A filament winding method and system without needing a resin dip bath are disclosed. The method comprises feeding a fiber band of a plurality of fibers onto a mandrel without dipping the fibers in a resin bath, and applying a resin onto the fiber band at or about where the fiber band contacts the mandrel or applied directly to the fiber band and then wound onto the mandrel so that the resin is between the mandrel and the fiber band at the point of contact. In some embodiments, the resin can be sprayed onto the fibers and in other embodiments, the resin can be delivered in at least one layer onto the fiber band that is then impregnated into the fiber band as the fiber band wraps around the mandrel. The fiber can comprise carbon fiber, basalt fiber, glass fibers, Kevlar fiber, polyester fiber, other fibers, or a combination thereof.

A fibrous insulation product having a plurality of randomly oriented glass fibers and a binder composition that holds the glass fibers together is disclosed. The fibrous insulation product has an R-value in the range of 10 to 54 and, after curing, has a density, when uncompressed, in the range of 0.30 pcf to 2.7 pcf. Furthermore, the fibrous insulation product includes glass fibers that, prior to the application of the binder composition, have an average fiber diameter in the range of 8 HT to 12 HT and a quantity of binder that is in the range of 2% to 10% by weight of the fibrous insulation product. The fibrous insulation product also has an average fiber diameter to density ratio (Fd/D) of less than or equal to 40 and a comfort factor less than or equal to 3.417(Fd/D)+60.

A process for manufacturing self-adhesive insulation products based on mineral wool includes (a) forming mineral fibers by centrifugation of molten glass or rock, (b) spraying, over the mineral fibers, immediately after the forming, a first liquid organic binder composition, (c) forming a blanket of mineral fibers which are coated with the first liquid organic binder composition, (d) covering a face of the blanket with a surfacing mat of glass or organic fibers having high heat resistance, (e) heating the blanket, covered with the surfacing mat, in a drying oven for a period of time and at a temperature sufficient to cure the organic binder, and (f) applying, to the exposed face of the surfacing mat, a self-adhesive material. A second liquid organic binder composition is applied, after stage (c), to the mat and/or face of the blanket which is intended to come into contact with the surfacing mat.

A process for manufacturing self-adhesive insulation products based on mineral wool includes (a) forming mineral fibers by centrifugation of molten glass or rock, (b) spraying, over the mineral fibers, immediately after the forming, a first liquid organic binder composition, (c) forming a blanket of mineral fibers which are coated with the first liquid organic binder composition, (d) covering a face of the blanket with a surfacing mat of glass or organic fibers having high heat resistance, (e) heating the blanket, covered with the surfacing mat, in a drying oven for a period of time and at a temperature sufficient to cure the organic binder, and (f) applying, to the exposed face of the surfacing mat, a self-adhesive material. A second liquid organic binder composition is applied, after stage (c), to the mat and/or face of the blanket which is intended to come into contact with the surfacing mat.

The system and methods for marking an optical fiber with color-coded marks disclosed herein include forming closely spaced multiple ink streams, with at least two of the ink streams having different colors. The optical fiber moves over a fiber path that resides adjacent the ink streams. The fiber path and the ink streams are made to briefly intersect so that the ink streams form on the outer surface of the optical fiber a group of spaced apart individual marks, wherein the group of individual marks constitute a color-coded mark. Repeating this marking process at different times as the fiber moves over the fiber path forms spaced apart color-coded marks along the length of the fiber. Subsequent drying and overcoating of the marks fixes and protects the color-coded marks.

The system and methods for marking an optical fiber with color-coded marks disclosed herein include forming closely spaced multiple ink streams, with at least two of the ink streams having different colors. The optical fiber moves over a fiber path that resides adjacent the ink streams. The fiber path and the ink streams are made to briefly intersect so that the ink streams form on the outer surface of the optical fiber a group of spaced apart individual marks, wherein the group of individual marks constitute a color-coded mark. Repeating this marking process at different times as the fiber moves over the fiber path forms spaced apart color-coded marks along the length of the fiber. Subsequent drying and overcoating of the marks fixes and protects the color-coded marks.

Disclosed herein is an optical fiber having an optically uniform coating having no physical defects in the coating greater than 100 micrometers in size over a length of 50 meters or greater.

Disclosed herein is an optical fiber having an optically uniform coating having no physical defects in the coating greater than 100 micrometers in size over a length of 50 meters or greater.

A process for manufacturing an optical fibre unit for air-blown installations includes: providing a deposition chamber for applying particulate material, the deposition chamber having an inlet end and an outlet end and a longitudinal axis; passing through the deposition chamber an optical fibre assembly including at least one optical fibre embedded in an inner layer of cured resin material, and having an outer layer around the inner layer, the outer layer including uncured resin material; injecting a flow of fluid and particle material in the chamber in a direction substantially parallel to the chamber longitudinal axis, at an injection speed of 5 m/s at most; perturbing the flow when in the chamber, thus causing the particle material to impact and partially embed into the outer layer of the optical fibre assembly; and curing the outer layer.

A process for manufacturing an optical fibre unit for air-blown installations includes: providing a deposition chamber for applying particulate material, the deposition chamber having an inlet end and an outlet end and a longitudinal axis; passing through the deposition chamber an optical fibre assembly including at least one optical fibre embedded in an inner layer of cured resin material, and having an outer layer around the inner layer, the outer layer including uncured resin material; injecting a flow of fluid and particle material in the chamber in a direction substantially parallel to the chamber longitudinal axis, at an injection speed of 5 m/s at most; perturbing the flow when in the chamber, thus causing the particle material to impact and partially embed into the outer layer of the optical fibre assembly; and curing the outer layer.