Patent ID: 7585454
Filing Date: 2009-09-08
Classification: D01D,D04H

Abstract:
1. A method of producing a substantially single layer non-lofted fiber veil of an orientable polymer for the production of insulation for a blown-in application having X, Y and Z vector directions, the method comprising steps of: a) extruding the polymer by melt blowing to form molten fibers; b) directing a high velocity hot air flow around the extruded fibers with both the air flow and a length of the fibers having a common direction, the X vector direction, to carry the fibers in said X vector direction and to orient molecules of the fibers substantially along the X vector direction of the fibers; c) locating a mechanical cold roller adjacent to the fibers being carried in said X vector direction, and the cold roller being spaced and offset from the high velocity hot air flow in the X vector direction such that the fibers are removed from the high velocity hot air flow by a removal loop, prior to the fibers engaging with the cold roller; d) placing the fibers on the cold roller which is spinning in a direction to carry the fibers further away from the air flow in the X vector direction; e) choosing a rate of rotation of the cold roller whereby a force generated by the air flow pushing in said X vector direction and the fibers moving across the air flow in the removal loop toward the cold roller yields additional orientation of the fibers in the X vector direction; f) placing the cold roller so a placement of the cold roller and turbulence created by the air flow causes a percentage of the fibers to be displaced into a transverse direction, the Y vector direction; g) cooling the cold roller to quench the fibers, after the additional orientation of the molecules thereof and subsequent to removal of the fibers from the air flow, as the fibers pass over the cold roller to prevent loss of orientation of the molecules and form the substantially single layer non-lofted fiber veil and; h) applying tension to the substantially single layer non-lofted fiber veil, prior to cutting the substantially single layer non-lofted fiber veil, to facilitate further alignment of the fibers in the X vector direction and minimize any alignment of the fibers in the Y and Z vector directions.