US 11,939,255 B2
Method of forming a web from fibrous material
Glenn Haley, Granville, OH (US); David J. Gaul, Granville, OH (US); and Michael T. Pellegrin, Newark, OH (US)
Assigned to Owens Corning Intellectual Capital, LLC, Toledo, OH (US)
Filed by Owens Corning Intellectual Capital, LLC, Toledo, OH (US)
Filed on May 16, 2014, as Appl. No. 14/279,554.
Application 14/279,554 is a division of application No. 13/839,350, filed on Mar. 15, 2013.
Application 13/839,350 is a continuation in part of application No. 13/632,895, filed on Oct. 1, 2012, abandoned.
Claims priority of provisional application 61/541,162, filed on Sep. 30, 2011.
Prior Publication US 2014/0245797 A1, Sep. 4, 2014
Int. Cl. C03B 37/04 (2006.01); C03C 25/1095 (2018.01); D04H 1/4218 (2012.01); D04H 1/4374 (2012.01); D04H 1/46 (2012.01); D04H 1/488 (2012.01); D04H 1/498 (2012.01); D04H 1/60 (2006.01); D04H 1/724 (2012.01); D04H 3/004 (2012.01); D04H 3/08 (2006.01); D04H 13/00 (2006.01)
CPC C03B 37/04 (2013.01) [C03C 25/1095 (2013.01); D04H 1/4218 (2013.01); D04H 1/4374 (2013.01); D04H 1/46 (2013.01); D04H 1/488 (2013.01); D04H 1/498 (2013.01); D04H 1/60 (2013.01); D04H 1/724 (2013.01); D04H 3/004 (2013.01); D04H 3/08 (2013.01); D04H 13/008 (2013.01); Y10T 442/608 (2015.04); Y10T 442/609 (2015.04); Y10T 442/667 (2015.04); Y10T 442/67 (2015.04)] 8 Claims
OG exemplary drawing
 
1. A continuous method for forming a pack of glass fibers, the continuous method comprising:
melting glass into molten glass;
forming glass fibers from the molten glass;
forming a binderless web of glass fibers from the glass fibers, the binderless web of glass fibers having a thickness of 0.1 to 0.5 inches;
lapping the binderless web of glass fibers to form a layered pack of glass fibers, said layered pack of glass fibers consisting essentially of glass fibers, the layered pack of glass fibers is free of any material that may bind the glass fibers together, wherein the layered pack of glass fibers has thickness of 0.75 inches to less than 2 inches and an area weight within the range of 0.10 pounds per square foot to 0.38 pounds per square foot; and
mechanically entangling the glass fibers of the layered pack of glass fibers, wherein the mechanically entangling comprises needling;
wherein the glass fibers have a diameter within the range of 15 to 19 hundred-thousandths of an inch;
wherein the glass fibers have a length within the range of 0.25 to 10.0 inches; and
wherein the melting, forming, and lapping steps occur without substantial breaks in production.