Molded insulation products and their manufacture using continuous-filament wool

• US 6,319,444 B1
• Filed: 09/07/1999
• Issued: 11/20/2001
• Est. Priority Date: 12/02/1996
• Status: Expired due to Fees

• Current Assignee: Ocv Intellectual Capital, Llc (Owens Corning)
• Original Assignee: Owens- Corning Fiberglas Technology Incorporated (Owens Corning)
• Inventors: Kirk, Simon R.
• Primary Examiner(s): Silbaugh, Jan H.
• Assistant Examiner(s): Staicovici, Stefan
• Application Number:
  US09/319,398
• Time in Patent Office: 805 Days
• Field of Search: 264/136, 264/137, 264/257, 264/319, 264/325, 422/179, 422/180, 181/222, 181/252, 181/258, 181/294
• US Class Current: 264/136
• CPC Class Codes: B29C 70/34 and shaping or impregnating by compression , i.e. combined with compressing after the lay-up operation
• CPC Class Codes: B29C 70/50 for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
• CPC Class Codes: B29K 2105/08 of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
• CPC Class Codes: B29K 2995/0002 insulating
• CPC Class Codes: B29K 2995/0015 Insulating
• CPC Class Codes: F01N 13/14 having thermal insulation exhaust manifolds F01N13/102
• CPC Class Codes: F01N 13/18 Construction facilitating manufacture, assembly, or disassembly
• CPC Class Codes: F01N 2310/02 Mineral wool, e.g. glass wool, rock wool, asbestos or the like
• CPC Class Codes: F01N 3/2853 using mats or gaskets between catalyst body and housing

Abstract

A process of forming a thermal insulation layer (34) includes advancing a multifilament strand of continuous filaments (12) through a nozzle (10) to separate the filaments (16) from each other to form a continuous-filament wool (14), applying a binder to the filaments, placing a charge comprising the wool in a mold (32), and molding the charge to form an insulation layer (34). In a preferred embodiment, the charge (30) further comprises a container, such as a bag (24) formed from a poylmer film. The filaments are preferably prepared from a high-strength, high-temperature resistant glass material. The molded wool is advantageously used to manufacture products, such as catalytic converters (46) wherein the wool is used to thermally insulate the catalytic core element (48).

Claims

1. A process of forming a thermal insulation layer comprising advancing a strand comprising continuous filaments composed of a glass material having a softening point of at least about 700°

C. through a nozzle to separate the filaments from each other and form a continuous-filament wool, applying a binder material to the filaments, placing a charge comprising the continuous-filament wool in a compression mold, and compression molding the charge to form an insulation layer.

2. A process as defined in claim 1 in which the binder material is applied to the filaments as the filaments advance through the nozzle.

3. A process as defined in claim 1 in which the binder material is applied to the filaments after the charge is placed in the mold.

4. A process as defined in claim 1 further comprising preparing the charge by placing the continuous-filament wool in a polymeric bag.

5. A process as defined in claim 1 in which the binder material is applied in an amount yielding a content of no more than about 5 percent by weight.

6. A process as defined in claim 5 in which the continuous-filament wool has a density within the range of from about 4 to about 20 pounds per cubic foot (64 to 320 g/l).

7. A process as defined in claim 1, wherein the advancing step comprises the step of collecting the charge outside of the mold, and the placing step occurs after the charge is collected.

8. A process as defined in claim 7, wherein the charge is collected in a container.

9. A process as defined in claim 8, wherein the container comprises a bag.

10. A process as defined in claim 8, wherein the container comprises a drum.