Abstract: A fibrous insulation media is formed from a non-woven mat of thermoplastic fibers having a mean diameter of less than about 15 microns. Preferably, when used as an acoustical insulation, the media is formed of fibers having a mean diameter of less than about 13 microns; the media has a density of less than about 60 Kg/m3; and the media has a Fraiser air permeability of less than 75 cubic feet per minute per square foot of surface area. The media has first and second major surfaces and a fibrous core with at least one of the major surfaces having an integral skin thereon. The skin is formed by melting fibers at and immediately adjacent the major surface of the mat formed into the media to form a thermoplastic melt layer which is subsequently solidified into a skin on the major surface of the mat. The thermoplastic fibers of the mat are point bonded together at spaced apart locations to increase the integrity of the mat.

Abstract: A fibrous insulation media is formed from a non-woven mat of thermoplastic fibers having a mean diameter of less than about 15 microns. Preferably, when used as an acoustical insulation, the media is formed of fibers having a mean diameter of less than about 13 microns; the media has a density of less than about 60 Kg/m3; and the media has a Fraiser air permeability of less than 75 cubic feet per minute per square foot of surface area. The media has first and second major surfaces and a fibrous core with at least one of the major surfaces having an integral skin thereon. The skin is formed by melting fibers at and immediately adjacent the major surface of the mat formed into the media to form a thermoplastic melt layer which is subsequently solidified into a skin on the major surface of the mat. The thermoplastic fibers of the mat are point bonded together at spaced apart locations to increase the integrity of the mat.

Abstract: A biosoluble glass fiber filtration media includes a fibrous filtration layer of randomly oriented, entangled glass fibers which has an initial efficiency of 25% or greater as measured by ASHRAE 52.1 test method. The glass fibers forming the media have a biodissolution rate in excess of 150 ng/cm2/hr and a mean diameter between about 2.5×10−5 inches and about 11.0×10−5 inches. Typically, the filtration layer has a thickness ranging from about 0.12 inches to about 0.35 inches and a density ranging from about 3.0 g/ft2 to about 8.0 g/ft2. The filtration has an initial pressure drop of about 0.35 inches of water or less and a dirt holding capacity of about 1.5 g/ft2 or greater.

Abstract: Relatively viscous glass is fiberized in a rotary fiberization process at relatively high disk speeds and through relatively large diameter holes to form long, fine diameter glass fibers which preferably are rapidly solubilized in biological fluids. The method of forming the long, fine diameter glass fibers includes maintaining a ratio of the velocity of the external surface of the peripheral wall of the fiberizing disk to the velocity of the glass passing through the fiberizing orifices within a specific range (the disc/glass velocity ratio); maintaining a ratio of the velocity of the air exiting the air ring to the velocity of the glass passing through the fiberizing orifices within a specific range (the air-ring/glass velocity ratio); and maintaining a ratio of the BTU content of the fuel expended forming the hot attenuating combustion gases to the BTU content of a pound of molten glass being fiberized within a specific range (the attenuating combustion gases/glass heat content ratio).

Abstract: A fibrous insulation media is formed from a non-woven mat of thermoplastic fibers having a mean diameter of less than about 15 microns. Preferably, when used as an acoustical insulation, the media is formed of fibers having a mean diameter of less than about 13 microns; the media has a density of less than about 60 Kg/m3; and the media has a Fraiser air permeability of less than 75 cubic feet per minute per square foot of surface area. The media has first and second major surfaces and a fibrous core with at least one of the major surfaces having an integral skin thereon. The skin is formed by melting fibers at and immediately adjacent the major surface of the mat formed into the media to form a thermoplastic melt layer which is subsequently solidified into a skin on the major surface of the mat. The thermoplastic fibers of the mat are point bonded together at spaced apart locations to increase the integrity of the mat.

Abstract: Fine fibers are formed and carried in a high energy, high temperature gaseous stream to a primary fine fiber collection surface where fine fibers are collected from the gaseous stream. Gases of the gaseous stream along with fine fibers not removed from the gaseous stream by the primary collection surface are drawn through the primary collection surface and formed into an exhaust gas stream which is passed through a secondary fine fiber collection surface to remove additional fibers from the exhaust gas stream before it is discharged to the atmosphere. To reduce the operating temperatures at and surrounding the primary and secondary collection surfaces, the gas streams are cooled by evaporative cooling. Water is sprayed into the gas streams by nozzles, shielded from the gas streams by scoops, so that fibers do not collect on the nozzles and form fiber wads.

Abstract: In a process of making gas laid products by entraining particles at least partially coated with a binder in a gaseous stream, passing the stream through a forming chamber and through a permeable collecting surface where the particles build up to form a product like fiber glass insulation, this invention prevents particles from contacting and building up on the walls of the forming chamber and causing wet spots in the finished product by maintaining a high velocity, high pressure layer of gas close to the exposed surface of the walls of the chamber and moving in the general direction of the gaseous stream. This is accomplished by apparatus including a plurality of plenum boxes forming the walls of the forming chamber with the surface exposed to the gaseous stream having gas directing openings therein. Also, an improved method of applying the binder to the particles is disclosed.

Abstract: In a process of making gas laid products by entraining particles including fibers at least partially coated with a binder in a gaseous stream, passing the stream through a forming chamber and through a permeable collecting surface where the particles including fibers build up to form a product like fiber glass insulation, this invention prevents particles including fibers from contacting and building up on the walls of the forming chamber and causing wet spots in the finished product by maintaining a high velocity, high pressure layer of gas close to the exposed surface of the walls of the chamber and moving in the general direction of the gaseous stream. This is accomplished by apparatus including a plurality of plenum boxes forming the walls of the forming chamber with the surface exposed to the gaseous stream having gas directing openings therein.