Fibrous product and method and apparatus for making the product

Abstract

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

1 . A nonwoven fibrous insulation product having at least a bi-modal fiber diameter distribution designed to provide the fibrous insulation product with selected thermal insulating performance and physical performance properties that are affected by fiber diameter, comprising:
 a first fiber grouping of fibers having a selected fiber diameter distribution with a selected mean fiber diameter;   a second fiber grouping of fibers having a selected fiber diameter distribution with a selected mean fiber diameter wherein the selected fiber diameter distribution of the second fiber grouping differs from the selected fiber diameter distribution of the first fiber grouping;   the nonwoven fibrous insulation product having a first percentage by weight of the fibers of the first fiber grouping intermingled and entangled with a second percentage by weight of the fibers of the second fiber grouping whereby, for a selected product density and thickness, the nonwoven fibrous insulation product exhibits a selected product thermal insulating performance property and one or more selected product physical performance properties.   
   
   
       2 . The nonwoven fibrous insulation product according to  claim 1 , wherein:
 the mean fiber diameter of the first fiber grouping and the mean fiber diameter of the second fiber grouping differ from each other.   
   
   
       3 . The nonwoven fibrous insulation product according to  claim 2 , wherein:
 the fiber diameter distribution of the first fiber grouping over a selected fiber diameter range of the first fiber grouping, graphically represented, forms a generally bell shaped curve; and   the fiber diameter distribution of the second fiber grouping over a selected fiber diameter range of the second fiber grouping, graphically represented, forms a generally bell shaped curve.   
   
   
       4 . The nonwoven fibrous insulation product according to  claim 3 , wherein:
 the fibers of the first fiber grouping are included in the nonwoven fibrous insulation product primarily for the thermal insulating performance and rigidity provided the nonwoven fibrous insulation product by the fibers of the first fiber grouping;   the mean fiber diameter of the second fiber grouping is greater than the mean fiber diameter of the first fiber grouping; and   the fibers of the second fiber grouping are included in the nonwoven fibrous insulation product primarily for the recovery from an application of compressive forces provided the nonwoven fibrous insulation product by the fibers of the second fiber grouping.   
   
   
       5 . The nonwoven fibrous insulation product according to  claim 4 , wherein:
 the first percentage by weight of the fibers of the first fiber grouping and second percentage by weight of the fibers of the second fiber grouping differ from each other.   
   
   
       6 . The nonwoven fibrous insulation product according to  claim 5 , wherein:
 the fibers of the first and second fiber groupings of the nonwoven fibrous insulation product are glass fibers.   
   
   
       7 . The nonwoven fibrous insulation product according to  claim 1 , wherein:
 the fibers of the first fiber grouping are included in the nonwoven fibrous insulation product primarily for the thermal insulating performance and rigidity provided the nonwoven fibrous insulation product by the fibers of the first fiber grouping;   the mean fiber diameter of the second fiber grouping is greater than the mean fiber diameter of the first fiber grouping; and   the fibers of the second fiber grouping are included in the nonwoven fibrous insulation product primarily for the recovery from an application of compressive forces provided the nonwoven fibrous insulation product by the fibers of the second fiber grouping.   
   
   
       8 . The nonwoven fibrous insulation product according to  claim 7 , wherein:
 the first percentage by weight of the fibers of the first fiber grouping and second percentage by weight of the fibers of the second fiber grouping differ from each other.   
   
   
       9 . The nonwoven fibrous insulation product according to  claim 8 , wherein:
 the fibers of the first and second fiber groupings of the nonwoven fibrous insulation product are glass fibers.   
   
   
       10 . The nonwoven fibrous insulation product according to  claim 1 , wherein:
 the fibers of the first and second fiber groupings of the nonwoven fibrous insulation product comprise glass fibers and non-glass fibers.   
   
   
       11 . A fibrous insulation product having at least a tri-modal fiber diameter distribution designed to provide the fibrous insulation product with selected thermal insulating performance and physical performance properties that are affected by fiber diameter, comprising:
 a first fiber grouping of fibers having a selected fiber diameter distribution with a selected mean fiber diameter;   a second fiber grouping of fibers having a selected fiber diameter distribution with a selected mean fiber diameter wherein the selected fiber diameter distribution of the second fiber grouping differs from the selected fiber diameter distribution of the first fiber grouping;   a third fiber grouping of fibers having a selected fiber diameter distribution with a selected mean fiber diameter, wherein the selected fiber diameter distribution of the third fiber grouping differs from the selected fiber diameter distributions of the first and second fiber groupings; and   the nonwoven fibrous insulation product having a first percentage by weight of the fibers of the first fiber grouping, a second percentage by weight of the fibers of the second fiber grouping, and a third percentage by weight of the fibers of the third fiber grouping intermingled and entangled together whereby, for a selected product density and thickness, the nonwoven fibrous insulation product exhibits a selected product thermal insulating performance property and one or more selected product physical performance properties.   
   
   
       12 . A method of making a nonwoven fibrous insulation product having at least a bi-modal fiber diameter distribution designed to provide the fibrous insulation product with selected thermal insulating performance and physical performance properties that are affected by fiber diameter, comprising:
 selecting thermal and physical properties desired for a nonwoven fibrous insulation product having a selected product density and thickness;   determining a thermal insulating performance property and one or more first physical performance properties provided at the selected product density and thickness for the nonwoven fibrous insulation product by a first fiber grouping having a selected fiber diameter distribution;   determining a thermal insulating performance property and one or more first physical performance properties provided at the selected product density and thickness for the nonwoven fibrous insulation product by a second fiber grouping having a selected fiber diameter distribution that differs from the selected fiber diameter distribution of the first fiber grouping;   determining a percentage by weight of fibers of the nonwoven fibrous insulation product of the first fiber grouping and a percentage by weight of the fibers of the nonwoven fibrous insulation product of the second fiber grouping required to form the nonwoven fibrous insulation product with the selected product thermal insulating performance property and one or more selected product physical performance properties at the selected product density and thickness; and   intermingling and entangling fibers of the first and second fiber groupings in the determined percentages by weight for the fibers of the first and second fiber groupings and in the selected product density and thickness to form a nonwoven fibrous insulation product which exhibits the selected product thermal insulating performance property and the one or more selected product physical performance properties.   
   
   
       13 . The method of making a nonwoven fibrous insulation product according to  claim 12 , wherein:
 there are at least two of the physical performance properties and the two physical performance properties are rigidity and recovery from an application of compressive forces.   
   
   
       14 . The method of making a nonwoven fibrous insulation product according to  claim 12 , wherein:
 the mean fiber diameter of the first fiber grouping and the mean fiber diameter of the second fiber grouping differ from each other.   
   
   
       15 . The method of making a nonwoven fibrous insulation product according to  claim 14 , wherein:
 the fiber diameter distribution of the first fiber grouping over a selected fiber diameter range of the first fiber grouping, graphically represented, forms a generally bell shaped curve; and   the fiber diameter distribution of the second fiber grouping over a selected fiber diameter range of the second fiber grouping, graphically represented, forms a generally bell shaped curve.   
   
   
       16 . The method of making a nonwoven fibrous insulation product according to  claim 15 , wherein:
 the fibers of the first fiber grouping are included in the nonwoven fibrous insulation product primarily for the thermal insulating performance and rigidity provided the nonwoven fibrous insulation product by the fibers of the first fiber grouping;   the mean fiber diameter of the second fiber grouping is greater than the mean fiber diameter of the first fiber grouping; and   the fibers of the second fiber grouping are included in the nonwoven fibrous insulation product primarily for the recovery from an application of compressive forces provided the nonwoven fibrous insulation product by the fibers of the second fiber grouping.   
   
   
       17 . The method of making a nonwoven fibrous insulation product according to  claim 16 , wherein:
 the first percentage by weight of the fibers of the first fiber grouping and second percentage by weight of the fibers of the second fiber grouping differ from each other.   
   
   
       18 . The method of making a nonwoven fibrous insulation product according to  claim 17 , wherein:
 the fibers of the first and second fiber groupings of the nonwoven fibrous insulation product are glass fibers.   
   
   
       19 . The method of making a nonwoven fibrous insulation product according to  claim 18 , wherein:
 the fibers of the nonwoven fibrous insulation product comprise glass fibers and non-glass fibers.   
   
   
       20 . The method of making a nonwoven fibrous insulation product according to  claim 12 , wherein:
 the fibers of the first and second fiber groupings are made by a rotary fiberization process.   
   
   
       21 . The method of making a nonwoven fibrous insulation product according to  claim 20 , wherein:
 the rotary glass fiberization process utilizes a fiberizing spinner having at least two sets of fiberizing holes wherein a first set of fiberizing holes is designed to form the fibers of the nonwoven fibrous insulation product of the first fiber grouping and a second set of fiberizing holes is designed to form the fibers of the nonwoven fibrous insulation product of the second fiber grouping in the percentages by weight of the nonwoven fibrous insulation product required to provide the selected product thermal insulating performance property and the one or more selected product physical performance properties.   
   
   
       22 . The method of making a nonwoven fibrous insulation product according to  claim 20 , wherein:
 the rotary glass fiberization process utilizes at least a first and a second fiberizing station with a fiberizing spinner of the first fiberizing station forming the fibers of the nonwoven fibrous insulation product of the first fiber grouping and a fiberizing spinner of the second fiberizing station forming the fibers of the nonwoven fibrous insulation product of the second fiber grouping in the percentages by weight of the nonwoven fibrous insulation product required to provide the selected product thermal insulating performance property and the one or more selected product physical performance properties.   
   
   
       23 . A method of making a nonwoven fibrous insulation product having at least a tri-modal fiber diameter distribution designed to provide the fibrous insulation product with selected thermal insulating performance and physical performance properties that are affected by fiber diameter, comprising:
 selecting thermal and physical properties desired for a nonwoven fibrous insulation product having a selected product density and thickness;   determining a thermal insulating performance property and one or more first physical performance properties provided at the selected product density and thickness for the nonwoven fibrous insulation product by a first fiber grouping having a selected fiber diameter distribution;   determining a thermal insulating performance property and one or more first physical performance properties provided at the selected product density and thickness for the nonwoven fibrous insulation product by a second fiber grouping having a selected fiber diameter distribution that differs from the selected fiber diameter distribution of the first fiber grouping;   determining a thermal insulating performance property and one or more first physical performance properties provided at the selected product density and thickness for the nonwoven fibrous insulation product by a third fiber grouping having a selected fiber diameter distribution that differs from the selected fiber diameter distributions of the first and second fiber groupings;   determining a percentage by weight of fibers of the nonwoven fibrous insulation product of the first fiber grouping, a percentage by weight of the fibers of the nonwoven fibrous insulation product of the second fiber grouping, and a percentage by weight of the fibers of the nonwoven fibrous insulation product of the third fiber grouping required to form the nonwoven fibrous insulation product with the selected product thermal insulating performance property and one or more selected product physical performance properties at the selected product density and thickness; and   intermingling and entangling fibers of the first, second, and third fiber groupings in the determined percentages by weight for the fibers of the first, second, and third fiber groupings and in the selected product density and thickness to form a nonwoven fibrous insulation product which exhibits the selected product thermal insulating performance property and the one or more selected product physical performance properties.   
   
   
       24 . A rotary glass fiberization apparatus for making a fibrous product having at least a bi-modal fiber diameter distribution designed to provide the fibrous insulation product with selected performance properties that are affected by fiber diameter, comprising:
 a spinner disc, the spinner disc having a round base and annular peripheral sidewall extending upward from a peripheral edge of the base; the annular peripheral sidewall having an upper annular edge portion, a lower annular edge portion, and a mid-portion extending between the upper and lower annular edge portions; the mid-portion of the sidewall having thousands of glass fiberization holes therein for forming glass fibers; the glass fiberization holes being sized to form at least a first fiber grouping and a second fiber grouping when glass is extruded through the glass fiberization holes; the fibers of the first fiber grouping having a selected fiber diameter distribution with a selected mean fiber diameter and the fibers of the second fiber grouping having a selected mean fiber diameter wherein the selected fiber diameter distribution of the second fiber grouping differs from the selected fiber diameter distribution of the first fiber grouping;   drive means for rotating the spinner disc about a generally vertical axis of rotation to extrude glass through the glass fiberization holes and form the fibers;   molten glass source means for introducing a molten glass into an interior of the spinner disc and onto the base of the spinner disc radially inward of the annular peripheral sidewall of the spinner disc;   attenuating means for attenuating the fibers of the first and second fiber groupings formed by extruding glass through the glass fiberization holes; the attenuating means attenuating the fibers of the first fiber grouping into a selected finer fiber diameter distribution with a selected finer mean fiber diameter and attenuating the fibers of the second fiber grouping into a selected finer fiber diameter distribution with a selected finer mean fiber diameter wherein the selected finer fiber distribution of the second fiber grouping differs from the selected finer fiber diameter distribution of the first fiber grouping; and   means for collecting the first and second fiber groupings, subsequent to the attenuation of the fibers of the first and second fiber groupings, into a nonwoven fibrous product of intermingled and entangled fibers of the first and second fiber groupings having desired performance properties provided by the first and second fiber groupings.   
   
   
       25 . The rotary glass fiberization apparatus according to  claim 24 , wherein:
 the glass fiberization holes sized to form the first and the second fiber groupings comprise a first set of holes sized to form the fibers of the first fiber grouping, a second set of holes sized to form the fibers of the second fiber grouping, and the proportion of the glass fiberization holes of the first set of holes relative to the proportion of the glass fiberization holes of the second set of holes is selected to form the nonwoven fibrous product with a first percentage by weight of the fibers of the first fiber grouping and a second percentage by weight of the second fiber grouping that cause the nonwoven fibrous product to exhibit selected product performance properties provided by the first and second fiber groupings.