Method for Forming a Melt-Resistant Glass Fiber Product, and Associated Apparatus

Abstract

A method is provided for forming a melt-resistant glass fiber product, by applying an insulating material to a glass fiber product comprised of filiform glass fibers so as to substantially coat each of the filiform glass fibers therewith, such that the coated filiform glass fibers render the glass fiber product resistant to heat. In one aspect, such a method comprises forming a wetted mixture including filiform glass fibers and insulating material comprising a fire-retarding solution, wherein the wetted mixture has a solids content of the fire-retarding solution substantially uniformly and thoroughly dispersed therethrough. An associated apparatus is also provided.

1 - 20 . (canceled) 
     
     
         21 . An apparatus for forming a melt-resistant glass fiber product, said apparatus comprising:
 a first mixing device arranged to apply an insulating material to filiform glass fibers, by forming a wetted mixture including the filiform glass fibers and the insulating material comprising a fire-retarding solution such that the fire retarding solution coats each of the filiform glass fibers, the wetted mixture having a solids content of the fire-retarding solution dispersed therethrough, and the coating rendering the coated filiform glass fibers resistant to heat;   a processing device arranged to receive the coated filiform glass fibers from the first mixing device and to de-liquefy the coated filiform glass fibers to form dry coated filiform glass fibers having a moisture content of between 0% and about 3%;   a second mixing device arranged to receive the dry coated filiform glass fibers from the processing device and to form a cohesive glass fiber mixture from the dry coated filiform glass fibers and a glass fiber binding agent; and   a forming device arranged to receive a layer of a cohesive cellulose fiber mixture between two layers of the cohesive glass fiber mixture from the second mixing device, such that the layers are adjacent to each other, the forming device being further arranged to intermix glass and cellulose fibers at interfaces between the cohesive cellulose fiber mixture layer and each of the cohesive glass fiber mixture layers to form the adjacent layers into an integral composite sheet or board product.   
     
     
         22 . An apparatus according to  claim 21 , wherein the first mixing device is arranged to apply the insulating material to the glass fiber product comprised exclusively of filiform glass fibers. 
     
     
         23 . An apparatus according to  claim 21 , wherein the first mixing device is arranged to form the wetted mixture by saturating the filiform glass fibers with the fire-retarding solution or forming a slurry from the filiform glass fibers and the fire-retarding solution. 
     
     
         24 . An apparatus according to  claim 21 , wherein the first mixing device is arranged to form the wetted mixture from the filiform glass fibers and the fire-retarding solution comprising a boron compound, a phosphorus compound, a chlorine compound, a fluorine compound, an antimony compound, a borate compound, a halogen compound, boric acid, an inorganic hydrate, a bromine compound, aluminum hydroxide, magnesium hydroxide, hydromagnesite, antimony trioxide, a phosphonium salt, ammonium phosphate, diammonium phosphate, methyl bromide, methyl iodide, bromochlorodifluoromethane, dibromotetrafluoroethane, dibromodifluoromethane, carbon tetrachloride, urea-potassium bicarbonate, or any combination thereof. 
     
     
         25 . An apparatus according to  claim 21 , wherein the processing device is arranged to dewater the coated filiform glass fibers; and to dry the dewatered coated filiform glass fibers to form the dry coated filiform glass fibers. 
     
     
         26 . An apparatus according to  claim 21 , wherein the processing device is arranged to heat the coated filiform glass fibers to form dry coated filiform glass fibers. 
     
     
         27 . An apparatus according to  claim 21 , further comprising a recovery device configured to recover excess fire-retarding solution, in one of a liquid and a vapor form, upon de-liquefying the coated filiform glass fibers to form the dry coated filiform glass fibers; and to add the recovered excess fire-retarding solution to the filiform glass fibers to form an additional quantity of the coated filiform glass fibers. 
     
     
         28 . An apparatus according to  claim 21 , wherein the first mixing device is configured to form a wetted mixture from the filiform glass fibers and one of an aqueous fire-retarding solution, a nontoxic liquid fire-retarding solution, and a neutral pH liquid fire-retarding solution. 
     
     
         29 . An apparatus according to  claim 21 , wherein the second mixing device is configured to form the cohesive glass fiber mixture from the dry coated filiform glass fibers and the glass fiber binding agent comprising one of a resin material and an adhesive material. 
     
     
         30 . An apparatus according to  claim 21 , wherein the second mixing device is arranged to form the cohesive glass fiber mixture having between about 0.1% by weight and about 50% by weight of the binding agent.