MINERAL FIBER INSULATION HAVING THERMOPLASTIC POLYMER BINDER AND METHOD OF MAKING THE SAME
First Claim
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1. A method of forming a fibrous insulation product, comprising:
- forming at least one fibrous veil comprising first fibers;
blowing a non-aqueous, formaldehyde-free, thermoplastic binder in powder, liquid or fibrous form into said veil during said forming step to form a mixture of said binder and said first fibers, said fibrous form having average length of less than or equal to about 15 mm;
collecting said mixture on said forming belt; and
forming said mixture into an insulation batt, board or molding media.
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Abstract
A method of forming a fibrous insulation product includes forming at least one fibrous veil including first fibers and blowing a non-aqueous, formaldehyde-free, thermoplastic binder in powder, liquid or fibrous form into said veil during said forming step to form a mixture of the binder and the first fibers. When in fibrous form, the binder fibers have average length of less than or equal to about 15 mm. The mixture is collected on the forming belt and formed into an insulation batt, board or molding media.
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Citations
28 Claims
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1. A method of forming a fibrous insulation product, comprising:
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forming at least one fibrous veil comprising first fibers; blowing a non-aqueous, formaldehyde-free, thermoplastic binder in powder, liquid or fibrous form into said veil during said forming step to form a mixture of said binder and said first fibers, said fibrous form having average length of less than or equal to about 15 mm; collecting said mixture on said forming belt; and forming said mixture into an insulation batt, board or molding media. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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14. A system for forming a fibrous insulation product, comprising:
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at least one fiberizing apparatus for forming a fibrous veil comprising first fibers; means for blowing a non-aqueous, formaldehyde-free, thermoplastic binder in powder, liquid or fibrous form into said veil to form a mixture of said binder and said first fibers, said fibrous form having average length of less than or equal to about 15 mm; a forming belt disposed below said fiberizing apparatus for collecting said mixture; and an oven for heating said mixture to a temperature at or above the melting temperature of said thermoplastic binder. - View Dependent Claims (15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26)
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27. A method of forming a fibrous insulation product, comprising:
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forming at least one fibrous veil comprising first fibers; directing from a hot melt applicator a non-aqueous, formaldehyde-free, thermoplastic binder into said veil to form a mixture of said binder and said first fibers; collecting said mixture on said forming belt; heating said mixture to a temperature above the melting temperature of said thermoplastic binder in an oven, wherein at least a majority of said thermoplastic binder is melted, whereby said melted thermoplastic binder forms meltbonds with said first fibers when cooled; and forming said mixture into an insulation batt, board or molding media.
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28. A method of forming a fibrous insulation product, comprising:
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forming at least one fibrous veil comprising first fibers; forming a non-aqueous, formaldehyde-free, thermoplastic powdered binder using a gas atomization process; directing said thermoplastic powdered binder into said veil to form a mixture of said binder and said first fibers; collecting said mixture on said forming belt; heating said mixture to a temperature above the melting temperature of said thermoplastic binder in an oven, wherein at least a majority of said thermoplastic binder is melted, whereby said melted thermoplastic binder forms meltbonds with said first fibers when cooled; and forming said mixture into an insulation batt, board or molding media.
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Specification