Fiberglass Product with Sinusoidal Fiber Curl Layer
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Solution Overview
Problem
Existing fiberglass mat manufacturing processes lack the ability to consistently produce a product with a fiber curl layer that provides both structural rigidity and filtering capacity, while maintaining uniform fiber bundle diameters and curl characteristics.
Innovation Solution
A method involving a fiberglass mat with a fiber curl layer, a fiber skin layer, and a fiber loft layer, where the fiber curl layer is formed using a sinusoidal pattern of fibers with controlled bundle diameters and curl lengths, and the skin and loft layers are created through specific traversing movements of a drum and furnace to achieve desired mechanical and filtering properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional fiberglass mat manufacturing processes are used, then production can proceed with standard equipment and methods, but the product lacks consistent fiber bundle diameter control and uniform curl characteristics
Solution Approach 1:
The manufacturing process is segmented into distinct operational phases: drum rotation at controlled speeds, furnace traversing at specific rates, and resin application at designated locations. This segmentation allows each parameter to be independently controlled and optimized, achieving consistent fiber bundle diameters and uniform curl characteristics without requiring complete process redesign.
Solution Approach 2:
The invention implements specific parameter changes including drum rotation speeds, furnace traversing rates, and resin application timing to control fiber bundle formation. By precisely adjusting these parameters, the process achieves uniform fiber bundle diameters and consistent curl characteristics while maintaining manufacturability with standard equipment.
2Strength
If fiber bundles are made tighter and more uniform, then structural rigidity and filtering capacity improve, but the manufacturing process becomes more difficult to control
Solution Approach 1:
The invention achieves tighter and more uniform fiber bundles by implementing specific parameter changes: controlling drum rotation speed to optimize fiber wrapping, adjusting furnace traversing rate to regulate heating and curing, and timing resin application to ensure proper bonding. These parameter adjustments produce the desired structural rigidity while maintaining ease of manufacture through systematic process control.
3Reliability
If multiple layers with different densities are created, then filtering capacity and structural support are enhanced, but the manufacturing process complexity increases
Solution Approach 1:
The invention applies local quality by creating distinct layers with different densities and properties at specific locations within the fiberglass mat. The fiber curl layer provides structural support while the loft layer enhances filtering capacity. Each layer is formed through localized process adjustments including drum position, furnace traversing, and resin application, achieving enhanced reliability without requiring complex multi-device systems.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method results in a fiberglass product with enhanced structural support and filtering capacity, characterized by consistent fiber bundle diameters and curl characteristics, improving the overall performance and usability in applications such as paint filtration.
Implementation Method 1
The fine glass fibers are in turn wrapped circumferentially around a rotating drum
Implementation Method 2
a melting furnace feeding molten glass to orifices which discharge fine glass fibers
Implementation Method 3
orifices which discharge fine glass fibers
Data Source
AI summary
In the description and drawings a final fiberglass product is disclosed. The final fiberglass product may have a fiber curl layer, a fiber skin layer, and a fiber loft layer between the fiber curl layer and the fiber skin layer. The fiber curl layer may be on an unfiltered air entry side of the final fiberglass product and have a plurality of generally sinusoidal fiber bundles therein.