Patent Description:
Fibrous material can be formed into various products including webs, packs, batts and blankets. Packs of fibrous material can be used in many applications, including the non-limiting examples of insulation and sound-proofing for buildings and building components, appliances and aircraft. Packs of fibrous material are typically formed by processes that include fiberizers, forming hoods, ovens, trimming and packaging machines. Typical processes also include the use of wet binders, binder reclaim water and washwater systems.

<CIT> discloses a method of forming a layered pack of glass fibers comprising a plurality of web layers that are interconnected (preferably by needle punching, or by another bonding process) to form an insulative non-woven fabric.

<CIT> discloses methods and apparatus relating to the production of mats or bats of multilayer or laminar construction fabricated of fibers from mineral materials. In the methods and apparatus disclosed therein, relatively thin veils, webs, or strata of attenuated fibers are folded or lapped upon themselves to form a mat.

<CIT> discloses glass fiber blends that are carded to form uniform coherent webs from which batts and felts may be formed.

<CIT> discloses a method for preparing a needled glass mat.

<CIT> discloses fibrous material webs and methods of making the fibrous material webs.

<CIT> discloses thin rotary-fiberized glass insulation and a process for producing the same. <CIT> discloses a glass wool shaped article and a method of formation thereof.

Accordingly, an aspect of the present invention provides a layered pack of glass fibers, the layered pack comprising: binderless webs of glass fibers formed by lapping a binderless web in the machine direction or by cross-lapping a binder less web at ninety degrees to the machine direction;.

The present invention will now be described with occasional reference to the specific exemplary embodiments of the invention.

The terminology used in the description of the invention herein is for describing particular embodiments only and is not intended to be limiting of the invention. As used in the description of the invention and the appended claims, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise.

Unless otherwise indicated, all numbers expressing quantities of dimensions such as length, width, height, and so forth as used in the specification and claims are to be understood as being modified in all instances by the term "about. " Accordingly, unless otherwise indicated, the numerical properties set forth in the specification and claims are approximations that may vary depending on the desired properties sought to be obtained in embodiments of the present invention. Any numerical values, however, inherently contain certain errors necessarily resulting from error found in their respective measurements.

The description and figures disclose an improved method of forming a pack from fibrous materials. Generally, the improved continuous methods replace the traditional methods of applying a wet binder to fiberized materials with new methods of making a batt or pack of fibers without any binder (i.e. material that binds fibers together) and/or new methods of making a batt or pack of fibers with dry binders.

The term "fibrous materials", as used herein, is defined to mean any material formed from drawing or attenuating molten materials. The term "pack", as used herein, is defined to mean any product formed by fibrous materials that are joined together by an adhesive and/or by mechanical entanglement.

<FIG> and <FIG> illustrate a continuous process or method <NUM> not in accordance with the invention of forming a pack <NUM> (see <FIG>) from fibrous materials. The dashed line <NUM> around the steps of the method <NUM> indicates that the method is a continuous method, as will be described in more detail below. The methods and packs will be described in terms of glass fibers, but the methods and packs are applicable as well to the manufacture of fibrous products formed from other mineral materials, such as the non-limiting examples of rock, slag and basalt.

Referring to <FIG>, glass is melted <NUM>. For example, <FIG> schematically illustrates a melter <NUM>. The melter <NUM> may supply molten glass <NUM> to a forehearth <NUM>. Melters and forehearths are known in the art and will not be described herein. The molten glass <NUM> can be formed from various raw materials combined in such proportions as to give the desired chemical composition.

Referring back to <FIG>, the molten glass <NUM> is processed to form <NUM> glass fibers <NUM>. The molten glass <NUM> can be processed in a variety of different ways to form the fibers <NUM>. For example, in the example illustrated by <FIG>, the molten glass <NUM> flows from the forehearth <NUM> to one or more rotary fiberizers <NUM>. The rotary fiberizers <NUM> receive the molten glass <NUM> and subsequently form veils <NUM> of glass fibers <NUM>. As will be discussed in more detail below, the glass fibers <NUM> formed by the rotary fiberizers <NUM> are long and thin. Accordingly, any desired fiberizer, rotary or otherwise, sufficient to form long and thin glass fibers <NUM> can be used. While the example not in accordance with the invention illustrated in <FIG> shows one rotary fiberizer <NUM>, it should be appreciated that any desired number of rotary fiberizers <NUM> can be used.

The long and thin fibers may take a wide variety of different forms. HT stands for hundred thousandths of an inch. The fibers <NUM> have a length in a range of from about <NUM> inch (<NUM>) to about <NUM> inches (<NUM>) and a diameter dimension in a range of from about <NUM> HT (<NUM> microns) to about <NUM> HT (<NUM> microns). In an exemplary embodiment, the fibers <NUM> have a length of about <NUM> inches (<NUM>) and an average diameter of about <NUM> HT (<NUM> microns) to <NUM> HT (<NUM> microns). While not being bound by the theory, it is believed the use of the relatively long and thin fibers advantageously provides a pack having better thermal and acoustic insulative performance, as well as better strength properties, such as higher tensile strength and/or higher bond strength, than a similar sized pack having shorter and thicker fibers.

In the exemplary embodiments described herein, the glass fibers <NUM> can optionally be coated or partially coated with a lubricant after the glass fibers are formed. For example, the glass fibers <NUM> can be coated with any lubricating material that does not bind the glass fibers together. In an exemplary embodiment, the lubricant can be a silicone compound, such as siloxane, dimethyl siloxane and/or silane. The lubricant can also be other materials or combinations of materials, such as, oil or an oil emulsion. The oil or oil emulsion may be a mineral oil or mineral oil emulsion and/or a vegetable oil or vegetable oil emulsion.

The glass fibers can be coated or partially coated with a lubricant in a wide variety of different ways. For example, the lubricant can be sprayed onto the glass fibers <NUM>. In an exemplary embodiment, the lubricant is configured to prevent damage to the glass fibers <NUM> as the glass fibers <NUM> move through the manufacturing process and come into contact with various apparatus as well as other glass fibers. The lubricant can also be useful to reduce dust in the manufacturing process. The application of the optional lubricant can be precisely controlled by any desired structure, mechanism or device.

Referring to <FIG>, a web <NUM> of fibers without a binder or other material that binds the fibers together is formed <NUM>. The web <NUM> can be formed in a wide variety of different ways. In the example illustrated by <FIG>, the glass fibers <NUM> are gathered by an optional gathering member <NUM>. The gathering member <NUM> is shaped and sized to receive the glass fibers <NUM>. The gathering member <NUM> is configured to divert the glass fibers <NUM> to a duct <NUM> for transfer to downstream processing stations, such as for example forming apparatus <NUM>, which forms the web <NUM>. In other described examples, the glass fibers <NUM> can be gathered on a conveying mechanism (not shown) to form the web.

The forming apparatus <NUM> can be configured to form a continuous dry web <NUM> of fibrous material having a desired thickness. In one exemplary embodiment, the dry webs <NUM> disclosed in this application can have a thickness in the range of about <NUM> inches (<NUM>) to about <NUM> inches (<NUM>) thick and a density in the range of about <NUM> lb/ft<NUM> (<NUM>/m<NUM>) to about <NUM> lb/ft<NUM> (<NUM>/m<NUM>). In one exemplary embodiment, the dry webs <NUM> disclosed in this application can have a thickness in the range of about <NUM> inch (<NUM>) to about <NUM> inches (<NUM>) thick and a density in the range of about <NUM> lb/ft<NUM> (<NUM>/m<NUM>) to about <NUM> lb/ft<NUM> (<NUM>/m<NUM>). In one exemplary embodiment, the dry webs <NUM> disclosed in this application can have a thickness of about <NUM> inches (<NUM>) and a density of about <NUM> lb/ft<NUM> (<NUM>/m<NUM>). The forming apparatus <NUM> can take a wide variety of different forms. Any arrangement for forming a dry web <NUM> of glass fibers can be used.

In one described example, the forming apparatus <NUM> includes a rotating drum with forming surfaces and areas of higher or lower pressure. Referring to <FIG>, the pressure P1 on a side <NUM> of the forming surface <NUM> where the fibers <NUM> are collected is higher than the pressure P2 on the opposite side <NUM>. This pressure drop ΔP causes the fibers <NUM> to collect on the forming surface <NUM> to form the dry web <NUM>. In one described example, the pressure drop ΔP across the forming surface <NUM> is controlled to be a low pressure and produce a low area weight web. For example, the pressure drop ΔP can be from about <NUM> inches of water and <NUM> inches of water. A velocity V of the air traveling through the web being formed that results in this low pressure drop ΔP may be up to <NUM>,<NUM> feet per minute.

A low area weight web <NUM> having an area weight of about <NUM> to about <NUM> grams per square foot. The low area weight web may have the density and thickness ranges mentioned above. The low area weight web may have a thickness in the range of about <NUM> inches (<NUM>) to about <NUM> inches (<NUM>) thick, about <NUM> inch (<NUM>) to about <NUM> inches (<NUM>) thick, or about <NUM> inches (<NUM>). The low area weight web may have a density in the range of about <NUM> lb/ft<NUM> (<NUM>/m<NUM>) to about <NUM> lb/ft<NUM> (<NUM>/m<NUM>), about <NUM> lb/ft<NUM> (<NUM>/m<NUM>) to about <NUM> lb/ft<NUM> (<NUM>/m<NUM>) or about <NUM> lb/ft<NUM> (<NUM>/m<NUM>). Referring to <FIG>, the dry web <NUM> leaves the forming apparatus <NUM>. In one example not according to the invention the low area weight web <NUM> has a measured area weight distribution Coefficient of Variation = Sigma (One Standard Deviation)/Mean (Average) x <NUM>% = of between <NUM> and <NUM>%. In one example not according to the invention, the weight distribution Coefficient of Variation is less than <NUM>%. Less than <NUM>% or less than <NUM>%. In one exemplary embodiment, the weight distribution Coefficient of Variation is between <NUM>% and <NUM>%, such as about <NUM>%. In one example not according to the invention, the weight distribution Coefficient of Variation is about <NUM>%. The weight distribution Coefficient of Variation by measuring multiple small sample area sizes, for example, <NUM>" x <NUM>" (<NUM> x <NUM>), of a large sample, for example a 6ft by <NUM> ft (<NUM> x <NUM>) sample with a light table.

In the example not according to the invention illustrated by <FIG>, the web <NUM> or multiple webs are layered <NUM>. For example, a single web <NUM> may be lapped in the machine direction or cross-lapped at ninety degrees to the machine direction to form a layered web <NUM>. In another example not according to the invention, the web may be cut into portions and the portions are stacked on top of one another to form the layered web. In yet another example not according to the invention, one or more duplicate fiberizers <NUM> and forming apparatus <NUM> can be implemented such that two or more webs are continuously produced in parallel. The parallel webs are then stacked on top of each other to form the layered web.

In one example not according to the invention, the layering mechanism <NUM> is a lapping mechanism or a cross-lapping mechanism that functions in association with a conveyor <NUM>. The conveyor <NUM> is configured to move in a machine direction as indicated by the arrow Dl. The lapping or cross-lapping mechanism is configured to receive the continuous web <NUM> and deposit alternating layers of the continuous web on the first conveyer <NUM> as the first conveyor moves in machine direction Dl. In the deposition process, a lapping mechanism <NUM> would form the alternating layers in a machine direction as indicated by the arrows D1 or the cross-lapping mechanism <NUM> would form the alternating layers in a cross-machine direction. Additional webs <NUM> may be formed and lapped or cross-lapped by additional lapping or cross-lapping mechanisms to increase the number of layers and throughput capacity.

In one example not according to the invention, a cross-lapping mechanism is configured to precisely control the movement of the continuous web <NUM> and deposit the continuous web on the conveyor <NUM> such that the continuous web is not damaged. The cross-lapping mechanism can include any desired structure and can be configured to operate in any desired manner. In one example not according to the invention, the cross-lapping mechanism includes a head (not shown) configured to move back and forth at <NUM> degrees to the machine direction D1. In this described example, the speed of the moving head is coordinated such that the movement of the head in both cross-machine directions is substantially the same, thereby providing uniformity of the resulting layers of the fibrous body. In an example not according to the invention, the cross-lapping mechanism comprises vertical conveyors (not shown) configured to be centered with a centerline of the conveyor <NUM>. The vertical conveyors are further configured to swing from a pivot mechanism above the conveyor <NUM> such as to deposit the continuous web on the conveyor <NUM>. While multiple examples of cross lapping mechanisms have been described above, it should be appreciated that the cross-lapping mechanism can be other structures, mechanisms or devices or combinations thereof.

The layered web <NUM> can have any desired thickness. The thickness of the layered web is a function of several variables. First, the thickness of the layered web <NUM> is a function of the thickness of the continuous web <NUM> formed by the forming apparatus <NUM>. Second, the thickness of the layered web <NUM> is a function of the speed at which the layering mechanism <NUM> deposits layers of the continuous web <NUM> on the conveyer <NUM>. Third, the thickness of the layered web <NUM> is a function of the speed of the conveyor <NUM>. In the illustrated embodiment, the layered web <NUM> has a thickness in a range of from about <NUM> inches (<NUM>) to about <NUM> inches (<NUM>). In an exemplary embodiment, a cross lapping mechanism <NUM> may form a layered web <NUM> having from <NUM> layer to <NUM> layers. Optionally, a cross-lapping mechanisms can be adjustable, thereby allowing the cross-lapping mechanisms <NUM> and <NUM> to form a pack having any desired width. In certain described examples, the pack can have a general width in a range of from about <NUM> inches (<NUM>) to about <NUM> inches (<NUM>).

In one example not according to the invention, the layered web <NUM> is produced in a continuous process indicated by dashed box <NUM> in <FIG>. The fibers produced by the fiberizer <NUM> are sent directly to the forming apparatus <NUM> (i.e. the fibers are not collected and packed and then unpacked for use at a remote forming apparatus). The web <NUM> is provided directly to the layering device <NUM> (i.e. the web is not formed and rolled up and then unrolled for use at a remote layering device <NUM>). In an of the continuous process not according to the invention, each of the processes (forming and layering in <FIG>) are connected to the fiberizing process, such that fibers from the fiberizer are used by the other processes without being stored for later use.

In one described example, the web <NUM> is relatively thick and has a low area weight, yet the continuous process has a high throughput. For example, a single layer of the web <NUM> may have an area weight of about <NUM> to about <NUM> grams per square foot (<NUM>/m<NUM> to <NUM>/m<NUM>). The low area weight web may have the density and thickness ranges mentioned above. The high output continuous process may produce between about <NUM> lbs/hr and <NUM> lbs/hr, such as at least <NUM> lbs/hr or at least <NUM> lbs/hr. The layered web <NUM> can be used in a wide variety of different applications.

<FIG> and <FIG> illustrate a method <NUM> not according to the invention of forming a pack <NUM> (see <FIG>) from fibrous materials without the use of a binder. The dashed line <NUM> around the steps of the method <NUM> indicates that the method is a continuous method. Referring to <FIG>, glass is melted <NUM>. The glass may be melted as described above with respect to <FIG>. The molten glass <NUM> is processed to form <NUM> glass fibers <NUM>. The molten glass <NUM> can be processed as described above with respect to <FIG> to form the fibers <NUM>. A web <NUM> of fibers without a binder or other material that binds the fibers together is formed <NUM>. The web <NUM> can be formed as described above with respect to <FIG>.

Referring to <FIG>, the fibers <NUM> of the web <NUM> are mechanically entangled <NUM> to form an entangled web <NUM> (see <FIG>). Referring to <FIG>, the fibers of the web <NUM> can be mechanically entangled by an entangling mechanism <NUM>, such as a needling device. The entanglement mechanism <NUM> is configured to entangle the individual fibers <NUM> of the web <NUM>. Entangling the glass fibers <NUM> ties the fibers of the web together. The entanglement causes mechanical properties of the web, such as for example, tensile strength and shear strength, to be improved. In the illustrated embodiment, the entanglement mechanism <NUM> is a needling mechanism. In other embodiments, the entanglement mechanism <NUM> can include other structures, mechanisms or devices or combinations thereof, including the non-limiting example of stitching mechanisms.

The entangled web <NUM> can have any desired thickness. The thickness of the entangled web is a function of the thickness of the continuous web <NUM> formed by the forming apparatus <NUM> and the amount of compression of the continuous web <NUM> by the entanglement mechanism <NUM>. In an exemplary embodiment, the entangled web <NUM> has a thickness in a range of from about <NUM> inches (<NUM>) to about <NUM> inches (<NUM>). In an exemplary embodiment, the entangled web <NUM> has a thickness in a range of from about <NUM> inches (<NUM>) to about <NUM> inches (<NUM>). For example, in one exemplary embodiment, the thickness of the entangled web is about ½" (<NUM>).

In one exemplary embodiment, the entangled web <NUM> is produced in a continuous process <NUM>. The fibers produced by the fiberizer <NUM> are sent directly to the forming apparatus <NUM> (i.e. the fibers are not collected and packed and then unpacked for use at a remote forming apparatus). The web <NUM> is provided directly to the entangling device <NUM> (i.e. the web is not formed and rolled up and then unrolled for use at a remote entangling device <NUM>). The entangled web <NUM> can be used in a wide variety of different applications. In an example not according to the invention of the continuous process, each of the processes (forming and entangling in <FIG>) are connected to the fiberizing process, such that fibers from the fiberizer are used by the other processes without being stored for later use.

<FIG> and <FIG> illustrate a third example not according to the invention of a method <NUM> of forming a pack <NUM> (see <FIG>) from fibrous materials without the use of a binder. Referring to <FIG>, glass is melted <NUM>. The dashed line <NUM> around the steps of the method <NUM> indicates that the method is a continuous method. The glass may be melted as described above with respect to <FIG>. Referring back to <FIG>, the molten glass <NUM> is processed to form <NUM> glass fibers <NUM>. The molten glass <NUM> can be processed as described above with respect to <FIG> to form the fibers <NUM>. Referring to <FIG>, a web <NUM> of fibers without a binder or other material that binds the fibers together is formed <NUM>. The web <NUM> can be formed as described above with respect to <FIG>. Referring to <FIG>, the web <NUM> or multiple webs are layered <NUM>. The web <NUM> or multiple webs can be layered as described above with respect to <FIG>. Referring to <FIG>, the fibers <NUM> of the layered webs <NUM> are mechanically entangled <NUM> to form an entangled pack <NUM> of layered webs.

Referring to <FIG>, the fibers of the layered webs <NUM> can be mechanically entangled by an entangling mechanism <NUM>, such as a needling device. The entanglement mechanism <NUM> is configured to entangle the individual fibers <NUM> forming the layers of the layered web. Entangling the glass fibers <NUM> ties the fibers of the layered webs <NUM> together to form the pack. The mechanical entanglement causes mechanical properties, such as for example, tensile strength and shear strength, to be improved. In the illustrated embodiment, the entanglement mechanism <NUM> is a needling mechanism. In other embodiments, the entanglement mechanism <NUM> can include other structures, mechanisms or devices or combinations thereof, including the non-limiting example of stitching mechanisms.

The entangled pack <NUM> of layered webs <NUM> can have any desired thickness. The thickness of the entangled pack is a function of several variables. First, the thickness of the entangled pack is a function of the thickness of the continuous web <NUM> formed by the forming apparatus <NUM>. Second, the thickness of the entangled pack <NUM> is a function of the speed at which the lapping or cross-lapping mechanism <NUM> deposits layers of the continuous web <NUM> on the conveyer <NUM>. Third, the thickness of the entangled pack <NUM> is a function of the speed of the conveyor <NUM>. Fourth, the thickness of the entangled pack <NUM> is a function of the amount of compression of the layered webs <NUM> by the entanglement mechanism <NUM>. The entangled pack <NUM> can have a thickness in a range of from about <NUM> inches (<NUM>) to about <NUM> inches (<NUM>). In an exemplary embodiment, the entangled pack <NUM> may having from <NUM> layer to <NUM> layers. Each entangled web layer <NUM> may be from <NUM> inches (<NUM>) to <NUM> inches (<NUM>) thick. For example, each entangled web layer may be about <NUM> inches (<NUM>) thick.

In one exemplary embodiment, the entangled pack <NUM> is produced in a continuous process. The fibers produced by the fiberizer <NUM> are sent directly to the forming apparatus <NUM> (i.e. the fibers are not collected and packed and then unpacked for use at a remote forming apparatus). The web <NUM> is provided directly to the layering device <NUM> (i.e. the web is not formed and rolled up and then unrolled for use at a remote layering device <NUM>). The layered web <NUM> is provided directly to the entangling device <NUM> (i.e. the layered web is not formed and rolled up and then unrolled for use at a remote entangling device <NUM>). In an exemplary embodiment of the continuous process, each of the processes (forming, layering, and entangling in <FIG>) are connected to the fiberizing process, such that fibers from the fiberizer are used by the other processes without being stored for later use.

In one described example, the entangled pack <NUM> of layered webs is made from a web <NUM> or webs that is relatively thick and has a low area weight, yet the continuous process has a high throughput. For example, a single layer of the web <NUM> may have the area weights, thicknesses, and densities mentioned above. The high output continuous process may produce between about <NUM> lbs/hr and <NUM> lbs/hr, such as at least <NUM> lbs/hr or at least <NUM> lbs/hr. In one described example, the combination of high web throughput and mechanical entanglement, such as needling, of a continuous process is facilitated by layering of the web <NUM>, such as lapping or cross-lapping of the web. By layering the web <NUM>, the linear speed of the material moving through the layering device is slower than the speed at which the web is formed. For example, in a continuous process, a two layer web will travel through the entangling apparatus <NUM> at ½ the speed at which the web is formed (<NUM> layers -<NUM>/<NUM> the speed, etc.). This reduction in speed allows for a continuous process where a high throughput, low area weight web <NUM> is formed and converted into a multiple layer, mechanically entangled pack <NUM>. The entangled pack <NUM> of layered webs can be used in a wide variety of different applications.

In an exemplary embodiment, the layering and entangling of the long, thin fibers results in a strong web <NUM>. For example, the entanglement of the long, thin glass fibers described in this application results in a layered, entangled web with a high tensile strength and a high bond strength. Tensile strength is the strength of the web <NUM> when the web is pulled in the direction of the length or width of the web. Bond strength is the strength of the web when the web <NUM> is pulled apart in the direction of the thickness of the web.

Tensile strength and bond strength may be tested in a wide variety of different ways. In one described example, a machine, such as an Instron machine, pulls the web <NUM> apart at a fixed speed (<NUM> inches per second in the examples described below) and measures the amount of force required to pull the web apart. Forces required to pull the web apart, including the peak force applied to the web before the web rips or fails, are recorded.

In one method of testing tensile strength, the tensile strength in the length direction is measured by clamping the ends of the web along the width of the web, pulling the web <NUM> along the length of the web with the machine at the fixed speed (<NUM> inches per second in the examples provided below), and recording the peak force applied in the direction of the length of the web. The tensile strength in the width direction is measured by clamping the sides of the web along the width of the web, pulling the web <NUM> along the width of the web at the fixed speed (<NUM> inches per second in the examples provided below), and recording the peak force applied. The tensile strength in the length direction and the tensile strength in the width direction are averaged to determine the tensile strength of the sample.

In one method of testing bond strength, a sample of a predetermined size (<NUM>" by <NUM>" in the examples described below) is provided. Each side of the sample is bonded to a substrate, for example by gluing. The substrates on the opposite side of the sample are pulled apart with the machine at the fixed speed (<NUM> inches per second in the examples provided below), and recording the peak force applied. The peak force applied is divided by the area of the sample (<NUM>" by <NUM>" in the examples described below) to provide the bond strength in terms of force over area.

The following examples are provided to illustrate the increased strength of the layered, entangled web <NUM>. In these examples, no binder is included. That is, no aqueous or dry binder is included. These examples do not limit the scope of the present invention, unless expressly recited in the claims. Examples of layered, entangled webs having <NUM>, <NUM>, and <NUM> layers are provided. However, the layered entangled web <NUM> may be provided with any number of layers. The layered, entangled web <NUM> sample length, width, thickness, number of laps, and weight may vary depending on the application for the web <NUM>.

In one described example, a web <NUM> sample that is <NUM> inches (<NUM>) by <NUM> inches (<NUM>), has multiple layers, such as two laps (i.e. four layers), is between <NUM> (<NUM>) inches thick and <NUM> inches (<NUM>) thick, has a weight per square foot between <NUM> lbs/sq ft (<NUM>/m<NUM>) and <NUM> lbs/sq ft (<NUM>/m<NUM>), has a tensile strength that is greater than <NUM> lbf, and has a tensile strength to weight ratio that is greater than <NUM> lbf/lbm, such as from about <NUM> to about <NUM> lbf/lbm. In a described example, a bond strength of this sample is greater than <NUM> lbs/sq ft. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf. In a described example, the tensile strength of the sample described in this paragraph is between <NUM> and <NUM> lbf. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lbs/sq ft. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lbs/sq ft. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lbs/sq ft. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lbs/sq ft. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lbs/sq ft. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf and the bond strength is greater than <NUM> lbs/sq ft. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf and the bond strength is greater than <NUM> lbs/sq ft. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf and the bond strength is greater than <NUM> lbs/sq ft. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf and the bond strength is greater than <NUM> lbs/sq ft. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf and the bond strength is greater than <NUM> lbs/sq ft. In a described example, the tensile strength of the sample described in this paragraph is between <NUM> and <NUM> lbf and the bond strength is between <NUM> and <NUM> lbs/ sq ft.

In one described example, a web <NUM> sample that is <NUM> inches (<NUM>) by <NUM> inches (<NUM>), has multiple layers, such as two laps (i.e. four layers), is between <NUM> inches (<NUM>) thick and <NUM> inches (<NUM>) thick, has a weight per square foot between <NUM> lbs/sq ft (<NUM>/m<NUM>) and <NUM> lbs/sq ft (<NUM>/m<NUM>), has a tensile strength that is greater than <NUM> lbf, and has a tensile strength to weight ratio that is greater than <NUM> lbf/lbm, such as from about <NUM> to about <NUM> lbf/lbm, and a bond strength that is greater than <NUM> lb/sq ft. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf. In one exemplary embodiment, the tensile strength of the sample described in this paragraph is between <NUM> and <NUM> lbf. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lbs/sq ft. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lbs/sq ft. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lbs/sq ft. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lbs/sq ft. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lbs/sq ft. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf and the bond strength is greater than <NUM> lbs/sq ft. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf and the bond strength is greater than <NUM> lbs/sq ft. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf and the bond strength is greater than <NUM> lbs/sq ft. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf and the bond strength is greater than <NUM> lbs/sq ft. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf and the bond strength is greater than <NUM> lbs/sq ft. In a described example, the tensile strength of the sample described in this paragraph is between <NUM> and <NUM> lbf and the bond strength is between <NUM> and <NUM> lbs/ sq ft.

In one described example, a web <NUM> sample that is <NUM> inches (<NUM>) by <NUM> inches (<NUM>), has multiple layers, such as two laps (i.e. four layers), is between <NUM> inches (<NUM>) thick and <NUM> inches (<NUM>) thick, has a weight per square foot between <NUM> lbs/sq ft (<NUM>/m<NUM>) and <NUM> lbs/sq ft (<NUM>/m<NUM>), has a tensile strength that is greater than <NUM> lbf, and has a tensile strength to weight ratio that is greater than <NUM> lbf/lbm, such as from about <NUM> about <NUM> lbf/lbm. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf. In one exemplary embodiment, the tensile strength of the sample described in this paragraph is between <NUM> and <NUM> lbf. In one exemplary embodiment, the bond strength of the sample described in this paragraph is greater than <NUM> lb/sq ft. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lb/sq ft. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lb/sq ft. In one exemplary embodiment, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf and the bond strength is greater than <NUM> lb/sq ft. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf and the bond strength is greater than <NUM> lb/sq ft. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf and the bond strength is greater than <NUM> lb/sq ft.

In one exemplary embodiment, a web <NUM> sample that is <NUM> inches (<NUM>) by <NUM> inches (<NUM>), has multiple layers, such as three laps (i.e. six layers), is between <NUM> inches (<NUM>) thick and <NUM> inches (<NUM>) thick, has a weight per square foot between <NUM> lbs/sq ft (<NUM>/m<NUM>) and <NUM> lbs/sq ft (<NUM>/m<NUM>), has a tensile strength that is greater than <NUM> lbf, and has a tensile strength to weight ratio that is greater than <NUM> lbf/lbm, such as from about <NUM> to about <NUM> lbf/lbm. In a described example, the bond strength of this sample is greater than <NUM> lbs/sq ft. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf. In a described example, the tensile strength of the sample described in this paragraph is between <NUM> and <NUM> lbf. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lbs/sq ft. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lbs/sq ft. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lbs/sq ft. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lbs/sq ft. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lbs/sq ft. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lbs/sq ft. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf and the bond strength is greater than <NUM> lbs/sq ft. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf and the bond strength is greater than <NUM> lbs/ sq ft. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf and the bond strength is greater than <NUM> lbs/ sq ft. In a described example, the tensile strength of the sample described in this paragraph is between <NUM> and <NUM> lbf and the bond strength is between <NUM> and <NUM> lbs/sq ft.

In one exemplary embodiment, a web <NUM> sample that is <NUM> inches (<NUM>) by <NUM> inches (<NUM>), has multiple layers, such as three laps (i.e. six layers), is between <NUM> inches (<NUM>) thick and <NUM> inches (<NUM>) thick, and has a weight per square foot between <NUM> lbs/sq ft (<NUM>/m<NUM>) and <NUM> lbs/sq ft (<NUM>/m<NUM>), has a tensile strength that is greater than <NUM> lbf, and has a tensile strength to weight ratio that is greater than <NUM> lbf/lbm, such as from about <NUM> to about <NUM> lbf/lbm. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM>. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf. In described example, the tensile strength of the sample described in this paragraph is between <NUM> and <NUM> lbf. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lbs/sq ft. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lbs/sq ft. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lbs/sq ft. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lbs/sq ft. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lbs/sq ft. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lbs/sq ft. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf and a bond strength that is greater than <NUM> lbs/sq ft. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM>. 5lbf and a bond strength that is greater than <NUM> lbs/sq ft. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf and a bond strength that is greater than <NUM> lbs/sq ft.

In one described example, a web <NUM> sample that is <NUM> inches (<NUM>) by <NUM> inches (<NUM>), has multiple layers, such as four laps (i.e. eight layers), is between <NUM> inches (<NUM>) thick and <NUM> inches (<NUM>) thick, and has a weight per square foot between <NUM> lbs/sq ft (<NUM>/m<NUM>) and <NUM> lbs/sq ft (<NUM>/m<NUM>), has a tensile strength that is greater than <NUM> lbf, and has a tensile strength to weight ratio that is greater than <NUM> lbf/lbm, such as from about <NUM> to about <NUM> lbf/lbm. In one described example, the web has a bond strength that is greater than <NUM> lbs/sq ft. In a described example, the bond strength of this sample is greater than <NUM> lbs/sq ft. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf. In one exemplary embodiment, the tensile strength of the sample described in this paragraph is between <NUM> and <NUM> lbf. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lbs/sq ft. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lbs/sq ft. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lbs/sq ft. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lbs/sq ft. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lbs/sq ft. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lbs/sq ft. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lbs/sq ft. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf and the bond strength is greater than. <NUM> lbs/sq ft. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf and the bond strength is greater than <NUM> lbs/sq ft. In one described example, the tensile strength of the sample described in this paragraph is between <NUM> and <NUM> lbf and the bond strength is between <NUM> and <NUM> lbs/sq ft.

In one described example, a web <NUM> sample that is <NUM> inches (<NUM>) by <NUM> inches (<NUM>), has multiple layers, such as four laps (i.e. eight layers), is between <NUM> inches (<NUM>) thick and <NUM> inches (<NUM>) thick, and has a weight per square foot between <NUM> lbs/sq ft (<NUM>/m<NUM>) and <NUM> lbs/sq ft (<NUM>/m<NUM>), has a tensile strength that is greater than <NUM> lbf, and has a tensile strength to weight ratio that is greater than <NUM> lbf/lbm. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lbs/sq ft. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lbs/sq ft. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lbs/sq ft. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lbs/sq ft. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lbs/sq ft. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lbs/sq ft. In a described example, the bond strength of the sample described in this paragraph is greater than <NUM> lbs/sq ft. In a described example, the tensile strength of the sample described in this paragraph is greater than <NUM> lbf and the bond strength is greater than <NUM> lbs/sq ft.

<FIG> illustrate exemplary embodiments of methods that are similar to the embodiments of <FIG>, except the web <NUM> (see <FIG>) is formed <NUM> with a dry or non-aqueous binder. The method <NUM> of <FIG> generally corresponds to the method <NUM> of <FIG>. The method <NUM> of <FIG> generally corresponds to the method <NUM> of <FIG>. The method <NUM> of <FIG> generally corresponds to the method <NUM> of <FIG>.

<FIG> illustrates a method <NUM> not in accordance with the invention that is similar to the method <NUM> of <FIG>. In <FIG>, the steps in boxes with dashed lines are optional. In the example not in accordance with the invention illustrated by <FIG>, the dry binder can optionally be added to the web step <NUM> and/or the layered web at step <NUM>, instead of (or in addition to) before the web is formed. For example, if step <NUM> is included, the web may be formed without a dry binder, and then the dry binder is added to the web before layering and/or during layering. If step <NUM> is included, the web may be formed and layered without a dry binder, and then the dry binder is added to the layered web.

Referring to <FIG> not in accordance with the invention, the dry binder (indicated by the large arrows) can be added to the fibers <NUM> and/or the web <NUM> at a variety of different points in the process. Arrow <NUM> indicates that the dry binder can be added to the fibers <NUM> at or above the collecting member. Arrow <NUM> indicates that the dry binder can be added to the fibers <NUM> in the duct <NUM>. Arrow <NUM> indicates that the dry binder can be added to the fibers <NUM> in the forming apparatus <NUM>. Arrow <NUM> indicates that the dry binder can be added to the web <NUM> after the web leaves the forming apparatus <NUM>. Arrow <NUM> indicates that the dry binder can be added to the web <NUM> as the web is layered by the layering apparatus <NUM>. Arrow <NUM> indicates that the dry binder can be added to the web <NUM> after the web is layered. Arrow <NUM> indicates that the dry binder can be added to the web <NUM> or layered web in the oven <NUM>. The dry binder can be added to the fibers <NUM> or the web <NUM> to form a web <NUM> with dry binder in any manner.

In one example not in accordance with the invention, the dry binder is applied to the fibers <NUM> at a location that is significant distance downstream from the fiberizer <NUM>. For example, the dry binder may be applied to the fibers at a location where the temperature of the fibers and/or a temperature of the air surrounding the fibers is significantly lower than the temperature of the fibers and the surrounding air at the fiberizer. In one described example, the dry binder is applied at a location where a temperature of the fibers and/or a temperature of air that surrounds the fibers is below a temperature at which the dry binder melts or a temperature at which the dry binder fully cures or reacts. For example, a thermoplastic binder may be applied at a point in the production line where a temperature of the fibers <NUM> and/or a temperature of air that surrounds the fibers are below the melting point of the of the thermoplastic binder. A thermoset binder may be applied at a point in the production line where a temperature of the fibers <NUM> and/or a temperature of air that surrounds the fibers are below a curing temperature of the thermoset binder. That is, the thermoset binder may be applied at a point where a temperature of the fibers <NUM> and/or a temperature of air that surrounds the fibers is below a point where the thermoset binder fully reacts or full crosslinking of the thermoset binder occurs. In one described example, the dry binder is applied at a location in the production line where the temperature of the fibers <NUM> and/or a temperature of air that surrounds the fibers are below <NUM> degrees F. In one described example, the temperature of the fibers and/or a temperature of air that surrounds the fibers at the locations indicated by arrows <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> in <FIG> is below a temperature at which the dry binder melts or fully cures.

In one example not according to the invention, the binder applicator is a sprayer configured for dry powders. The sprayer may be configured such that the force of the spray is adjustable, thereby allowing more or less penetration of the dry powder into the continuous web of fibrous material. Alternatively, the binder applicator can be other structures, mechanisms or devices or combinations thereof, such as for example a vacuum device, sufficient to draw the dry binder into the continuous web <NUM> of glass fibers.

The optional dry binder can take a wide variety of different forms. Any non-aqueous medium that holds the fibers <NUM> together to form a web <NUM> can be used. In one example not in accordance with the invention, the dry binder, while being initially applied to the fibers, is comprised of substantially <NUM>% solids. The term "substantially <NUM>% solids", as used herein, means any binder material having diluents, such as water, in an amount less than or equal to approximately two percent, and preferably less than or equal to approximately one percent by weight of the binder (while the binder is being applied, rather than after the binder has dried or cured). However, it should be appreciated that in certain described examples not in accordance with the invention, the binder can include diluents, such as water, in any amount as desired depending on the specific application and design requirements. In one described example, the dry binder is a thermoplastic resin-based material that is not applied in liquid form and further is not water based. In other described examples, the dry binder can be other materials or other combinations of materials, including the non-limiting example of polymeric thermoset resins. The dry binder can have any form or combinations of forms including the non-limiting examples of powders, particles, fibers and/or hot melt. Examples of hot melt polymers include, but are not limited to, ethylene-vinyl acetate copolymer, ethylene-acrylate copolymer, low density polyethylene, high density polyethylene, atactic polypropylene, polybutene-<NUM>, styrene block copolymer, polyamide, thermoplastic polyurethane, styrene block copolymer, polyester and the like. In one example not in accordance with the invention, sufficient dry binder is applied such that a cured fibrous pack can be compressed for packaging, storage and shipping, yet regains its thickness - a process known as "loft recovery" - when installed.

In the examples illustrated by <FIG> and <FIG>, the glass fibers <NUM> can optionally be coated or partially coated with a lubricant before or after the dry binder is applied to the glass fibers. In a described example, the lubricant is applied after the dry binder to enhance the adhesion of the dry binder to the glass fibers <NUM>. The lubricant can be any of the lubricants described above.

Referring to <FIG>, the continuous web with unreacted dry binder <NUM> is transferred from the forming apparatus <NUM> to the optional layering mechanism <NUM>. The layering mechanism may take a wide variety of different forms. For example, the layering mechanism may be a lapping mechanism that layers the web <NUM> in the machine direction D1 or a cross-lapping mechanism that laps the web in a direction that is substantially orthogonal to the machine direction. The cross-lapping device described above for layering the binderless web <NUM> can be used to layer the web <NUM> with unreacted dry binder.

In an example not according to the invention, the dry binder of the continuous web <NUM> is configured to be configured to be thermally set in a curing oven <NUM>. In an example not according to the invention, the curing oven <NUM> replaces the entanglement mechanism <NUM>, since the dry binder holds the fibers <NUM> together. In another example not according to the invention, both a curing oven <NUM> and an entanglement mechanism <NUM> are included.

<FIG> and <FIG> schematically illustrate another example of a method not in accordance with the invention for forming a pack from fibrous materials is illustrated generally at <NUM>. Referring to <FIG>, molten glass <NUM> is supplied from a melter <NUM> to a forehearth <NUM>. The molten glass <NUM> can be formed from various raw materials combined in such proportions as to give the desired chemical composition. The molten glass <NUM> flows from the forehearth <NUM> to a plurality of rotary fiberizers <NUM>.

Referring to <FIG>, the rotary fiberizers <NUM> receive the molten glass <NUM> and subsequently form veils <NUM> of glass fibers <NUM> entrained in a flow of hot gases. As will be discussed in more detail below, the glass fibers <NUM> formed by the rotary fiberizers <NUM> are long and thin. Accordingly, any desired fiberizer, rotary or otherwise, sufficient to form long and thin glass fibers <NUM> can be used. While the described example illustrated in <FIG> and <FIG> show a quantity of two rotary fiberizers <NUM>, it should be appreciated that any desired number of rotary fiberizers <NUM> can be used.

The flow of hot gases can be created by optional blowing mechanisms, such as the non-limiting examples of annular blowers (not shown) or annular burners (not shown). Generally, the blowing mechanisms are configured to direct the veil <NUM> of glass fibers <NUM> in a given direction, usually in a downward manner. It should be understood that the flow of hot gasses can be created by any desired structure, mechanism or device or any combination thereof.

As shown in <FIG>, optional spraying mechanisms <NUM> can be positioned beneath the rotary fiberizers <NUM> and configured to spray fine droplets of water or other fluid onto the hot gases in the veils <NUM> to help cool the flow of hot gases, protect the fibers <NUM> from contact damage and/or enhance the bonding capability of the fibers <NUM>. The spraying mechanisms <NUM> can be any desired structure, mechanism or device sufficient to spray fine droplets of water onto the hot gases in the veils <NUM> to help cool the flow of hot gases, protect the fibers <NUM> from contact damage and/or enhance the bonding capability of the fibers <NUM>. While the example not according to the invention shown in <FIG> illustrates the use of the spraying mechanisms <NUM>, it should be appreciated that the use of the spraying mechanisms <NUM> is optional and the method of forming the pack from fibrous materials <NUM> can be practiced without the use of the spraying mechanisms <NUM>.

Optionally, the glass fibers <NUM> can be coated with a lubricant after the glass fibers are formed. In the illustrated embodiment, a plurality of nozzles <NUM> can be positioned around the veils <NUM> at a position beneath the rotary fiberizers <NUM>. The nozzles <NUM> can be configured to supply a lubricant (not shown) to the glass fibers <NUM> from a source of lubricant (not shown).

The application of the lubricant can be precisely controlled by any desired structure, mechanism or device, such as the non-limiting example of a valve (not shown). In certain embodiments, the lubricant can be a silicone compound, such as siloxane, dimethyl siloxane, and/or silane. The lubricant can also be other materials or combinations of materials, such as for example an oil or an oil emulsion. The oil or oil emulsion may be a mineral oil or mineral oil emulsion and/or a vegetable oil or vegetable oil emulsion. In an exemplary embodiment, the lubricant is applied in an amount of about <NUM> percent oil and/or silicone compound by weight of the resulting pack of fibrous materials. However, in other embodiments, the amount of the lubricant can be more or less than about <NUM> percent oil and/or silicone compound by weight.

While the examples not according to the invention shown in <FIG> illustrates the use of nozzles <NUM> to supply a lubricant (not shown) to the glass fibers <NUM>, it should be appreciated that the use of nozzles <NUM> is optional and the method of forming the pack from fibrous materials <NUM> can be practiced without the use of the nozzles <NUM>.

In the example not according to the invention, the glass fibers <NUM>, entrained within the flow of hot gases, can be gathered by an optional gathering member <NUM>. The gathering member <NUM> is shaped and sized to easily receive the glass fibers <NUM> and the flow of hot gases. The gathering member <NUM> is configured to divert the glass fibers <NUM> and the flow of hot gases to a duct <NUM> for transfer to downstream processing stations, such as for example forming apparatus 632a and 632b. In other described examples, the glass fibers <NUM> can be gathered on a conveying mechanism (not shown) such as to form a blanket or batt (not shown). The batt can be transported by the conveying mechanism to further processing stations (not shown). The gathering member <NUM> and the duct <NUM> can be any structure having a generally hollow configuration that is suitable for receiving and conveying the glass fibers <NUM> and the flow of hot gases. While the described example shown in <FIG> illustrates the use of the gathering member <NUM>, it should be appreciated that the use of gathering member <NUM> to divert the glass fibers <NUM> and the flow of hot gases to the duct <NUM> is optional and the method of forming the pack from fibrous materials <NUM> can be practiced without the use of the gathering member <NUM>.

In the described example shown in <FIG> and <FIG>, a single fiberizer <NUM> is associated with an individual duct <NUM>, such that the glass fibers <NUM> and the flow of hot gases from the single fiberizer <NUM> are the only source of the glass fibers <NUM> and the flow of hot gasses entering the duct <NUM>. Alternatively, an individual duct <NUM> can be adapted to receive the glass fibers <NUM> and the flow of hot gases from multiple fiberizers <NUM> (not shown).

Referring again to <FIG>, optionally, a header system (not shown) can be positioned between the forming apparatus 632a and 632b and the fiberizers <NUM>. The header system can be configured as a chamber in which glass fibers <NUM> and gases flowing from the plurality of fiberizers <NUM> can be combined while controlling the characteristics of the resulting combined flow. In certain described examples, the header system can include a control system (not shown) configured to combine the flows of the glass fibers <NUM> and gases from the fiberizers <NUM> and further configured to direct the resulting combined flows to the forming apparatus 632a and 632b. Such a header system can allow for maintenance and cleaning of certain fiberizers <NUM> without the necessity of shutting down the remaining fiberizers <NUM>. Optionally, the header system can incorporate any desired means for controlling and directing the glass fibers <NUM> and flows of gases.

Referring now to <FIG>, the momentum of the flow of the gases, having the entrained glass fibers <NUM>, will cause the glass fibers <NUM> to continue to flow through the duct <NUM> to the forming apparatus 632a and 632b. The forming apparatus 632a and 632b can be configured for several functions. First, the forming apparatus 632a and 632b can be configured to separate the entrained glass fibers <NUM> from the flow of the gases. Second, the forming apparatus 632a and 632b can be configured to form a continuous thin and dry web of fibrous material having a desired thickness. Third, the forming apparatus 632a and 632b can be configured to allow the glass fibers <NUM> to be separated from the flow of gasses in a manner that allows the fibers to be oriented within the web with any desired degree of "randomness". The term "randomness", as used herein, is defined to mean that the fibers <NUM>, or portions of the fibers <NUM>, can be nonpreferentially oriented in any of the X, Y or Z dimensions. In certain instances, it may be desired to have a high degree of randomness. In other instances, it may be desired to control the randomness of the fibers <NUM> such that the fibers <NUM> are non-randomly oriented, in other words, the fibers are substantially coplanar or substantially parallel to each other. Fourth, the forming apparatus 632a and 632b can be configured to transfer the continuous web of fibrous material to other downstream operations.

In the example not according to the invention illustrated in <FIG>, each of the forming apparatus 632a and 632b include a drum (not shown) configured for rotation. The drum can include any desired quantity of foraminous surfaces and areas of higher or lower pressure. Alternatively, each of the forming apparatus 332a and 332b can be formed from other structures, mechanisms and devices, sufficient to separate the entrained glass fibers <NUM> from the flow of the gases, form a continuous web of fibrous material having a desired thickness and transfer the continuous web of fibrous material to other downstream operations. In the illustrated described example shown in <FIG>, each of the forming apparatus 632a and 632b are the same. However, in other described examples, each of the forming apparatus 632a and 632b can be different from each other.

Referring again to <FIG> not in accordance with the invention, the continuous web of fibrous material is transferred from the forming apparatus 632a and 632b to an optional binder applicator <NUM>. The binder applicator <NUM> is configured to apply a "dry binder" to the continuous web of fibrous material. The term "dry binder", as used herein, is defined to mean that the binder is comprised of substantially <NUM>% solids while the binder is being applied. The term "substantially <NUM>% solids", as used herein, is defined to mean any binder material having diluents, such as water, in an amount less than or equal to approximately two percent, and preferably less than or equal to approximately one percent by weight of the binder (while the binder is being applied, rather than after the binder has dried and/or cured). However, it should be appreciated that in certain examples not in accordance with the invention, the binder can include diluents, such as water, in any amount as desired depending on the specific application and design requirements. The binder may be configured to thermally set in a curing oven <NUM>. In this application, the terms "cure" and "thermally set" refer to a chemical reaction and/or one or more phase changes that cause the dry binder to bind the fibers of the web together. For example, a thermoset dry binder (or thermoset component of the dry binder) cures or thermally sets as a result of a chemical reaction that occurs as a result of an application of heat. A thermoplastic dry binder (or thermoplastic component of the dry binder) cures or thermally sets as a result of being heated to a softened or melted phase and then cooled to a solid phase.

In an example not according to the invention, the dry binder is a thermoplastic resin-based material that is not applied in liquid form and further is not water based. In other embodiments, the dry binder can be other materials or other combinations of materials, including the non-limiting example of polymeric thermoset resins. The dry binder can have any form or combinations of forms including the non-limiting examples of powders, particles, fibers and/or hot melt. Examples of hot melt polymers include, but are not limited to, ethylene-vinyl acetate copolymer, ethylene-acrylate copolymer, low density polyethylene, high density polyethylene, atactic polypropylene, polybutene-<NUM>, styrene block copolymer, polyamide, thermoplastic polyurethane, styrene block copolymer, polyester and the like. Sufficient dry binder is applied such that a cured fibrous pack can be compressed for packaging, storage and shipping, yet regains its thickness - a process known as "loft recovery" - when installed. Applying the dry binder to the continuous web of fibrous material forms a continuous web, optionally with unreacted binder.

In the example not according to the invention illustrated by <FIG> and <FIG>, the binder applicator <NUM> is a sprayer configured for dry powders. The sprayer is configured such that the force of the spray is adjustable, thereby allowing more or less penetration of the dry powder into the continuous web of fibrous material. Alternatively, the binder applicator <NUM> can be other structures, mechanisms or devices or combinations thereof, such as for example a vacuum device, sufficient to draw a "dry binder" into the continuous web of fibrous material.

Referring again to <FIG> not in accordance with the invention, the continuous web, optionally with unreacted binder is transferred from the binder applicators <NUM> to the corresponding cross-lapping mechanism 634a and 634b. As shown in <FIG>, forming apparatus 632a is associated with cross-lapping mechanism 634a and forming apparatus 632b is associated with cross-lapping mechanism 634b. The cross-lapping mechanisms 634a and 634b function in association with a first conveyor <NUM>. The first conveyor <NUM> is configured to move in a machine direction as indicated by the arrow Dl. The cross-lapping mechanism 634a is configured to receive the continuous web, optionally with unreacted binder, from the optional binder applicators <NUM> and is further configured to deposit alternating layers of the continuous web, optionally with unreacted binder, on the first conveyer <NUM> as the first conveyor <NUM> moves in machine direction Dl, thereby forming the initial layers of a fibrous body. In the deposition process, the cross-lapping mechanism 634a forms the alternating layers in a cross-machine direction as indicated by the arrows D2. Accordingly, as the deposited continuous web, optionally with unreacted binder, from crosslapping mechanism 634a travels in machine direction Dl, additional layers are deposited on the fibrous body by the downstream cross-lapping mechanism 634b. The resulting layers of the fibrous body deposited by cross-lapping mechanisms 634a and 634b form a pack.

In the illustrated example not according to the invention, the cross-lapping mechanisms 634a and 634b are devices configured to precisely control the movement of the continuous web with unreacted binder and deposit the continuous web with unreacted binder on the first conveyor <NUM> such that the continuous web, optionally with unreacted binder, is not damaged. The cross-lapping mechanisms 634a and 634b can include any desired structure and can be configured to operate in any desired manner. In one example, the cross-lapping mechanisms 634a and 634b can include a head (not shown) configured to move back and forth in the cross-machine direction D2. In this described example, the speed of the moving head is coordinated such that the movement of the head in both cross-machine directions is substantially the same, thereby providing uniformity of the resulting layers of the fibrous body. In another example, vertical conveyors (not shown) configured to be centered with a centerline of the first conveyor <NUM> can be utilized. The vertical conveyors are further configured to swing from a pivot mechanism above the first conveyor <NUM> such as to deposit the continuous web, optionally with unreacted binder, on the first conveyor <NUM>. While several examples of cross lapping mechanisms have been described above, it should be appreciated that the cross-lapping mechanisms 634a and 634b can be other structures, mechanisms or devices or combinations thereof.

Referring again to <FIG> not according to the invention, optionally the positioning of the continuous web, optionally with unreacted binder, on the first conveyor <NUM> can be accomplished by a controller (not shown), such as to provide improved uniformity of the pack. The controller can be any desired structure, mechanism or device or combinations thereof.

The layered web or pack can have any desired thickness. The thickness of the pack is a function of several variables. First, the thickness of the pack is a function of the thickness of the continuous web, optionally with unreacted binder, formed by each of the forming apparatus 632a and 632b. Second, the thickness of the pack is a function of the speed at which the cross-lapping mechanisms 634a and 634b alternately deposit layers of the continuous web, optionally with unreacted binder, on the first conveyer <NUM>. Third, the thickness of the pack is a function of the speed of the first conveyor <NUM>. In the illustrated described examples, the pack has a thickness in a range of from about <NUM> inches to about <NUM> inches. In other described examples, the pack can have a thickness less than about <NUM> inches or more than about <NUM> inches.

As discussed above, the cross lapping mechanisms 634a and 634b are configured to deposit alternating layers of the continuous web, optionally with unreacted binder, on the first conveyer <NUM> as the first conveyor <NUM> moves in machine direction Dl, thereby forming layers of a fibrous body. In the described example, the cross lapping mechanism 634a and 634b and the first conveyor <NUM> are coordinated such as to form a fibrous body having a quantity of layers in a range of from about <NUM> layer to about <NUM> layers. In other described examples, the cross lapping mechanism 634a and 634b and the first conveyor <NUM> can be coordinated such as to form a fibrous body having any desired quantity of layers, including a fibrous body having in excess of <NUM> layers.

Optionally, the cross-lapping mechanisms 634a and 634b can be adjustable, thereby allowing the cross-lapping mechanisms 634a and 634b to form a pack having any desired width. In certain embodiments, the pack can have a general width in a range of from about <NUM> inches (<NUM>) to about <NUM> inches (<NUM>). Alternatively, the pack can have a general width less than about <NUM> inches (<NUM>) or more than about <NUM> inches (<NUM>).

While the cross-lapping mechanisms 634a and 634b have been described above as being jointly involved in the formation of a fibrous body, it should be appreciated that in other described examples, the cross-lapping mechanisms 634a and 634b can operate independently of each other such as to form discrete lanes of fibrous bodies.

Referring to <FIG> and <FIG> not in accordance with the invention, the pack, having the layers formed by the cross-lapping mechanisms 634a and 634b, is carried by the first conveyor <NUM> to an optional trim mechanism <NUM>. The optional trim mechanism <NUM> is configured to trim the edges of the pack, such as to form a desired width of the pack. In an exemplary embodiment, the pack can have an after-trimmed width in a range of from about <NUM> inches (<NUM>) to about <NUM> inches (<NUM>). Alternatively, the pack can have an after trimmed width less than about <NUM> inches (<NUM>) or more than about <NUM> inches (<NUM>).

In the illustrated described example, the optional trim mechanism <NUM> includes a saw system having a plurality of rotating saws (not shown) positioned on either side of the pack. Alternatively, the trim mechanism <NUM> can be other structures, mechanisms or devices or combinations thereof including the non-limiting examples of water jets, compression knives.

In the illustrated example not in accordance with the invention, the trim mechanism <NUM> is advantageously positioned upstream from the curing oven <NUM>. Positioning the trim mechanism <NUM> upstream from the curing oven <NUM> allows the pack to be trimmed before the pack is thermally set in the curing oven <NUM>. Optionally, materials that are trimmed from the pack by the trim mechanism <NUM> can be returned to the flow of gasses and glass fibers in the ducts <NUM> and recycled in the forming apparatus 632a and 632b. Recycling of the trim materials advantageously prevents potential environmental issues connected with the disposal of the trim materials. As shown in <FIG> not in accordance with the invention, ductwork <NUM> connects the trim mechanism <NUM> with the ducts <NUM> and is configured to facilitate the return of trim materials to the forming apparatus 632a and 632b. While the described example shown in <FIG> and <FIG> illustrate the recycling of the trimmed materials, it should be appreciated that the recycling of the trimmed materials is optional and the method of forming the pack from fibrous materials <NUM> can be practiced without recycling of the trimmed materials. In another example not in accordance with the invention, the trim mechanism <NUM> is positioned downstream from the curing oven <NUM>. This positioning is particularly useful if the trimmed materials are not recycled. Trimming the pack forms a trimmed pack.

The trimmed pack is conveyed by the first conveyor <NUM> to a second conveyor <NUM>. As shown in <FIG> not in accordance with the invention, the second conveyor <NUM> may be positioned to be "stepped down" from the first conveyor <NUM>. The term "stepped down", as used herein, is defined to mean the upper surface of the second conveyor <NUM> is positioned to be vertically below the upper surface of the first conveyor <NUM>. The stepping down of the conveyors will be discussed in more detail below.

Referring again to <FIG> and <FIG> not in accordance with the invention, the trimmed pack is carried by the second conveyor <NUM> to an optional entanglement mechanism <NUM>. The entanglement mechanism <NUM> is configured to entangle the individual fibers <NUM> forming the layers of the trimmed pack. Entangling the glass fibers <NUM> within the pack ties the pack together. In the examples not in accordance with the invention where dry binder is included, entangling the glass fibers <NUM> advantageously allows mechanical properties, such as for example, tensile strength and shear strength, to be improved. In the illustrated described example, the entanglement mechanism <NUM> is a needling mechanism. In other described examples, the entanglement mechanism <NUM> can include other structures, mechanisms or devices or combinations thereof, including the non-limiting example of stitching mechanisms.

The second conveyor <NUM> conveys the pack with optional dry binder (not in accordance with the invention), that is optionally trimmed, and/or optionally entangled (hereafter both the trimmed pack and the entangled pack are simply referred to as the "pack") to a third conveyor <NUM>. When the pack includes a dry binder, the third conveyor <NUM> is configured to carry the pack to an optional curing oven <NUM>. The curing oven <NUM> is configured to blow a fluid, such as for example, heated air through the pack such as to cure the dry binder and rigidly bond the glass fibers <NUM> together in a generally random, three-dimensional structure. Curing the pack in the curing oven <NUM> forms a cured pack.

As discussed above not in accordance with the invention, the pack optionally includes a dry binder. The use of the dry binder, rather than a traditional wet binder, advantageously allows the curing oven <NUM> to use less energy to cure the dry binder within the pack. In the illustrated described example, the use of the dry binder in the curing oven <NUM> results in an energy savings in a range of from about <NUM>% to about <NUM>% compared to the energy used by conventional curing ovens to cure wet or aqueous binder. In still other described examples, the energy savings can be in excess of <NUM>%. The curing oven <NUM> can be any desired curing structure, mechanism or device or combinations thereof.

The third conveyor <NUM> conveys the cured pack to a fourth conveyor <NUM>. The fourth conveyor <NUM> is configured to carry the cured pack to a cutting mechanism <NUM>. Optionally, the cutting mechanism <NUM> can be configured for several cutting modes. In a first optional cutting mode, the cutting mechanism is configured to cut the cured pack in vertical directions along the machine direction Dl such as to form lanes. The formed lanes can have any desired widths. In a second optional cutting mode, the cutting mechanism is configured to bisect the cured pack in a horizontal direction such as to form continuous packs having thicknesses. The resulting bisected packs can have any desired thicknesses. Cutting the cured pack forms cut pack.

In the illustrated described example, the cutting mechanism <NUM> includes a system of saws and knives. Alternatively, the cutting mechanism <NUM> can be other structures, mechanisms or devices or combinations thereof. Referring again to <FIG> and <FIG>, the cutting mechanism <NUM> is advantageously positioned such as to allow the capture of dust and other waste materials formed during the cutting operation. Optionally, dust and other waste materials stemming from the cutting mechanism can be returned to the flow of gasses and glass fibers in the ducts <NUM> and recycled in the forming apparatus 632a and 632b. Recycling of the dust and waste materials advantageously prevents potential environmental issues connected with the disposal of the dust and waste materials. As shown in <FIG> and <FIG> not in accordance with the invention, ductwork <NUM> connects the cutting mechanism <NUM> with the ducts <NUM> and is configured to facilitate the return of dust and waste materials to the forming apparatus 632a and 632b. While the described examples shown in <FIG> and <FIG> illustrate the recycling of the dust and waste materials, it should be appreciated that the recycling of the dust and waste materials is optional and the method of forming the pack from fibrous materials <NUM> can be practiced without recycling of the dust and waste materials.

Optionally, prior to the conveyance of the cured pack to the cutting mechanism <NUM>, the major surfaces of the cured pack can be faced with facing material or materials by facing mechanisms 662a, 662b as shown in <FIG>. In the illustrated embodiment, the upper major surface of the cured pack is faced with facing material 663a provided by facing mechanism 662a and the lower major surface of the cured pack is faced with facing material 663b provided by facing mechanism 662b. The facing materials can be any desired materials including paper, polymeric materials or non-woven webs. The facing mechanisms 662a and 662b can be any desired structures, mechanisms or devices or combinations thereof. In the illustrated embodiment, the facing materials 663a and 663b are applied to the cured pack (if the pack includes a binder) by adhesives. In other embodiments, the facing materials 663a and 663b can be applied to the cured pack by other methods, including the non-limiting example of sonic welding. While the described examples shown in <FIG> illustrates the application of the facing materials 663a and 663b to the major surfaces of the cured pack, it should be appreciated that the application of the facing materials 663a and 663b to the major surfaces of the cured pack is optional and the method of forming the pack from fibrous materials <NUM> can be practiced without the application of the facing materials 663a and 663b to the major surfaces of the cured pack.

Referring to <FIG> and <FIG> not in accordance with the invention, the fourth conveyor <NUM> conveys the cut pack to an optional chopping mechanism <NUM>. The chopping mechanism <NUM> is configured to section the cut pack into desired lengths across the machine direction Dl. In the illustrated described example, the chopping mechanism <NUM> is configured to section the cut pack as the cut pack continuously moves in the machine direction Dl. Alternatively, the chopping mechanism <NUM> can be configured for batch chopping operation. Sectioning the cut pack into lengths forms a dimensioned pack. The lengths of the chopped pack can have any desired dimension.

Chopping mechanisms are known in the art and will not be described herein. The chopping mechanism <NUM> can be any desired structure, mechanism or device or combinations thereof.

Optionally, prior to the conveyance of the cut pack to the chopping mechanism <NUM>, the minor surfaces of the cut pack can be faced with edging material or materials by edging mechanisms 666a, 666b as shown in <FIG>. The edging materials can be any desired materials including paper, polymeric materials or nonwoven webs. The edging mechanisms 666a and 666b can be any desired structures, mechanisms or devices or combinations thereof. In the illustrated embodiment, the edging materials 667a and 667b are applied to the cut pack by adhesives. In other described examples, the edging materials 667a and 667b can be applied to the cut pack by other methods, including the non-limiting example of sonic welding. While the described example shown in <FIG> illustrates the application of the edging materials 667a and 667b to the minor surfaces of the cut pack, it should be appreciated that the application of the edging materials 667a and 667b to the minor surfaces of the cut pack is optional and the method of forming the pack from fibrous materials <NUM> can be practiced without the application of the edging materials 667a and 667b to the minor surfaces of the cut pack.

Referring again to <FIG> not in accordance with the invention, the fourth conveyor <NUM> conveys the dimensioned pack to a fifth conveyor <NUM>. The fifth conveyor <NUM> is configured to convey the dimensioned pack to a packaging mechanism <NUM>. The packaging mechanism <NUM> is configured to package the dimensioned pack for future operations. The term "future operations," as used herein, is defined to include any activity following the forming of the dimensioned pack, including the non-limiting examples of storage, shipping, sales and installation.

In the illustrated described example, the packaging mechanism <NUM> is configured to form the dimensioned pack into a package in the form of a roll. In other described examples, the packaging mechanism <NUM> can form packages having other desired shapes, such as the non-limiting examples of slabs, batts and irregularly shaped or die cut pieces. The packaging mechanism <NUM> can be any desired structure, mechanism or device or combinations thereof.

Referring again to <FIG>, the conveyors <NUM>, <NUM>, <NUM>, <NUM> and <NUM> are in a "stepped down" relationship in the machine direction Dl. The "stepped down" relationship means that the upper surface of the successive conveyor is positioned to be vertically below the upper surface of the preceding conveyor. The "stepped down" relationship of the conveyors advantageously provides a self-threading feature to the conveyance of the pack. In the illustrated described example, the vertical offset between adjacent conveyors is in a range of from about <NUM> inches to about <NUM> inches. In other described examples, the vertical offset between adjacent conveyors can be less than about <NUM> inches or more than about <NUM> inches.

As illustrated in <FIG> and <FIG>, the method for forming a pack from fibrous materials <NUM> eliminates the use of a wet binder, thereby eliminating the traditional needs for washwater and washwater related structures, such as forming hoods, return pumps and piping. The elimination of the use of water, with the exception of cooling water, and the application of lubricant, color and other optional chemicals, advantageously allows the overall size of the manufacturing line (or "footprint") to be significantly reduced as well as reducing the costs of implementation, operating costs and maintenance and repair costs.

As further illustrated in <FIG> and <FIG>, the method for forming a pack from fibrous materials <NUM> advantageously allows the uniform and consistent deposition of long and thin fibers on the forming apparatus 632a and 632b. In the illustrated described example, the fibers <NUM> have a length in a range of from about <NUM> inches (<NUM>) to about <NUM> inches (<NUM>) and a diameter dimension in a range of from about <NUM> HT (<NUM> microns) to about <NUM> HT (<NUM> microns). In the present invention, the fibers <NUM> have a length in a range of from about <NUM> inch (<NUM>) to about <NUM> inches (<NUM>) and a diameter dimension in a range of from about <NUM> HT (<NUM> microns) to about <NUM> HT (<NUM> microns). In examples not in accordance with the invention, the fibers <NUM> can have a length less than about <NUM> inches (<NUM>) or more than about <NUM> inches (<NUM>) and a diameter dimension less than about <NUM> HT (<NUM> microns) or more than about <NUM> HT (<NUM> microns). While not being bound by the theory, it is believed the use of the relatively long and thin fibers advantageously provides a pack having better thermal and acoustic insulative performance than a similar sized pack having shorter and thicker fibers.

While the described examples illustrated in <FIG> and <FIG> have been generally described above to form packs of fibrous materials, it should be understood that the same apparatus can be configured to form "unbonded loosefill insulation". The term "unbonded loosefill insulation", as used herein, is defined to mean any conditioned insulation material configured for application in an airstream.

Referring to <FIG> in another described example of the method <NUM> not in accordance with the invention, the cross lapping mechanisms 634a and 634b are configured to provide precise deposition of alternating layers of the continuous web on the first conveyer <NUM>, thereby allowing elimination of downstream trim mechanism <NUM>.

Referring again to <FIG> in described example of the method <NUM> not in accordance with the invention, the various layers of the pack can be "stratified". The term "stratified", as used herein, is defined to mean that each of the layers can be configured with different characteristics, including the non-limiting examples of fiber diameter, fiber length, fiber orientation, density, thickness and glass composition. It is contemplated that the associated mechanisms forming a layer, that is, the associated fiberizer, forming apparatus and cross lapping mechanism can be configured to provide a layer having specific and desired characteristics. Accordingly, a pack can be formed from layers having different characteristics.

In another described example, the dry binder can include or be coated with additives to impart desired characteristics to the pack. One non-limiting example of an additive is a fire retardant material, such as for example baking soda. Another non-limiting example of an additive is a material that inhibits the transmission of ultraviolet light through the pack. Still another non-limiting example of an additive is a material that inhibits the transmission of infrared light through the pack.

Referring to <FIG> in another described example of the method <NUM> not in accordance with the invention and as discussed above, a flow of hot gases can be created by optional blowing mechanisms, such as the non-limiting examples of annular blowers (not shown) or annular burners (not shown). It is known in the art to refer to the heat created by the annular blowers and the annular burners as the "heat of fiberization". It is contemplated in this described example, that the heat of fiberization is captured and recycled for use in other mechanisms or devices. The heat of fiberization can be captured at several locations in the method <NUM>. As shown in <FIG> and <FIG>, duct work <NUM> is configured to capture the heat emanating from the fiberizers <NUM> and convey the heat for use in other mechanisms, such as for example the optional curing oven <NUM>. Similarly, duct work <NUM> is configured to capture the heat emanating from the flow of hot gases within the duct <NUM> and duct work <NUM> is configured to capture the heat emanating from the forming apparatus 632a and 632b. The recycled heat can also be used for purposes other than the forming of fibrous packs, such as for example heating an office.

In certain described examples, the duct <NUM> can include heat capturing devices, such as for example, heat extraction fixtures configured to capture the heat without significantly interfering with the momentum of the flow of the hot gasses and entrained glass fibers <NUM>. In other embodiments, any desired structure, device or mechanism sufficient to capture the heat of fiberization can be used.

Referring to <FIG> in another described example of the method <NUM> not in accordance with the invention, fibers or other materials having other desired characteristics can be mixed with glass fibers <NUM> entrained in the flow of gasses. In this embodiment, a source <NUM> of other materials, such as for example, synthetic or ceramic fibers, coloring agents and/or particles can be provided to allow such materials to be introduced into a duct <NUM>.

The duct <NUM> can be connected to the duct <NUM> such as to allow mixing with the glass fibers <NUM> entrained in the flow of gasses. In this manner, the characteristics of the resulting pack can be engineered or tailored for desired properties, such as the nonlimiting examples acoustic, thermal enhancing or UV inhibiting characteristics.

In still other embodiments, it is contemplated that other materials can be positioned between the layers deposited by the cross-lapping mechanisms 634a and 634b on the first conveyor <NUM>. The other materials can include sheet materials, such as for example, facings, vapor barriers or netting, or other non-sheet materials including the non-limiting examples of powders, particles or adhesives. The other materials can be positioned between the layers in any desired manner. In this manner, the characteristics of the resulting pack can be further engineered or tailored as desired.

While the described example illustrated in <FIG> illustrates use of the continuous web by the cross-lapping mechanisms 634a and 634b, it should be appreciated that in other embodiments, the web can be removed from the forming apparatus 632a and 632b and stored for later use.

Claim 1:
A layered pack of glass fibers, the layered pack comprising:
binderless webs of glass fibers formed by lapping a binderless web in the machine direction or by cross-lapping a binder less web at ninety degrees to the machine direction;
wherein the glass fibers of the binderless webs are mechanically entangled;
wherein the binderless webs have an area weight of <NUM> grams per square meter to <NUM> grams per square meter (<NUM> to <NUM> grams per square foot);
wherein the glass fibers have a diameter range of in a range of <NUM> microns to <NUM> microns (<NUM> HT to <NUM> HT); and
wherein the glass fibers have a length range of <NUM> millimeters to <NUM> millimeters (<NUM> inch to <NUM> inches).