Nonwoven fibrous insulation material
First Claim
1. A nonwoven composite fibrous material comprising:
- a discrete layer consisting essentially of inorganic fibrous material containing fibers in an unbonded state;
at least one discrete nonwoven carrier web positioned on a surface of said discrete layer of said inorganic fibrous material;
said discrete nonwoven carrier web including an admixture of inorganic fibers and organic fibers;
said inorganic fibers and said organic fibers of said nonwoven discrete carrier web being blended in a nonwoven structure with a preselected thickness and density with said organic fibers of said discrete carrier web comprising about 1% or less by weight of said composite fibrous material; and
said nonwoven discrete carrier web being needle punched to said discrete layer of said inorganic fibrous material to interlock said inorganic fibers and said organic fibers of said carrier web with said fibers of said layer of inorganic fibrous material so as to bond together said fibers of said inorganic fibrous material and form said nonwoven composite fibrous material which is cohesive and has a mechanical strength and flexibility to resist separation of said fibers of said layer of said inorganic fibrous material upon handling.
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Accused Products
Abstract
A nonwoven composite fibrous material adaptable as an insulation medium is formed by a loose layer of inorganic fibers, such as rock wool, glass, ceramic, carbon-graphite or the like, bonded together by at least one carrier web layer positioned on a surface of the inorganic fibrous layer. The carrier web layer is a blend of inorganic fibers and organic fibers with the organic fibers comprising about 1% or less by weight of the total nonwoven composite fibrous material. Both organic and inorganic fibers of the carrier web are advanced into interlocking relation with the fibers of the inorganic layer by needle punching the carrier web. The carrier web organic and inorganic fibers have a length greater than the thickness of the inorganic layer in the composite fibrous material so that the needle punching advances organic and inorganic fibers from the carrier web completely through the inorganic layer to mechanically bind together the fibers of the inorganic layer to resist separation of the fibers and delamination of the inorganic layer upon handling and installation.
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Citations
19 Claims
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1. A nonwoven composite fibrous material comprising:
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a discrete layer consisting essentially of inorganic fibrous material containing fibers in an unbonded state; at least one discrete nonwoven carrier web positioned on a surface of said discrete layer of said inorganic fibrous material; said discrete nonwoven carrier web including an admixture of inorganic fibers and organic fibers; said inorganic fibers and said organic fibers of said nonwoven discrete carrier web being blended in a nonwoven structure with a preselected thickness and density with said organic fibers of said discrete carrier web comprising about 1% or less by weight of said composite fibrous material; and said nonwoven discrete carrier web being needle punched to said discrete layer of said inorganic fibrous material to interlock said inorganic fibers and said organic fibers of said carrier web with said fibers of said layer of inorganic fibrous material so as to bond together said fibers of said inorganic fibrous material and form said nonwoven composite fibrous material which is cohesive and has a mechanical strength and flexibility to resist separation of said fibers of said layer of said inorganic fibrous material upon handling. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A nonwoven composite insulation material comprising:
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a discrete layer consisting essentially of mineral wool fibers, said layer having a preselected thickness, said mineral wool fibers of said layer being in an unbonded state; at least one carrier web for bonding together said mineral wool fibers; said carrier web including an admixture of inorganic fibers and organic fibers; said inorganic fibers and said organic fibers being blended to form a nonwoven structure with said organic fibers thereof comprising about 1% or less by weight of said composite insulation material; said carrier web being positioned with said layer of said mineral wool fibers; and said carrier web being needle punched to said layer of said mineral wool fibers to interlock said inorganic fibers and said organic fibers of said carrier web with said mineral wool fibers so as to bond together said mineral wool fibers and form said nonwoven composite insulation material.
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11. A process for making a nonwoven fibrous material comprising the steps of:
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blending inorganic fibrous material in a concentration by weight of at least about 90% with organic fibrous material to form at least one composite nonwoven carrier web of carrier fibers having a preselected thickness and density; positioning said carrier web in contact with a layer of inorganic fibers, said layer comprising an unstructured concentration of said inorganic fibers of a preselected thickness and density; and needle punching said carrier web to advance said carrier fibers into interlocking relation with said inorganic fibers to bond together said inorganic fibers to form said nonwoven fibrous material having a preselected thickness and density and a content of said organic fibrous material of about 1% or less by weight. - View Dependent Claims (12, 13)
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14. A process for making a carrier web comprising the steps of:
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providing a plurality of inorganic fibers; providing a plurality of organic fibers; coating said inorganic fibers to increase the surface friction of said inorganic fibers; and blending said coated inorganic fibers in a preselected concentration with said organic fibers to form said carrier web having a preselected thickness and density and containing about 10% or less by weight of said organic fibers. - View Dependent Claims (15, 16, 17, 18, 19)
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Specification