Apparatus and method for controlling moisture in the manufacture of glass fiber insulation

Abstract

Apparatus, systems and methods for monitoring and controlling the amount of moisture introduced into the forming hood area in the manufacture of mineral fiber insulation products. Moisture from coolant liquids, binder dispersions and binder diluents are all introduced deliberately into a forming hood; ambient moisture and water from combustion are additional sources. A series of global variable control valves, one for each fluid system; as well as individual variable control valves for each fiberizing unit are provided with associated meters. Sensors monitor fibrous pack conditions and ambient conditions and provide inputs to the valve control system. A specific 3-ring liquid dispensing system is also disclosed.

1 . A method of making a fibrous product comprising;
 attenuating molten material into fibers at a plurality of fiberizing units associated with a conveyor moving in a machine direction, and directing the fibers toward the conveyor to form a fibrous pack;   spraying the fibers with a vaporizable coolant liquid and with a dispersion of curable binder, optionally mixed with a binder diluent; and   curing the binder in the pack;   wherein the sprayed vaporizable coolant liquid as a percent of total sprayed liquids, including any optional binder diluent, is between about 35% and about 80% on average for all fiberizing units combined.   
     
     
         2 . The method of  claim 1  wherein the sprayed vaporizable coolant liquid as a percent of total sprayed liquids, including any optional binder diluent, is between about 40% and about 80% on average for all fiberizing units combined. 
     
     
         3 . The method of  claim 2  wherein the sprayed vaporizable coolant liquid as a percent of total sprayed liquids, including any optional binder diluent, is between about 45% and about 60% on average for all fiberizing units combined. 
     
     
         4 . The method of  claim 1  wherein the flow of coolant liquid is substantially constant at all fiberizing units. 
     
     
         5 . The method of  claim 1  wherein the flow of coolant liquid is up to 100% higher at initial fiberizing units than at subsequent units. 
     
     
         6 . The method of  claim 5  wherein the flow of coolant liquid is up to 50% higher at initial and last fiberizing units, and lower at intermediate fiberizing units. 
     
     
         7 . The method of  claim 1  wherein the flow of coolant liquid is up to 10% lower at initial fiberizing units and then substantially constant at subsequent units. 
     
     
         8 . The method of  claim 1  wherein at least one of the liquids delivered to the fibers is delivered through an atomizing nozzle. 
     
     
         9 . The method of  claim 8  wherein the coolant liquid is delivered through an air atomized nozzle. 
     
     
         10 . The method of  claim 8  wherein the degree of atomization of coolant liquid is varied between one fiberizing unit and at least one other fiberizing unit. 
     
     
         11 . The method of  claim 10  wherein the degree of atomization is changed by altering the flow rate or pressure of the coolant liquid. 
     
     
         12 . The method of  claim 10  wherein the degree of atomization is changed by altering the flow rate or pressure of an atomizing gas. 
     
     
         13 . A method of improving the ramp height to ramp moisture ratio in manufacturing a fibrous product, the method comprising;
 attenuating molten material into fibers at a plurality of fiberizing units associated with a conveyor moving in a machine direction, and directing the fibers toward the conveyor to form a fibrous pack;   spraying the fibers with a vaporizable coolant liquid and with a dispersion of curable binder, optionally mixed with a binder diluent; and   curing the binder in the pack;   wherein the ramp height to ramp moisture ratio is increased by spraying the coolant liquid or binder diluent sacrificially in favor over the binder dispersion liquid.   
     
     
         14 . The method of  claim 13  wherein sprayed vaporizable coolant liquid as a percent of total sprayed liquids, including any optional binder diluent, is greater than about 35% on average. 
     
     
         15 . The method of  claim 13  wherein sprayed vaporizable coolant liquid is between about 35% and about 80% on average for all fiberizing units combined. 
     
     
         16 . The method of  claim 14  wherein sprayed vaporizable coolant liquid as a percent of total sprayed liquids, including any optional binder diluent, is greater than about 40% on average. 
     
     
         17 . The method of  claim 16  wherein sprayed vaporizable coolant liquid is between about 40% and about 80% on average for all fiberizing units combined. 
     
     
         18 . The method of  claim 16  wherein sprayed vaporizable coolant liquid is between about 45% and about 65% on average for all fiberizing units combined. 
     
     
         19 . A method of according to  claim 1 , further comprising;
 spraying the fibers with a vaporizable coolant liquid and with a dispersion of curable binder, the sprayed vaporizable coolant liquid as a percent of total sprayed liquids, including any optional binder diluent, being between about 35% and about 80% on average for all fiberizing units combined, the sprayed liquids creating a ramp moisture in the pack and the pack having a ramp height so as to define a ramp height to ramp moisture ratio of the pack;   wherein the ramp height to ramp moisture ratio is increased relative to a pack in which coolant liquid is not sprayed sacrificially at levels between about 35% and about 80% on average for all fiberizing units combined.   
     
     
         20 . A method of according to  claim 2 , further comprising;
 spraying the fibers with a vaporizable coolant liquid and with a dispersion of curable binder, the sprayed vaporizable coolant liquid as a percent of total sprayed liquids, including any optional binder diluent, being between about 40% and about 80% on average for all fiberizing units combined, the sprayed liquids creating a ramp moisture in the pack and the pack having a ramp height so as to define a ramp height to ramp moisture ratio of the pack;   wherein the ramp height to ramp moisture ratio is increased relative to a pack in which coolant liquid is not sprayed sacrificially at levels between about 40% and about 80% on average for all fiberizing units combined.