Insulation containing a layer of textile, rotary and/or flame attenuated fibers, and process for producing the same

Abstract

An insulation product contains a layer of textile, rotary and/or flame attenuated fibers. A process for manufacturing the insulation product includes passing fibrous bundles of one or more of textile fibers and of rotary and/or flame attenuated fibers together through an apparatus that separates the fibers and the mixes the separated fibers. The bundles of rotary and/or flame attenuated fibers can be in the form of specially manufactured mats and/or can be production scraps. The resulting mixture of fibers is formed into a non-woven batt, mat, blanket, or board. The process provides homogeneous fiber product with an improved appearance. The textile fibers can enhance thickness recovery of compressed product. Blends of textile glass fiber with rotary and/or flame attenuated glass fiber exhibit an improved combination of thermal and acoustic insulating performance and adequate strength, at a low production cost.

1 . A method of making an insulation product, the method comprising 
 passing at least one of a first fibrous material and a second fibrous material through a sheet former at a relative humidity of 40% or more to produce a collection of fibers; and    forming the collection of fibers into a non-woven batt, mat, blanket or board, wherein    the first fibrous material contains first fibers each having a diameter in a range of from greater than 5 μm to about 16 μm; and    the second fibrous material contains second fibers each having a diameter in a range of from about 2 μm to 5 μm.    
   
   
       2 . The method according to  claim 1 , wherein the relative humidity is 50% or more.  
   
   
       3 . The method according to  claim 1 , further comprising adding an antistatic agent to the sheet former while the at least one of a first fibrous material and a second fibrous material passes through the sheet former.  
   
   
       4 . The method according to  claim 3 , wherein the antistatic agent comprises water.  
   
   
       5 . The method according to  claim 1 , wherein 
 the first fibrous material is passed through the sheet former; and    the first fibers are each about 2 cm to about 15 cm long.    
   
   
       6 . The method according to  claim 1 , wherein 
 the second fibrous material is passed through the sheet former; and    the second fibers are each about 1 cm to about 5 cm long.    
   
   
       7 . The method according to  claim 1 , wherein at least one of the first fibers and the second fibers comprises a glass.  
   
   
       8 . The method according to  claim 1 , wherein at least one of the first fibers and the second fibers comprises a polymer.  
   
   
       9 . The method according to  claim 1 , wherein the forming comprises 
 adding a binder to the collection of fibers; and    heating the binder to bond the collection of fibers.    
   
   
       10 . A method of making an insulation product, the method comprising 
 adding an antistatic agent to at least one of a first fibrous material and a second fibrous material;    passing the antistatic agent and the at least one of a first fibrous material and a second fibrous material through a sheet former to produce a collection of fibers; and    forming the collection of fibers into a non-woven batt, mat, blanket or board, wherein    the first fibrous material contains first fibers each having a diameter in a range of from greater than 5 μm to about 16 μm; and    the second fibrous material contains second fibers each having a diameter in a range of from about 2 μm to 5 μm.    
   
   
       11 . The method according to  claim 10 , wherein the relative humidity in the sheet former is 40% or more.  
   
   
       12 . The method according to  claim 10 , wherein the antistatic agent comprises water.  
   
   
       13 . The method according to  claim 10 , wherein 
 the first fibrous material is passed through the sheet former; and    the first fibers are each about 2 cm to about 15 cm long.    
   
   
       14 . The method according to  claim 10 , wherein 
 the second fibrous material is passed through the sheet former; and    the second fibers are each about 1 cm to about 5 cm long.    
   
   
       15 . The method according to  claim 10  wherein at least one of the first fibers and the second fibers comprises a glass.  
   
   
       16 . The method according to  claim 10 , wherein at least one of the first fibers and the second fibers comprises a polymer.  
   
   
       17 . The method according to  claim 10 , wherein the forming comprises 
 adding a binder that is not the antistatic agent to the collection of fibers; and    heating the binder to bond the collection of fibers.    
   
   
       18 . The method according to  claim 10 , wherein 
 the antistatic agent comprises a binder; and    the forming comprising heating the binder to bond the collection of fibers.