Abstract: A method of forming a needled rotary fiberglass glass insulation product is provided. The formation of the needled insulation product may be conducted in a continuous in-line process in which the fibers are rotary formed, a binder is sprayed onto the hot fibers, the fibers are collected onto a conveyor and formed into a fiberglass pack, the fiberglass pack is passed through the oven, and the cured insulation blanket is passed through a needling apparatus. The reduction in thickness and increased density caused by the needling process permits the production of lower thickness and higher density insulation products. In particular, the needled insulation product may have a thickness of less than about 0.75 inches and a density from about 1 pcf to about 10 pcf. The needled insulation product may be utilized in household appliances, water heaters, and HVAC equipment.

Abstract: The present invention relates to a method of making mineral fibers, comprising providing a circulating combustion chamber (1) which comprises a top section (2), a bottom section (3) and a base section (4), injecting primary fuel, particulate mineral material and primary combustion gas into the top section of the circulating combustion chamber and combusting the primary fuel thereby melting the particulate material to form a mineral melt and generating exhaust gases, separating the mineral melt from the exhaust gases wherein the exhaust gases pass through an outlet (8) in the circulating combustion chamber and the mineral melt collects in the base section of the circulating combustion chamber, injecting secondary fuel, which comprises liquid or gaseous fuel, and secondary combustion gas into the bottom section of the circulating combustion chamber to form a flame in the bottom section which heats the melt, and flowing a stream of the collected melt through an outlet (15) in the base section to a centrifugal fi

Abstract: Fibrous material webs and methods of making the fibrous material webs. Binderless webs can be formed in a continuous process where fiber material, such as glass is melted and formed into fibers. The fibers are formed into a web of binderless glass fibers or a web with a dry binder. The binderless web or the web with dry binder can be layered and/or the fibers that make up the web can be mechanically entangled, for example, by needling.

Abstract: An apparatus for the production of a mineral melt burns combustible material in the presence of inorganic material to form a melt. The apparatus includes a circulating combustion chamber which receives a fuel, pre-heated mineral material and a combustion gas, melts the mineral material and generates exhaust gases which are separated from the melt. The gases pass through an exhaust pipe to a conduit of a heat exchange system. The apparatus includes a quenching hood for quenching the exhaust gases by drafting a cooling fluid, such as ambient air, into the flow of exhaust gases around the exhaust pipe, and wherein the exhaust gases exit the exhaust pipe inside the hood.

Abstract: An apparatus for the production of a mineral melt burns combustible material in the presence of inorganic particulate material to form a melt. The apparatus has a circulating combustion chamber having at least two inlets which receive fuel, pre-heated mineral material, and combustion gas. A heat exchange system for pre-heating the mineral material has a pre-heater cyclone, a conduit running from the circulating combustion chamber to the first pre-heater cyclone for transporting exhaust gases, a material inlet for injecting the material into the conduit, and a bottom cyclone outlet for feeding pre-heated mineral material to the combustion chamber. The outlet of the pre-heater cyclone stabilizes and splits the mineral material flow into two material flows for feeding combustion chamber inlets.

Abstract: In a method of producing fibers having property enhancing inclusions, a molten material is supplied to a fiber forming apparatus. A controlled amount of particulate is added to the molten material. The molten material with the added particulate is formed into fibers. An undissolved portion of the added particulate forms inclusions in the fibers, the inclusions having an absorption index in a 2-7 ?m wavelength region that is greater than a corresponding absorption index of the material.

Abstract: A novel spinner, for fiberizing hollow, irregularly-shaped insulating fibers is the subject matter of the present invention. The spinner is unique in a sense that its hole/slot pattern can be done by some standard drilling/milling techniques, which lower the cost of manufacturing. The invention uses two molten glasses (A and B) of different coefficients of thermal expansion, which are moved outwardly around the corresponding gas orifices by centrifugal force in a spinner pot. A stream of pressurized combustion gases is thrust through these central gas orifices to produce a hollow, non collapsible fiber of irregular shape. Molten glass A is introduced from the bottom of the spinner, and molten glass B is introduced above an uppermost flange and by means of centrifugal force, the two glasses A and B are forced upwardly and downwardly, respectively, into fiberizing centers.

Abstract: The present invention relates to a method for spinning fibers, or fiberizers, using a rotary fiber-making die system made up of thin plates, embodied by a housing fixture, configured and stacked to define slots, channels and/or grooves through which the material used to make the fibers will flow. The die system allows for the production of different size and types of fibers, including nanofibers having a diameter of less than 1 micron, and facilitates a variety of cost effective methods for extrusion. The use of plates means the dies can be manufactured cost effectively, with easier clean-outs, replacements and/or variations.

Abstract: A nonwoven fibrous insulation product has at least a bi-modal fiber diameter distribution designed to provide the product with selected thermal insulating and physical performance properties that are affected by fiber diameter such as rigidity and recovery properties. The product is made by: forming two or more fiber groupings that each have a selected fiber diameter distribution with a selected mean fiber diameter wherein the selected fiber diameter distributions of the fiber groupings differ from each other. The fibers of the fiber groupings are intermingled and entangled together in selected percentages by weight to form a product with a selected density and thickness that exhibits selected product performance properties based on the properties of the fiber groupings and the relative percentages by weight of the fiber groupings.

Abstract: A method for distributing fibrous material, wherein fibrous material, which is fiberized by a spinner of a fiberizing unit, is accumulated on a collection conveyor disposed under the spinner, is characterized by rotatably disposing a hollow cylindrical bucket at a position just under the spinner, the hollow cylindrical bucket having a two-stage structure comprising an upper stage part and a lower stage part, the lower stage part being inclined at an angle with respect to a rotary axis of the hollow cylindrical bucket; and rotating the hollow cylindrical bucket, dispersing the fibrous material in the hollow cylindrical bucket and accumulating the fibrous material on the collection conveyor after flowing down the fibrous material in the hollow cylindrical bucket.

Abstract: A method of producing glass fiber comprising: driving a bottomed hollow cylindrical rotor to rotate at high speed around a vertical rotary shaft, said rotor comprising a bottom, a peripheral wall and an annular flange, said peripheral wall being extended upwardly from an outer peripheral edge of the bottom and provided with a large number of fine holes, said annular flange extending inwardly from an upper edge of the peripheral wall; falling molten glass to the bottom of the rotor; and ejecting molten glass through said fine holes by centrifugal force generated by the high speed rotation of the rotor, to form the molten glass into filaments, and to produce glass fiber; characterized in that molten glass is made to fall at a position on the bottom, said position being apart from an inner edge of said annular flange by at least 10 mm or more, and apart from an inner surface of said peripheral wall by not more than 75 mm, the bottom having a large thickness at the position.

Abstract: A method for producing fibers from molten waste includes melting waste in a melter into high-temperature molten fluid, discharging the high-temperature molten fluid from the melter, and fiberizing the high-temperature molten fluid to form solid fibers. The solid fibers possess excellent fire-resistant properties and thus can be used as fire-resistant materials.

Abstract: An apparatus for making mineral fibers is provided. The apparatus comprises a rotary fiberizer capable of receiving molten mineral material and centrifuging the molten mineral material into mineral fibers. A fiberizer burner is connected to the rotary fiberizer. The fiberizer burner is configured to receive a first flow of combustion gas and burn the first flow of combustion gas to support the making of the mineral fibers. A gas supply assembly is configured to supply the fiberizer burner with the first flow of combustion gas. The gas supply assembly comprises a pilot assembly having a pilot burner. The pilot burner is operable to burn a pilot flame from a second flow of combustion gas. The pilot flame is operable to ignite the first flow of combustion gas flowing to the fiberizer burner. A flame sensor is operable to detect a change in the pilot flame and communicate the change in the pilot flame.

Abstract: A method for producing fibers from molten waste includes melting waste in a melter into high-temperature molten fluid, discharging the high-temperature molten fluid from the melter, and fiberizing the high-temperature molten fluid to form solid fibers. The solid fibers possess excellent fire-resistant properties and thus can be used as fire-resistant materials.

Abstract: A method for distributing fibrous material, wherein fibrous material, which is fiberized by a spinner of a fiberizing unit, is accumulated on a collection conveyor disposed under the spinner, is characterized by rotatably disposing a hollow cylindrical bucket at a position just under the spinner, the hollow cylindrical bucket having a two-stage structure comprising an upper stage part and a lower stage part, the lower stage part being inclined at an angle with respect to a rotary axis of the hollow cylindrical bucket; and rotating the hollow cylindrical bucket, dispersing the fibrous material in the hollow cylindrical bucket and accumulating the fibrous material on the collection conveyor after flowing down the fibrous material in the hollow cylindrical bucket.

Abstract: A method of controlling process variables, for a fiberizing assembly including a rotary fiberizing disk in the manufacture of fibers from a high temperature, molten, clear or translucent, thermoplastic, fiberizable material, utilizes an optical sensor assembly. The optical sensor assembly includes a water-cooled optical fiber sensor probe which, in effect, only gathers light emitted from the external sidewall surface of the rotary fiberizing disk. The light is conducted from the probe to an electronic unit that converts the light energy into a temperature value. This temperature value is used to monitor the process and to make any changes in process variables, such as but not limited to heat input to the fiberizing disk, rate of rotation of the fiberizing disk, burner air/fuel ratio, required to produce fibers having desired fiber properties.

Abstract: A spinner disc for fiberizing a molten thermoplastic fiberizable material in a rotary fiberization process includes a base plate, an annular peripheral sidewall, and an upper annular reinforcing flange. The annular peripheral sidewall of the disc has a plurality of annular extending rows of fiberizing holes therein for fiberizing thermoplastic materials by centrifugal force. At least an uppermost row of the annular extending rows of fiberizing holes is interrupted by a plurality of spaced apart generally vertically extending holeless retaining bands for maintaining the upper annular reinforcing flange connected to the annular peripheral sidewall when the annular peripheral sidewall cracks along one of the annular extending rows of fiberizing holes due to the hole wear and enlargement that occurs during service.

Abstract: Provided is a process and apparatus for applying a liquid binder to fibers. The process involves introducing heat curable liquid binder onto moving fibers by atomizing the liquid binder and applying the atomized binder from a point within the moving column of fibers. Better binder efficiency and a more efficient overall process is realized.

Abstract: The process for manufacturing mineral wool by internal centrifuging is characterized in that the temperature of the mineral material in the fiberizing spinner dish is at least 1150° C. and in that the fiberizing spinner dish is made of a cobalt-based alloy comprising the following elements (in percentages by weight of the alloy): 1 Cr  23 to 34% Fe less than 3% Ni   6 to 12% Si less than 1% Ta   3 to 10% Mn less than 0.5% C 0.2 to 1.2% Zr less than 0.

Abstract: A method of controlling process variables, for a fiberizing assembly including a rotary fiberizing disk in the manufacture of fibers from a high temperature, molten, clear or translucent, thermoplastic, fiberizable material, utilizes an optical sensor assembly. The optical sensor assembly includes a water-cooled optical fiber sensor probe which, in effect, only gathers light emitted from the external sidewall surface of the rotary fiberizing disk. The light is conducted from the probe to an electronic unit that converts the light energy into a temperature value. This temperature value is used to monitor the process and to make any changes in process variables, such as but not limited to heat input to the fiberizing disk, rate of rotation of the fiberizing disk, burner air/fuel ratio, required to produce fibers having desired fiber properties.

Abstract: Reinforced fiber insulation is formed by depositing a mixture of textile fiber segments and rotary and/or flame attenuated segments on a surface, mixing a binder with the fibers, and heating the binder to join the fibers together. The low cost process provides a mixed fiber insulation product with improved strength after compression.

Abstract: A spinner disc for a rotary fiberization process, includes a base plate and an annular peripheral sidewall extending upward from the base plate which has a plurality of rows of fiberizing holes therein for fiberizing molten thermoplastic fiberizable materials by centrifugal force. The base plate has: a central bore therein on a rotational axis of the spinner disc for mounting the spinner disc on a drive shaft; an outer annular portion for receiving molten thermoplastic fiberizable materials to be fiberized; and an inner annular portion intermediate the central bore and the outer annular base plate portion.

Abstract: Mineral wool capable of dissolving in a physiological medium, which mineral wool comprises the constituents below in the following percentages by weight: SiO2 39-55%, preferably 40-52% Al2O3 16-27%, ″ 16-25% CaO  3-35%, ″ 10-25% MgO  0-15%, ″  0-10% Na2O  0-15%, ″  6-12% K2O  0-15%, ″  3-12% R2O (Na2O + K2O) 10-17%, ″ 12-17% P2O5 0-3%, ″ 0-2% Fe2O3  0-15%, B2O3 0-8%, ″ 0-4% TiO2 0-3%, and in that MgO is between 0 and 5%, especially between 0 and 2%, when R2O≦13.0%.

Abstract: Man-made vitreous fibers have a solubility at pH 4.5 of at least 20 nm per day, a liquidus temperature of below 1300.degree. C., a viscosity at the liquidus temperature of about 300 poise, and a composition which includes at least 15% by weight Al.sub.2 O.sub.3.

Abstract: A multi-component fiberizing disk for fiberizing a molten fiberizable material in a rotary fiberization process includes: an annular sidewall having fiberizing holes therein through which a molten fiberizable material passes to fiberize the molten fiberizable material; an upper annular flange; and a base having an annular outer peripheral edge. The annular sidewall, the upper annular flange and the base are made from at least two separate components and, preferably, from three separate components. The separate components are secured to together as the fiberizing disk by fasteners, such as bolt and nut fasteners, that permits the separate components of the fiberizing disk to be disassembled after service. The different components can be made of different metal alloys and a distribution manifold can be incorporated into the fiberizing disk for distributing the molten fiberizable material(s) within the fiberizing disk and to make bi-component fibers.

Abstract: The invention relates to the electric melting technique, in which the melting energy is dissipated in the bath of melted glass as a result of the Joule effect by means of electrodes which dip through the surface of the bath. According to the invention, the electrodes dip into a bath of melted glass which has a height h below 800 mm and a surface S such that the ratio h/S is lower than 0.5 m/m.sup.2. According to another aspect, the exchange surface between the electrodes and the bath is above 0.075 m.sup.2 /m.sup.3 of glass.The invention is used in the manufacture of glass-based products, such as insulating materials based on glass fiber.

Abstract: A method for collecting long glass fibers produces substantial lattice uniformity, eliminates the need for binder, and results in a generally rectangular wool pack which displays significant compressibility and recovery desired for commercial products. Generally spiral flow of fibers in the veil is captured on collecting conveyors and conveyed through direct forming apparatus with generally minimal disturbance of the spiral relationship between glass fibers. Further, a system is disclosed for producing wool insulation products of long glass fibers in accordance with the method. The principles and practices of the method and system may further be employed with short fibers to produce a wool pack of generally oriented short fibers.

Abstract: In a process for producing insulating materials with environmentally safe binding components, a long-chain starch is used as binder, besides silicone. The starch is heated up to 50.degree. to 60.degree. C., held at this temperature and sprayed on the glass fibers separately from the silicone; 6 to 8% binder, consisting of starch and silicone, are used, then a spun-glass mat or slab may be shaped and dried at about 180.degree. C. A spun-glass mat (16), insulating mat or slab or adsorber is thus obtained which surprisingly is water-proofed and held together exclusively by starch, resin and silicone, which may be used without any problems and has a uniform bulk density throughout. In the plant (1) provided for that purpose, supply rings for water (9), for starch (10) and for silicone (11) are provided. The nozzles (13) for the supply ring 10 have a larger opening and separation edges. The premixing container (17) and the supply pipe (15) are heatable or heat-insulated.

Abstract: In a method for producing hollow mineral fibers such as glass fibers, molten glass is supplied to a rotating glass spinner having a peripheral wall. The spinner rotates so that molten glass is centrifuged through a first tube positioned at least mostly inside the peripheral wall of the spinner in an orifice to form fibers. Gas is introduced into the interior of the molten glass to form hollow glass fibers. A second tube positioned inside the first tube includes an inlet in the wall of the first tube, wherein the orifice and first tube are adapted to allow gas to be introduced through the inlet from outside the peripheral wall. The hollow glass fibers are then collected to form a product such as a mat.

Abstract: A method for producing mineral fibers includes centrifuging mineral fibers from one or more rotary mineral fiber spinners to establish one or more downwardly moving veils of mineral fibers positioned above a collecting surface, centrifuging organic fibers from molten organic material using one or more rotary organic fiber spinners to establish one or more downwardly moving veils of organic fibers positioned above the collecting surface, the veils of mineral fibers being generally colinear with the veils of organic fibers, the veils of organic fibers alternating with the veils of mineral fibers to integrate the organic material and the mineral fibers, and collecting the integrated organic material and mineral fibers on the collecting surface.

Abstract: A method for making dual-glass fibers includes supplying first and second molten glass to a rotating spinner having an orificed peripheral wall, where the first glass has a higher viscosity than that of the second glass, centrifuging the first and second glasses through the orifices as molten dual-glass streams, maintaining the dual-glass streams at a temperature sufficient to enable the second glass to flow around the first glass, and cooling the dual-glass streams to make dual-glass fibers.