b may include a head (not shown) configured to move back and forth in the mechanical crossing direction D2. In this embodiment, the speed of the movable head is adjusted so that the movement of the head in both directions of the mechanical crossing direction is substantially the same, thereby resulting in uniformity of the resulting fiber layer. In another example, a vertical conveyor (not shown) configured to be centered on the centerline of the first conveyor 636 can be used. This vertical conveyor is further configured to swing above the first conveyor 636 by a pivot mechanism to optionally deposit continuous webs containing unreacted binder onto the first conveyor 36. Although several examples of cross-folding mechanisms have been described above, it should be noted that the cross-folding mechanisms 634a and 634b may be other structures, mechanisms, or devices or combinations thereof. 【0091】 Referring again to Figure 7, a controller (not shown) can optionally position the continuous web containing the unreacted binder on the first conveyor 636 to improve pack uniformity. The controller can be any desired structure, mechanism, or device, or a combination thereof. 【0092】 The laminated web or pack can have any desired thickness. The thickness of the pack is a function of several variables. Firstly, the thickness of the pack is a function of the thickness of the continuous web, which optionally contains unreacted binder, formed by each of the forming apparatuses 632a and 632b. Secondly, the thickness of the pack is a function of the rate at which the cross-folding mechanisms 634a and 634b alternately deposit layers of the continuous web, which optionally contains unreacted binder, onto the first conveyor 636. Thirdly, the thickness of the pack is a function of the speed of the first conveyor 636. In the illustrated embodiment, the pack has a thickness ranging from about 0.1 inches to about 20.0 inches. In other embodiments, the pack can have a thickness of less than about 0.1 inches or greater than about 20.0 inches. 【0093】 As described above, the cross-folding mechanisms 634a and 634b are configured to optionally deposit alternating layers of continuous webs containing unreacted binder onto the first conveyor 636 as the first conveyor 636 moves in the machine direction D1, thereby forming layers of fiber. In the illustrated embodiment, the cross-folding mechanisms 634a and 634b and the first conveyor 636 are adjusted to form a fiber having a number of layers ranging from about 1 to about 60. In other embodiments, the cross-folding mechanisms 634a and 634b and the first conveyor 636 can be adjusted to form a fiber having any number of layers, including a fiber having more than 60 layers. 【0094】 Optionally, the cross-folding mechanisms 634a and 634b can be made adjustable, thereby enabling them to form packs of any desired width. In certain embodiments, the pack can have an overall width ranging from about 98.0 inches to about 236.0 inches. Alternatively, the pack can have an overall width less than about 98.0 inches or more than about 236.0 inches. 【0095】 Although the cross-folding mechanisms 634a and 634b are described above as being jointly involved in the formation of the fiber body, it should be noted that in other embodiments, the cross-folding mechanisms 634a and 634b can operate independently of each other to form separate lanes of fiber body. 【0096】 Referring to Figures 6 and 7, the pack having layers formed by the cross-folding mechanisms 634a and 634b is transported by the first conveyor 636 to an optional trimming mechanism 640. The optional trimming mechanism 640 is configured to trim the edges of the pack to form a desired pack width. In an exemplary embodiment, the pack may have a trimmed width ranging from about 980 inches to about 236.0 inches. Alternatively, the pack may have a trimmed width of less than about 98.0 inches or more than about 236.0 inches. 【0097】 In the illustrated embodiment, the optional trimming mechanism 640 includes a saw system having a plurality of rotary saws (not shown) positioned on both sides of the pack. Alternatively, the trimming mechanism 640 may be other structures, mechanisms, or devices or combinations thereof, including, but not limited to, a water jet or compression knife. 【0098】 In the illustrated embodiment, the trimming mechanism 640 is advantageously positioned upstream of the curing furnace 650. Positioning the trimming mechanism 640 upstream of the curing furnace 650 allows the pack to be trimmed before it is heat-cured in the curing furnace 650. Optionally, the material trimmed from the pack by the trimming mechanism 640 can be returned to the gas and glass fiber flow in the duct 630 for reuse in the molding apparatus 632a and 632b. Reusing the trimmed material advantageously prevents potential environmental problems associated with the disposal of trimmed material. As shown in Figure 6, the conduit 642 is configured to connect the trimming mechanism 640 to the duct 630 and facilitate the return of the trimmed material to the molding apparatus 632a and 632b. While the embodiments shown in Figures 6 and 7 illustrate the reuse of trimmed material, it should be noted that the reuse of trimmed material is optional, and the method 610 for forming a pack from fibrous material can be carried out without reusing trimmed material. In another exemplary embodiment, the trimming mechanism 640 is located downstream of the curing furnace 650. This arrangement is particularly useful when the trimmed material is not to be reused. Trimming the pack forms a trimmed pack. 【0099】 The trimmed packs are transported by the first conveyor 636 to the second conveyor 644. As shown in Figure 6, the second conveyor 644 can be positioned to "step down" from the first conveyor 636. The term "stepped down," as used herein, is defined to mean that the upper surface of the second conveyor 644 is positioned vertically below the upper surface of the first conveyor 636. The step-down of the conveyors will be described in more detail later. 【0100】 Referring again to Figures 1 and 2, the trimmed pack is carried by a second conveyor 644 to an optional entanglement mechanism 645. The entanglement mechanism 645 is configured to entangle the individual fibers 622 that form the layers of the trimmed pack. The entanglement of the glass fibers 622 in the pack binds the pack together. In embodiments that include a dry binder, the entanglement of the glass fibers 622 can advantageously improve mechanical properties such as tensile strength and shear strength. In the illustrated embodiment, the entanglement mechanism 645 is a needling mechanism. In other embodiments, the entanglement mechanism 645 may include other structures, mechanisms, or devices or combinations thereof, including a stitching mechanism, which is a non-limiting example. While the embodiments shown in Figures 6 and 7 illustrate the use of the entanglement mechanism 645, it should be noted that the use of the entanglement mechanism 645 is optional, and the method 610 for forming a pack from fibrous material can be carried out without using the entanglement mechanism 645. Entanglement of the fibers in the pack forms an entangled pack. 【0101】 A second conveyor 644 transports packs (hereafter both trimmed and entangled packs will be simply referred to as "packs") that are optionally trimmed and / or entangled, and optionally contain a dry binder, to a third conveyor 648. If a pack contains a dry binder, the third conveyor 648 is configured to transport the pack to an optional curing furnace 650. The curing furnace 650 is configured to blow a fluid, such as heated air, through the pack, thereby curing the dry binder and rigidly binding the glass fibers 622 together to form a generally random three-dimensional structure. When the pack is cured in the curing furnace 650, a cured pack is formed. 【0102】 As mentioned above, the pack optionally includes a dry binder. Using a dry binder instead of a traditional wet binder is advantageous in that it allows the curing furnace 650 to use less energy to cure the dry binder in the pack. In the illustrated embodiment, the use of a dry binder in the curing furnace 650 results in energy savings ranging from about 30.0% to about 80.0% compared to the energy used by conventional curing furnaces to cure wet or aqueous binders. In yet other embodiments, energy savings may exceed 80.0%. The curing furnace 650 can be any desired curing structure, mechanism, or apparatus, or a combination thereof. 【0103】 A third conveyor 648 transports the hardened packs to a fourth conveyor 652. The fourth conveyor 652 is configured to transport the hardened packs to a cutting mechanism 654. Optionally, the cutting mechanism 654 can be configured in several cutting modes. In a first optional cutting mode, the cutting mechanism is configured to cut the hardened packs vertically along the machine direction D1 to form lanes. The formed lanes can have any desired width. In a second optional cutting mode, the cutting mechanism is configured to divide the hardened packs horizontally into two equal parts to form continuous packs with thickness. The resulting bisected packs can have any desired thickness. When the hardened packs are cut, cut packs are formed. 【0104】 In the illustrated embodiment, the cutting mechanism 654 includes a system of saws and knives. Alternatively, the cutting mechanism 654 can be any other structure, mechanism, or device, or a combination thereof. Referring again to Figures 6 and 7, the cutting mechanism 654 is advantageously positioned to capture the dust and other waste material formed during the cutting operation. Optionally, the dust and other waste material generated from the cutting mechanism can be returned to the gas and fiberglass flow in the duct 630 for reuse in the molding devices 632a and 632b. Reuse of dust and waste material advantageously prevents potential environmental problems associated with the disposal of dust and waste material. As shown in Figures 6 and 7, the conduit 655 is configured to connect the cutting mechanism 654 to the duct 630 and to facilitate the return of dust and waste material to the molding devices 632a and 632b. While the embodiments shown in Figures 6 and 7 illustrate the reuse of dust and waste materials, it should be noted that the reuse of dust and waste materials is optional, and method 10 for forming a pack from fibrous material can be carried out without reusing dust and waste materials. 【0105】 Optionally, prior to transporting the cured pack to the cutting mechanism 654, the main surface of the cured pack may be covered with one or more overlay materials by overlay mechanisms 662a, 662b, as shown in Figure 6. In the illustrated embodiment, the upper main surface of the cured pack is covered with overlay material 663a provided by overlay mechanism 662a, and the lower main surface of the cured pack is covered with overlay material 663b provided by overlay mechanism 662b. The overlay material can be any desired material, including paper, polymer material, or nonwoven web. The overlay mechanisms 662a and 662b can be any desired structure, mechanism, or apparatus, or a combination thereof. In the illustrated embodiment, the overlay materials 663a and 663b are attached to the cured pack (if the pack contains a binder) by adhesive. In other embodiments, the overlay materials 663a and 663b are attached to the cured pack by other methods, including ultrasonic welding, which is a non-limiting example. The embodiment shown in Figure 6 illustrates the application of the outer covering materials 663a and 663b to the main surface of the cured pack. However, the application of the outer covering materials 663a and 663b to the main surface of the cured pack is optional, and it should be noted that the method 610 for forming a pack from a fibrous material can be carried out without applying the outer covering materials 663a and 663b to the main surface of the cured pack. 【0106】 Referring to Figures 6 and 7, the fourth conveyor 652 transports the cut packs to an optional chopping mechanism 656. The chopping mechanism 656 is configured to cut the cut packs to a desired length across the machine direction D1. In the illustrated embodiment, the chopping mechanism 656 is configured to cut the cut packs as they move continuously in the machine direction D1. Alternatively, the chopping mechanism 656 can be configured for batch chopping operations. When the cut packs are cut to a predetermined length, a dimensioned pack is formed. The length of the chopped pack can be any desired dimension. 【0107】 Chopping mechanisms are known in the art and will not be described herein. The chopping mechanism 656 can be any desired structure, mechanism, or device, or a combination thereof. 【0108】 Optionally, prior to transporting the cut packs to the chopping mechanism 656, the secondary surfaces of the cut packs may be overlaid with one or more edging materials by edging mechanisms 666a, 666b, as shown in Figure 7. The edging materials may be any desired material, including paper, polymer materials, or nonwoven webs. The edging mechanisms 666a and 666b may be any desired structure, mechanism, or apparatus, or a combination thereof. In the illustrated embodiment, the edging materials 667a and 667b are attached to the cut packs by adhesive. In other embodiments, the edging materials 667a and 667b may be attached to the cut packs by other methods, including ultrasonic welding, which is a non-limiting example. The embodiment shown in Figure 7 illustrates the application of edging materials 667a and 667b to the secondary surface of the cut pack. However, the application of edging materials 667a and 667b to the secondary surface of the cut pack is optional, and it should be noted that the method 610 for forming a pack from fibrous material can be carried out without applying edging materials 667a and 667b to the secondary surface of the cut pack. 【0109】 Referring again to Figure 6, the fourth conveyor 652 transports the predetermined-size packs to the fifth conveyor 658. The fifth conveyor 658 is configured to transport the predetermined-size packs to the packaging mechanism 660. The packaging mechanism 660 is configured to package the predetermined-size packs for future operations. The term “future operations,” as used herein, is defined to include any activities following the formation of the predetermined-size packs, including, but not limited to, storage, shipping, and installation. 【0110】 In the illustrated embodiment, the packaging mechanism 660 is configured to form a pack of predetermined dimensions into a roll-shaped package. In other embodiments, the packaging mechanism 660 can form packages of other desired shapes, such as slabs, bats, and irregularly shaped pieces or punched pieces, which are not limiting examples. The packaging mechanism 660 can be any desired structure, mechanism, or apparatus or combination thereof. 【0111】 Referring again to Figure 6, conveyors 636, 644, 648, 652, and 658 are in a “step-down” relationship in the machine direction D1. A “step-down” relationship means that the top surface of the next conveyor is positioned vertically below the top surface of the previous conveyor. The “step-down” relationship of the conveyors provides a favorable self-threading feature for pack transport. In the illustrated embodiment, the vertical offset between adjacent conveyors ranges from about 3.0 inches to about 10.0 inches. In other embodiments, the vertical offset between adjacent conveyors can be less than about 3.0 inches or greater than about 10.0 inches. 【0112】 As shown in Figures 6 and 7, the method 610 for forming packs from fibrous material eliminates the use of a wet binder, thereby eliminating the conventional need for wash water and wash water-related structures, such as molding hoods, return pumps, and piping. The elimination of the use of water other than for cooling water and the application of lubricants, colorants, and other optional chemicals significantly reduces the overall size (or "installation area") of the production line, and advantageously allows for reductions in implementation costs, operating costs, and maintenance and repair costs. 【0113】 As further shown in Figures 6 and 7, the method 610 for forming a pack from fibrous material advantageously allows for uniform and even deposition of long, thin fibers on the molding apparatuses 632a and 632b. In the illustrated embodiments, the fibers 622 have lengths ranging from about 0.25 inches to about 10.0 inches and diameters ranging from about 9 HT to about 35 HT. In other embodiments, the fibers 22 have lengths ranging from about 1.0 inch to about 5.0 inches and diameters ranging from about 14 HT to about 25 HT. In yet another embodiment, the fibers 22 may have lengths of less than about 0.25 inches or greater than about 10.0 inches and diameters of less than about 9 HT or greater than about 35 HT. Although not constrained by theory, it is believed that using relatively long, thin fibers advantageously provides packs with superior thermal and sound insulation performance compared to packs of similar size having shorter, thicker fibers. 【0114】 While the embodiments shown in Figures 6 and 7 have been generally described above for forming packs of fibrous material, it should be understood that the same apparatus can be configured to form “unbonded, loosely packed insulating material.” The term “unbonded, loosely packed insulating material,” as used herein, is defined to mean any conditioned insulation material configured for use in airflow. 【0115】 While exemplary embodiments of packs and methods 610 for forming packs from fibrous materials have been generally described above, it should be noted that other embodiments and variations of method 610 are available, which are generally described below. 【0116】 Referring to Figure 7, in another embodiment of method 610, the cross-folding mechanisms 634a and 634b are configured to give precise stacking of alternating layers of continuous web on the first conveyor 36, thereby eliminating the need for the downstream trimming mechanism 40. 【0117】 Referring again to Figure 7, in another embodiment of Method 610, the various layers of the pack can be “stratified.” The term “stratified,” as used herein, is defined to mean that each layer and / or portion of a layer can be configured to have different properties, including, but not limited to, fiber diameter, fiber length, fiber orientation, density, thickness, and glass composition. It is intended that the associated mechanisms for forming the layers, i.e., associated spinning machines, molding devices, and cross-folding mechanisms, can be configured to provide layers and / or portions of layers having specific desired properties. Thus, a pack can be formed from layers and / or portions of layers having different properties. 【0118】 Figures 10A–10C show exemplary embodiments of an insulating product 1000 comprising one or more thick low-density cores 1002 and one or more thin high-density tensile layers 1004. The thick low-density cores 1002 can take on a variety of different forms. For example, the low-density cores 1002 can be made from any of the aforementioned low weight-per-area packs. In one exemplary embodiment, the low-density cores 1002 are made from needled and / or laminated glass fibers. In one exemplary embodiment, the low-density cores 1002 are binderless. In another exemplary embodiment, the fibers 322 of the low-density core are bonded to each other by a binder. 【0119】 The thin, high-density tensile layer 1004 can take on a variety of different forms. In one exemplary embodiment, the thin, high-density tensile layer 1004 is made from fiberglass fibers that are needled together. However, the fibers of the high-density tensile layer 1000 can be processed using other processes and / or products that achieve the appropriate tensile strength. In one exemplary embodiment, the high-density tensile layer 1004 is made from the high-density pack 300 of the embodiment in Figure 3D. 【0120】 In an exemplary embodiment, a high-density tensile layer 1004 is attached to a low-density core 1002. The high-density tensile layer 1004 can be attached to the low-density core 1002 in a variety of different ways. For example, layers 1002 and 1004 can be attached to each other by adhesive, an additional needling step, or thermal bonding (when one or both of layers 1002 and 1004 include a binder). Any method of attaching the layers to each other can be used. In an exemplary embodiment, layers 1002 and 1004 give the insulating product 1000 distinct properties. 【0121】 In an exemplary embodiment, a thick, low-density layer 1002 provides a high thermal resistance R but has low tensile strength, while a thin, high-density tensile layer 1004 provides a low thermal resistance R but has high tensile strength. The combination of the two layers provides the insulating product 1000 with both high tensile strength and a high R value. 【0122】 Figures 10D–10F show exemplary embodiments of an insulating product 1000 comprising one or more thick low-density cores 1002 and one or more thin cladding layers 1004. The thick low-density cores 1002 can take on a variety of different forms, as described with respect to the embodiments shown in Figures 10A–10C. The cladding layers 1004 can take on a variety of different forms. The material of the cladding layers 1004 can be selected to give the insulating product a variety of different properties. For example, the cladding material can be selected to give the insulating product a desired amount of strength, reflectivity, acoustic performance, water impermeability, and / or vapor impermeability. The cladding layers can be made from a variety of different materials, including, but not limited to, plastics, metal foils, scrim, paper, and combinations of these materials. Any known cladding layer can be used. 【0123】 In an exemplary embodiment, the cladding layer 1004 is attached to the low-density core 1002. The cladding layer 1004 can be attached to the low-density core 1002 in a variety of different ways. For example, layers 1002 and 1004 can be attached to each other by adhesive, thermal bonding, etc. Any method of attaching the layers to each other can be used. In an exemplary embodiment, layers 1002 and 1004 give distinct properties to the insulating product 1000. In an exemplary embodiment, the thick low-density layer 1002 has a high thermal resistance value R but low tensile strength, while the cladding layer 1004 gives tensile strength and other properties. 【0124】 The example shown in Figures 10G-10I illustrates a strata having different densities. However, strata can have different properties, which may or may not include different densities. These varying properties can be achieved by varying the fiber density, fiber length, fiber diameter, and / or fiber type throughout the thickness of the pack. Figures 10G-10I show an exemplary embodiment of a layered vat or pack 1050 including one or more low-density strata 1052 and one or more high-density strata 1054. However, the transition between the low-density strata 1052 and the high-density strata 1054 can be gradual. In the example shown in Figures 10A-10F, the insulating product 1000 is formed from separate layers. In the exemplary embodiment shown in Figures 10G-10I, the layered vat or pack 1050 is formed to have properties that vary throughout the thickness of the vat or pack. The low-density strata 1052 can take a variety of different forms. For example, the low-density layer 1052 can be manufactured in the same manner as any of the low-weight-per-area packs described above. In one exemplary embodiment, the low-density layer 1052 is made from fiberglass fibers. In one exemplary embodiment, the low-density layer 1052 is binderless. In another exemplary embodiment, the fibers 322 of the low-density layer 1052 are bonded to each other by a binder. 【0125】 The thin, high-density layer 1054 can take on a variety of different forms. In one exemplary embodiment, the high-density layer 1054 is made from fiberglass fibers that are needled together. However, the fibers of the high-density layer 1054 can be treated with other processes and / or products that achieve the appropriate tensile strength. In one exemplary embodiment, the high-density layer 1054 is made in the same manner as the high-density pack 300 in the embodiment of Figure 3D is made. 【0126】 In an exemplary embodiment, the fibers of high-density layer 1054 are attached to and / or entangled with the fibers of low-density layer 1052. The fibers of high-density layer 1054 can be attached to the fibers of low-density layer 1052 in a variety of different ways. For example, the fibers of layers 1002 and 1004 can be attached to each other by adhesives such as binders applied to the pack, and / or by needling performed when the pack 1050 is manufactured. Any method can be used to attach or entangle the fibers of layers 1052 and 1054. In an exemplary embodiment, layers 1052 and 1054 give the insulating product 1000 different properties. 【0127】 The insulating bats, packs, and products in the embodiments shown in Figures 10A-10I can be combined with each other. For example, any of the layers of the insulating products shown in Figures 10A-10F can be layered, and one or more outer layers or separate high-density layers can be provided in the layered bats or packs shown in Figures 10G-10I. A variety of different insulating structures can be constructed from the embodiments shown in Figures 10A-10I. 【0128】 In an exemplary embodiment, a thick, low-density layer 1052 provides a high thermal resistance R but has low tensile strength, while a thin, high-density tensile layer 1004 provides a low thermal resistance R but has high tensile strength. A combination of the two layers provides the bat or pack 1050 with both high tensile strength and a high R value. The layers can be configured to give the bat or pack a variety of different properties. For example, alternating thin, high-density layers and thick, low-density layers provide a bat or pack with excellent acoustic properties. 【0129】 In one exemplary embodiment, the dry binder may contain or be coated with additives to impart desired properties to the pack. One non-limiting example of an additive is a flame retardant, such as baking soda. Another non-limiting example of an additive is a material that prevents the transmission of ultraviolet light through the pack. Yet another non-limiting example of an additive is a material that prevents the transmission of infrared light through the pack. 【0130】 Referring to Figure 6, in another embodiment of Method 610, as previously mentioned, the flow of high-temperature gas can be generated by an optional blowing mechanism, such as an annular blower (not shown) or an annular burner (not shown), which are non-limiting examples. In the art, the heat generated by an annular blower or annular burner is known to be called "heat of fiberization." In this embodiment, the heat of fiberization is intended to be acquired and reused for use in other mechanisms or devices. Heat of fiberization can be acquired at several locations in Method 610. As shown in Figures 6 and 7, conduit 670 is configured to acquire heat from the spinning machine 618 and transport this heat for use in other mechanisms, such as an optional hardening furnace 650. Similarly, piping 672 is configured to acquire heat from the flow of high-temperature gas in duct 30, and further piping 674 is configured to acquire heat from the molding devices 632a and 632b. The reused heat can also be used for purposes other than forming fibrous packs, such as heating an office. 【0131】 In certain embodiments, the duct 630 may include a heat acquisition device, such as a heat extraction fixture configured to acquire heat without significantly affecting the momentum of the flow of the hot gas and the entrained glass fibers 622. In other embodiments, any desired structure, device, or mechanism sufficient to acquire spinning heat may be used. 【0132】 Referring to Figure 6, in another embodiment of method 610, fibers or other materials having other desired properties can be mixed with the glass fibers 622 encompassed in the gas flow. In this embodiment, a source 676 for other materials such as synthetic fibers or ceramic fibers, colorants and / or particles can be provided so that such materials are introduced into the duct 678. 【0133】 Duct 678 can be connected to duct 630 to allow mixing with glass fibers 622 entrained in the gas flow. In this way, the properties of the resulting pack can be designed or tuned to suit desired properties, including, but not limited to, acoustic properties, thermal strengthening properties, or UV suppression properties. 【0134】 In yet another embodiment, it is intended that other materials can be placed between the layers deposited on the first conveyor 636 by the cross-folding mechanisms 634a and 634b. The other materials may include sheet materials such as cladding, moisture-proofing layers, or mesh products, or other non-sheet materials, including, but not limited to, powders, particles, or adhesives. The other materials can be placed between the layers in any desired manner. In this way, the properties of the resulting pack can be further designed or adjusted as desired. 【0135】 The embodiment shown in Figure 6 illustrates the application of a dry binder by a binder applicator 646, but it should be noted that in other embodiments, the dry binder can be applied to glass fibers 622 encompassed in a gaseous flow. In this embodiment, a dry binder source 680 can be introduced into a duct 682. The duct 682 is connected to a duct 630 to allow mixing of the glass fibers 622 encompassed in the gaseous flow with the dry binder. The dry binder can be configured to adhere to the glass fibers in any desired manner, including an electrostatic process. 【0136】 The embodiment shown in Figure 6 illustrates the use of a continuous web with cross-folding mechanisms 634a and 634b, but it should be noted that in other embodiments, the web can be removed from the forming apparatus 632a and 632b and stored for later use. 【0137】 As described above, the trimmed material can optionally be returned to the gas and glass fiber flow in the duct 630 and reused in the molding apparatus 632a and 632b. In an exemplary embodiment, when an optional binder is included in the pack, the operating temperature of the molding apparatus 332a and 332b is kept lower than the softening temperature of the dry binder, thereby preventing the binder from hardening before the operation of the downstream curing furnace 550. In this embodiment, the maximum operating temperature of the curing furnace 650 is in the range of about 165°F to about 180°F. In other embodiments, the maximum operating temperature of the curing furnace 650 can be lower than about 165°F or higher than about 180°F. 【0138】 In exemplary embodiments, the elongated, thin fibers 322 described herein are used for other applications different from those described above. For example, Figure 11 shows that the elongated, thin fibers 322 described above are provided as staple fibers that are air-laminated, carded, or otherwise processed for use in a variety of different applications, rather than being formed into webs and / or packs. In one application, the unbonded staple fibers are blended with aramid fibers such as Kevlar and Konex, and / or heat-bonded fibers such as Celbond. These blended fibers can be used to form staple yarn and / or dry-laid nonwoven materials. 【0139】 In the embodiment shown in Figure 11, the melting apparatus 314 supplies molten glass 312 to the fore hearth 316. The molten glass 312 is processed to form glass fibers 322. The molten glass 312 can be processed in various different ways to form the fibers 322. For example, a rotary spinning machine 318 receives the molten glass 312 and then forms a veil 320 of glass fibers 322. Any desired spinning machine, rotary or of another type, can be used as long as it is sufficient to form long, thin glass fibers 322. 【0140】 Referring to Figure 11, the applicator 1100 applies a lubricant, also called a sizing agent, to the unadhesive glass fibers. In the illustrated embodiment, the sizing agent is applied to the glass fibers below the spinning machine. However, in other embodiments, the sizing agent is applied to the glass fibers at other locations, such as inside the duct 330. The sizing agent strengthens and / or lubricates the fibers, which assists in fiber processing such as needling or carding. The unadhesive stapled fibers 322 are provided at the outlet of the duct 330, as indicated by arrow 1102, where the fibers are collected in a container 1103 and used for a variety of different applications, either on their own or in combination with other fibers such as aramid fibers. 【0141】 Sizing agents can take on a variety of different forms. For example, sizing agents can include silicone and / or silane. However, any sizing agent can be used depending on the application. The sizing agent can be adjusted based on the application in which the glass fiber is used. 【0142】 The small fiber diameter and long fiber length allow sizing-treated fibers to be used in applications where fibers could not previously be used because they would break too easily. In one exemplary embodiment, since thinner fibers are more easily bent without breaking, a fiber 322 with a diameter of approximately 4 microns has a superior flexural modulus and resulting strength compared to conventional fibers. This improved flexural modulus and strength of the fiber helps it withstand processes such as carding and air lamination processes, which are typically destructive for conventional fibers. Furthermore, the fine diameter of the glass fiber improves both its thermal and acoustic properties. 【0143】 Glass webs, packs, and stapled fibers can be used in a variety of different applications. Examples of applications, but not limited to, include heating appliances such as ovens, ranges, and water heaters; heating, ventilation, and air conditioning (HVAC) components such as HVAC ducts; soundproofing panels and materials such as soundproofing panels for buildings and / or vehicles; and molded fiberglass components such as compression-molded or vacuum-formed fiberglass components. In one exemplary embodiment, heating appliances such as ovens, ranges, and water heaters; heating HVAC components such as HVAC ducts; soundproofing panels and materials such as soundproofing panels for buildings and / or vehicles; and / or molded fiberglass components such as compression-molded or vacuum-formed fiberglass components are manufactured using or from binderless fiberglass packs made by one or more embodiments disclosed in this patent application. In the exemplary embodiment, since the fiberglass pack is binderless, formaldehyde is not present within the fiberglass pack. In one exemplary embodiment, heating electrical appliances such as ovens, ranges and water heaters, heating HVAC components such as HVAC ducts, soundproofing panels and materials such as soundproofing panels for buildings and / or vehicles, and / or molded fiberglass components such as compression-molded or vacuum-formed fiberglass components are manufactured using or from dry binder fiberglass packs made by one or more embodiments disclosed in this patent application. In this exemplary embodiment, the dry binder may be formaldehyde-free or formaldehyde-free dry binder. In the case of formaldehyde-free binder, the binder itself does not contain formaldehyde, but formaldehyde may be a by-product when the binder is burned. 【0144】 The fiberglass insulation pack described in this patent application can be used in a variety of different cooking ranges and in various different configurations within any given cooking range. Patent Document 10 discloses an example of an insulation system used in a range. Patent Document 10 is incorporated herein by reference in its entirety. The fiberglass pack described herein can be used in any of the insulation structures for heating appliances described in Patent Document 10, including configurations classified as prior art. Figures 12-14 correspond to Figures 1-3 of Patent Document 10. 【0145】 Referring to Figure 12, the hot oven 1210 includes a substantially flat upper cooking surface 1212. As shown in Figures 12-14, the hot oven 1210 includes a pair of opposing side panels 1252 and 1254, a rear panel 1224, a bottom panel 1225, and a front panel 1232. The opposing side panels 1252 and 1254, the rear panel 1224, the bottom panel 1225, the front panel 1232, and the cooking surface 1212 are configured to form an outer oven cabinet 1233. The front panel 1232 includes an insulated oven door 1218 that is pivotably connected to the front panel 1232. The oven door 1218 is hinged to the lower end of the front panel 1232 so that it can pivot away from the front panel 1232 and the oven cavity 1216. In the example shown in Figure 12, the oven door 1218 includes a window. In the example shown in Figure 12A, the oven door 1218 does not include a window, and insulation is applied to the entire interior of the door. 【0146】 As shown in Figures 13 and 14, the outer oven cabinet 1233 supports the inner oven liner 1215. The inner oven liner 1215 includes opposing liner sides 1215a and 1215b, a top liner 1215c, a bottom liner 1215d, and a back liner 1215e. The opposing liner sides 1215a and 1215b, the top liner 1215c, the bottom liner 1215d, the back liner 1215e, and the oven door 1218 are configured to define the oven cavity 1216. 【0147】 As further shown in Figures 13 and 14, the outside of the oven liner 1215 is covered with an insulating material 1238, which can be made by any embodiment disclosed herein. The oven door 1238 can also be filled with an insulating material 1238, which can be made by any embodiment disclosed herein. The insulating material 1238 is positioned to be in contact with the outer surface of the oven liner 1215. The insulating material 1238 is used for a number of purposes, including retaining heat within the oven cavity 1216 and limiting the amount of heat transferred to the outer oven cabinet 1233 by conduction, convection, and radiation. 【0148】 As shown in the examples in Figures 13 and 14, an air gap 1236 is formed between the insulating material 1238 and the outer oven cabinet 1233. The air gap 1236 is used as additional insulation to limit conductive heat transfer between the oven liner 1215 and the outer oven cabinet 1233. The use of the air gap 1236 complements the insulating material 1238 to minimize the surface temperature of the outer surface of the outer oven cabinet 1233. As shown in the examples in Figures 13A and 14A, the insulating material 1238 can be sized such that no air gap is formed between the insulating material 1238 and the outer oven cabinet 1233. That is, in the embodiments of Figures 13A and 14A, the insulating layer 1238 completely fills the space between the oven liner 1215 and the outer oven cabinet 1233. In one exemplary embodiment, the thermal insulation material used in the configuration shown in Figures 13, 13A, 14, and 14A, and in any other configuration disclosed in Patent Document 10, is made from a binderless fiberglass pack made by one or more embodiments disclosed in this patent application. In the exemplary embodiment, since the fiberglass pack is binderless, there is no formaldehyde in the thermal insulation layer 1238 of the embodiments in Figures 13, 13A, 14, and 14A. 【0149】 The fiberglass pack described herein can be used in a variety of different heating, ventilation, and air conditioning (HVAC) systems, such as ducts in HVAC systems. Furthermore, the insulation pack described herein can be installed in various different configurations within any given HVAC duct. Patent documents 11, 12, and U.S. Patent Application No. 13 / 764,920, pending February 12, 2013, all of which are assigned to the assignees of this application, disclose examples of fiberglass insulation systems used in HVAC ducts. Patent documents 11, 12, and U.S. Patent Application No. 13 / 764,920 are incorporated herein by reference in their entirety. The fiberglass pack described herein can be used in any of the HVAC duct configurations described herein. 【0150】 In one exemplary embodiment, the thermal insulation material used in HVAC ducts disclosed in Patent Documents 11, 12, and the pending U.S. Patent Application No. 13 / 764,920 can be constructed from a dry binder fiberglass pack made by one or more embodiments disclosed in this patent application. In this exemplary embodiment, the dry binder can be a formaldehyde-free dry binder or a formaldehyde-free dry binder. In a formaldehyde-free binder, the binder itself does not contain formaldehyde, but formaldehyde may be a by-product when the binder is burned. 【0151】 In exemplary embodiments, the thermal insulation materials used in HVAC ducts disclosed in Patent Documents 11, 12, and pending U.S. Patent Application No. 13 / 764,920 can be constructed from binderless fiberglass packs made by one or more embodiments disclosed in this patent application. In exemplary embodiments, since the fiberglass packs are binderless, formaldehyde is not present in the thermal insulation material. 【0152】 The fiberglass insulation pack described in this patent application can be used for a variety of different acoustic applications, and can take on various different configurations for each application. Examples of soundproofing batts include the Owens Corning Sound Attenuation Batt and Owens Corning Sonobatts insulation materials, which can be placed behind various panels of a building, such as ceiling tiles or walls. Patent documents 13 and 14 describe examples of soundproofing applications and are incorporated herein by reference in their entirety. The fiberglass pack described herein can be used as a substitute for the Owens Corning Sound Attenuation Batt and Owens Corning Sonobatts soundproofing materials and can be used in any of the applications disclosed in Patent documents 13 and 14. Additional acoustic applications of the fiberglass soundproofing pack described in this patent application include, but are not limited to, ductliners, duct traps, ceiling panels, wall panels, and the like. 【0153】 In one exemplary embodiment, a soundproof pack manufactured by one or more embodiments of the binderless pack or dry binder pack disclosed in this patent application and tested according to ASTM C522 at an altitude of 1,500 feet above sea level has an average air permeability resistivity of 3,000–150,000 (mks Rayls / m). In one exemplary embodiment, a soundproof pack manufactured by one or more embodiments of the binderless pack or dry binder pack disclosed in this patent application and tested according to ASTM C423 at an altitude of 1,500 feet above sea level has a sound absorption average (SAA) in the range of 0.25 to 1.25. In one exemplary embodiment, a soundproof pack manufactured by one or more embodiments of the binderless pack or dry binder pack disclosed in this patent application and tested according to ISO 354 at an altitude of 1,500 feet above sea level has a sound absorption coefficient αw in the range of 0.25 to 1.25. 【0154】 [Table 2] 【0155】 In one exemplary embodiment, a soundproofing material used as a substitute for the soundproofing materials of Owens Corning Sound Attenuation Batt and Owens Corning Sonobatts, and / or for any of the applications disclosed in Patent Documents 13 and 14, is constructed from a dry binder fiberglass pack made by one or more embodiments disclosed in this patent application. In this exemplary embodiment, the dry binder may be a formaldehyde-free dry binder or a formaldehyde-free dry binder. In a formaldehyde-free dry binder, the binder itself does not contain formaldehyde, but formaldehyde may be a by-product when the binder is burned. 【0156】 In exemplary embodiments, a soundproofing material used as a substitute for the soundproofing materials of Owens Corning Sound Attenuation Batt and Owens Corning Sonobatts, and / or for any of the applications disclosed in Patent Documents 13 and 14, is constructed from a binderless fiberglass pack made by one or more embodiments disclosed in this patent application. In this exemplary embodiment, since the fiberglass pack is binderless, no formaldehyde is present in the soundproofing material. 【0157】 The fiberglass insulation pack described in this patent application can be used in a variety of molded fiberglass products. For example, referring to Figures 15A-15C, in one embodiment, a compression-molded fiberglass product can be manufactured using the binderless and / or dry-binder fiberglass pack described in this application. Referring to Figure 15A, the binderless and / or dry-binder fiberglass pack 1522 manufactured by any exemplary embodiment described in this application is placed between the first and second mold halves 1502. In the exemplary embodiment, only the binderless or dry-binder fiberglass pack 1522 is placed between the mold halves. That is, additional materials such as, for example, plastic sheets or plastic resins are not molded together with the fiberglass pack. 【0158】 Referring to Figure 15B, the mold half compresses the fiberglass pack 1522 as indicated by arrow 1504. The mold half and / or fiberglass pack can be optionally heated as indicated by arrow 1506. For example, if pack 1522 is a binderless fiberglass pack, the mold half and / or fiberglass pack can be heated to a high temperature, for example, above 700°F, for example, between 700°F and 1100°F, and in one exemplary embodiment to about 900°F. If pack 1522 is a dry-binder fiberglass pack, the mold half and / or fiberglass pack can be heated to a lower temperature, for example, to the melting point of the dry binder in the pack. 【0159】 Referring to Figure 15C, the mold half is then moved away as indicated by arrow 1508, and the compression-molded fiberglass part 1510 is removed. In one exemplary embodiment, the compression-molded fiberglass part 1510 consists of, or essentially consists of, the material of pack 1522. 【0160】 In the examples shown in Figures 15A-15C, the compression-molded fiberglass component is shaped. However, in other exemplary embodiments, the compression-molded fiberglass component can be substantially flat. In one exemplary embodiment, the binderless or dry-binder compression-molded fiberglass component 1610 has a density substantially higher than the density of the initially prepared fiberglass pack 1522, for example, four times or more the density of the initially prepared fiberglass pack 1522. 【0161】 Referring to Figures 16A-16C, in one exemplary embodiment, a vacuum-formed fiberglass product can be manufactured using a binderless or dry-binder fiberglass pack described in this application. Referring to Figure 16A, the binderless and / or dry-binder fiberglass pack 1522 manufactured by any exemplary embodiment described in this application is placed on a vacuum mold component 1602. In one exemplary embodiment, only the binderless or dry-binder fiberglass pack 1522 is placed on the mold component 1602. That is, additional materials such as, for example, a plastic sheet or plastic resin are not molded together with the fiberglass pack. 【0162】 Referring to Figure 16B, the mold component applies a vacuum to the fiberglass pack 1522 as indicated by arrow 1604. Heat is optionally applied to the mold component 1602 and / or the fiberglass pack as indicated by arrow 1606. For example, if the pack 1522 is a binderless fiberglass pack, the vacuum mold component 1602 and / or the fiberglass pack 1522 can be heated to a high temperature, for example, above 700°F, for example, between 700°F and 1100°F, and in one exemplary embodiment to about 900°F. If the pack 1522 is a dry-binder fiberglass pack, the mold component and / or the fiberglass pack can be heated to a lower temperature, for example, to the melting point of the dry binder in the pack. 【0163】 Referring to Figure 15C, the vacuum mold component 1602 stops applying vacuum, and the vacuum-formed fiberglass component 1610 is removed. In one exemplary embodiment, the compression-formed fiberglass component 1610 consists of, or essentially consists of, the material of pack 1522. 【0164】 In the examples shown in Figures 16A-16C, the vacuum-formed fiberglass component is shaped. However, in other exemplary embodiments, the vacuum-formed fiberglass component can be substantially flat. In one exemplary embodiment, the binderless or dry-binder vacuum-formed fiberglass component 1610 has a density substantially higher than the density of the initially prepared fiberglass pack 1522, for example, four times or more the density of the initially prepared fiberglass pack 1522. 【0165】 In one exemplary embodiment, the insulating material molded by the embodiments shown in Figures 15A–15C or 16A–16C is made from a binderless fiberglass pack made by one or more embodiments disclosed in this patent application. In the exemplary embodiment, since the fiberglass pack is binderless, formaldehyde is not present in the compression-molded part 1510 or vacuum-formed part of the embodiments shown in Figures 15A–15C and 16A–16C. 【0166】 In exemplary embodiments, the insulating material formed by the embodiments shown in Figures 15A–15C or Figures 16A–16C is made from a dry binder fiberglass pack made by one or more embodiments disclosed in this patent application. In these exemplary embodiments, the dry binder may be a formaldehyde-free dry binder or a formaldehyde-free dry binder. In a formaldehyde-free binder, the binder itself does not contain formaldehyde, but formaldehyde may be produced as a by-product when the binder is burned. 【0167】 Several exemplary embodiments of mineral fiber webs, packs, and staple fibers, as well as methods for producing mineral fiber webs, packs, and staple fibers, are disclosed in this application. Mineral fiber webs and packs and methods for producing mineral fiber webs and packs according to the present invention may include any combination or subcombination of the features disclosed in this application. 【0168】 In accordance with the provisions of the Patent Act, the principle and embodiments of an improved method for forming a pack from a fibrous material are described and illustrated in preferred embodiments. However, it should be understood that the improved method for forming a pack from a fibrous material can be carried out in ways other than those specifically described and illustrated, without departing from its spirit or scope. [Explanation of Symbols] 【0169】 300: Pack 312, 612: Molten glass 314, 614: Melting equipment 316, 616: Forehaars 318, 618: Rotary spinning machine 320, 620: Fiberglass veil 321, 521: Web 322, 622: Glass fiber 324, 624: Collection members 330, 630, 678, 680, 682: Duct 332, 332', 632a, 632b: Molding equipment 334, 634a, 634b: Lamination mechanism (folding mechanism) 345, 645: Entanglement mechanism 336, 636, 644, 648, 652, 658: Conveyor 350: Laminated Web 352: Entangled Web 370: Entanglement Pack 375: Compression mechanism 390, 590: Storage machine 525, 527, 529, 531, 533, 535, 537, 594, 595, 596, 597, 827, 829, 831, 833: Dry binder addition 398, 598: Diversion mechanism 550, 650: Hardening furnace 610: Method for forming a pack from fibrous material 640: Trimming mechanism 646: Binder Applicator 654: Cutting mechanism 656: Chopping mechanism 660: Packaging mechanism 900: Binder 902: Air Trumpet 910: Rotating drum 1000: Insulating products 1002: Thick low-density core (low-density layer) 1004: Thin, high-density tensile layer (outer layer) 1050: Hierarchical Bat or Pack 1052: Low density hierarchy 1054: Dense hierarchy 1210: Hot oven 1215: Inner oven liner 1216: Oven Cavity 1233: Exterior oven cabinet 1236: Air gap 1238: Insulation materials 1502:Mold half part 1510: Compression-molded fiberglass parts 1522: Binderless or dry binder fiberglass pack 1602: Vacuum mold components 1610: Vacuum-formed fiberglass parts

Claims

[Claim 1] An insulation system for thermal equipment, An outer cabinet having an inner surface, Displaced within the aforementioned outer cabinet, the liner includes an outer surface, The liner includes a fibrous insulating material deposited between the outer surface and the inner surface of the outer cabinet, The fibrous thermal insulation material comprises a layer of a binderless web of glass fibers, and the binderless web of glass fibers comprises glass fibers that are mechanically intertwined to form the web. The aforementioned web has a density of 5 to 50 grams per square foot (0.054 to 0.54 kg / m²). 2 ) has a weight per unit area, The glass fibers have diameters ranging from 9 HT (2.3 μm) to 35 HT (8.9 μm), and the glass fibers in each layer have the same average diameter. The glass fibers have a length range from 0.25 inches (0.64 cm) to 10.0 inches (25.4 cm). The fibrous insulating material is formed by folding the binderless web. An insulating system characterized by the following features. [Claim 2] The thermal insulation system according to claim 1, characterized in that the glass fibers are mechanically entangled by needling. [Claim 3] The thermal insulation system according to claim 1, characterized in that the thermal equipment is a thermal oven. [Claim 4] An insulation system for thermal equipment, An outer cabinet having an inner surface, Displaced within the aforementioned outer cabinet, the liner includes an outer surface, A laminated binderless web of glass fibers deposited between the outer surface of the liner and the inner surface of the outer cabinet, wherein the glass fibers are mechanically entangled to form the web, comprising: The aforementioned laminated binderless web of glass fibers The first web of glass fibers, The first web of glass fibers comprises at least one additional web of glass fibers deposited on the first web of glass fibers, The first web has a density of 5 to 50 grams per square foot (0.054 to 0.54 kg / m²). 2 ) has a weight per unit area, The glass fibers have a diameter range from 9 HT (2.3 μm) to 35 HT (8.9 μm), and the glass fibers of the first web have the same average diameter as the glass fibers of the at least one additional web. The glass fibers have a length range from 0.25 inches (0.64 cm) to 10.0 inches (25.4 cm). An insulating system characterized by the following features. [Claim 5] The thermal insulation system according to claim 4, characterized in that the glass fibers of the first web are mechanically entangled with the glass fibers of at least one additional web. [Claim 6] The thermal insulation system according to claim 4, characterized in that the glass fibers are mechanically entangled by needling. [Claim 7] The thermal insulation system according to claim 4, characterized in that the thermal equipment is a thermal oven. [Claim 8] An insulation system for thermal equipment, An outer cabinet having an inner surface, Displaced within the aforementioned outer cabinet, the liner includes an outer surface, The liner includes a fibrous insulating material deposited between the outer surface and the inner surface of the outer cabinet, The fibrous thermal insulation material is formed from one or more binderless webs of glass fibers that are laminated together to form a fibrous thermal insulation material, and the binderless webs of glass fibers include glass fibers that are mechanically entangled to form the web. The aforementioned web has a density of 0.10 to 0.38 pounds per square foot (0.5 to 1.9 kg / m²). 2 ) has a weight per unit area, The glass fibers have a diameter range from 9 HT (2.3 μm) to 35 HT (8.9 μm), and the glass fibers in each web have the same average diameter as the glass fibers in adjacent webs. The glass fibers have a length range from 0.25 inches (0.64 cm) to 10.0 inches (25.4 cm). An insulating system characterized by the following features. [Claim 9] The thermal insulation system according to claim 8, characterized in that the binderless web of glass fibers contains 99% to 100% glass, or 99% to 100% glass and an inert component that does not bond the glass fibers to each other. [Claim 10] The thermal insulation system according to claim 8, characterized in that the glass fibers are mechanically entangled by needling. [Claim 11] An insulation system for thermal equipment, An outer cabinet having an inner surface, Displaced within the aforementioned outer cabinet, the liner includes an outer surface, A laminated binderless web of glass fibers deposited between the outer surface of the liner and the inner surface of the outer cabinet, wherein the glass fibers are mechanically entangled to form the web, comprising: The aforementioned laminated binderless web of glass fibers The first web of glass fibers, The first web of glass fibers comprises at least one additional web of glass fibers deposited on the first web of glass fibers, The first web has a density of 0.05 to 0.2 pounds per square foot (0.24 to 0.98 kg / m²). 2 ) has a weight per unit area, The glass fibers have a diameter range from 9 HT (2.3 μm) to 35 HT (8.9 μm), and the glass fibers of the first web have the same average diameter as the glass fibers of the at least one additional web. The glass fibers have a length range from 0.25 inches (0.64 cm) to 10.0 inches (25.4 cm). An insulating system characterized by the following features. [Claim 12] The thermal insulation system according to claim 11, characterized in that the laminated binderless web of glass fibers contains 99% to 100% glass, or 99% to 100% glass and an inert component that does not bond the glass fibers to each other. [Claim 13] The thermal insulation system according to claim 11, characterized in that the glass fibers are mechanically entangled by needling. [Claim 14] An insulation system for thermal equipment, An outer cabinet having an inner surface, Displaced within the aforementioned outer cabinet, the liner includes an outer surface, The liner includes a fibrous insulating material deposited between the outer surface and the inner surface of the outer cabinet, The fibrous thermal insulation material is formed from one or more binderless webs of glass fibers that are laminated together to form the fibrous thermal insulation material, and the binderless webs of glass fibers include glass fibers that are mechanically entangled to form the web. The aforementioned web has a density of 5 to 50 grams per square foot (0.054 to 0.54 kg / m²). 2 ) has a weight per unit area, The glass fibers have a diameter range from 9 HT (2.3 μm) to 35 HT (8.9 μm), and the glass fibers in each web have the same average diameter as the glass fibers in adjacent webs. The glass fibers have a length range from 0.25 inches (0.64 cm) to 10.0 inches (25.4 cm). The binderless web of the glass fibers contains 99% to 100% glass, or 99% to 100% glass and an inert component that does not bond the glass fibers to each other. An insulating system characterized by the following features. [Claim 15] An insulation system for thermal equipment, An outer cabinet having an inner surface, Displaced within the aforementioned outer cabinet, the liner includes an outer surface, A laminated binderless web of glass fibers deposited between the outer surface of the liner and the inner surface of the outer cabinet, wherein the glass fibers are mechanically entangled to form the web, comprising: The aforementioned laminated binderless web of glass fibers The first web of glass fibers, The comprising at least one additional web of glass fibers deposited on the first web of glass fibers. The first web has a density of 5 to 50 grams per square foot (0.054 to 0.54 kg / m²). 2 ) has a weight per unit area, The glass fibers have a diameter range from 9 HT (2.3 μm) to 35 HT (8.9 μm), and the glass fibers of the first web have the same average diameter as the glass fibers of the at least one additional web. The glass fibers have a length range from 0.25 inches (0.64 cm) to 10.0 inches (25.4 cm). The laminated binderless web of glass fibers contains 99% to 100% glass, or 99% to 100% glass and an inert component that does not bond the glass fibers to each other. An insulating system characterized by the following features.

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