Abstract: The invention includes fibrous nonwoven multiple layer mats having at least two layers with a body portion layer and a surface portion layer having fine fibers and/or particles therein, both layers being bonded together and to each other with a same resin binder. Preferably most or essentially all of the particles and/or fibers in the surface layer are larger than openings between the fibers in the body portion of the mat. The mats produced according to this invention are useful as a facer for all types of boards such as wood boards, wood product boards, insulating boards and hard boards of all types, and also as reinforcement and dimensional stabilizers for making a large number of novel laminate products and for a myriad of other uses. These mats are made an a wet laid nonwoven mat machine with a modification to the binder preparation system, an inventive step in the preparation of the binder and in the selection of ingredients for a binder slurry.

Abstract: Provided is a novel fiberglass binder comprising a polycarboxy polymer and a polyol. The amount of polycarboxy polymer and polyol contained in the binder is such that the ratio of equivalents of hydroxyl groups to carboxy groups is preferably in the range from from about 0.6/1 to 0.8/1. It is further preferred that the molecular weight of the polycarboxy polymer is less than 10,000, and more preferably less than 5000.

Abstract: The present invention provides a method for the production of bounded non-wovens carriers. The method includes providing a glass staple fiber containing non-woven which is pre-consolidated with a binder. The glass staple fiber non-woven is placed adjacent to one or more non-wovens of synthetic fibers and hydro-dynamically needling at a water beam pressure in the range of 100 to 400 bar.

Abstract: An insulation sheet for insulating a wall, floor, ceiling or roof cavity is flexible, compressible and resilient and has lateral edges extending the length of the sheet. The lateral edges of the sheet are formed with contours along the lengths of the lateral edges, which with the flexibility, compressibility and resilience of the insulation sheet, increase the effective width of the sheet, relative to a conventional insulation sheet of the same length, width, thickness and density with straight lateral edges extending perpendicular between the major surfaces of the conventional sheet, with no or substantially no increase in the amount of insulation material forming the sheet relative to the insulation material used in the conventional insulation sheet.

Abstract: Glass fibers prepared by flame attenuation display excellent chemical resistance to both acids and moisture while being highly biosoluble at the same time. The glass compositions are characterized by ratios of components which are reflective of acid resistance, biosolubility, and moisture resistance. Preferred glass fibers exhibit a biodissolution greater than about 350 ng/cm/2hr.

Abstract: An on-line method of forming a multilayered coating on a sheet of fibrous or foam insulation, includes: applying a first coating layer of a first coating composition directly to a first major surface of the insulation sheet; heating an exposed major surface of the first coating layer to stabilize the coating composition at the exposed major surface of the first coating layer so that the first coating layer remains an essentially discrete layer when a second coating layer is applied to the exposed major surface of the first coating layer and to only partially cure the coating composition at the exposed major surface of the coating composition so that a second coating layer applied to the exposed major surface of the first coating layer will readily bond to the first coating layer; applying a second coating layer of a second coating composition directly to the exposed major surface of the first coating layer subsequent to heating the exposed major surface of the first coating layer; and heating the insulation s

Abstract: A single ply membrane roofing system includes a roofing insulation board which, preferably, is at least 45% by dry weight expanded perlite. One major surface of the insulation board is coated with a latex coating comprising, by dry weight, between 48.3% and 96% clay; between 3.1% and 33.3% latex; and between 0% and 34% sodium silicate. A single ply roofing membrane is adhered to the coated major surface of the insulation board with a roofing contact adhesive.

Abstract: Provided is a glass fiber prepared by combining two glasses, preferably at least one of which is biosoluble, in a core/sheath arrangement. Such an arrangement can provide fibers potentially stronger than those of single glasses, while also having a permanent twist or curl to impart improved loft and recovery to blankets or mats comprised of them. Preferably, the core is offset from the center of the fiber. In one embodiment, the glass fibers of the present invention comprise a core and a sheath, where the core glass of the structure contracts as it cools to a greater extent than the sheath glass of the structure. Benefits are achieved in this manner, preferably with regard to biosoluble fibers.

Abstract: A fibrous insulation blanket is pre-cut for custom fitting the insulation blanket into wall, floor, ceiling and roof cavities of different widths formed by the framework of a building. The insulation blanket has one or more pairs of longitudinally extending cuts in the major surfaces of the blanket. Each pair of cut(s) leaves a separable connector within the blanket between adjacent sections of the insulation blanket whereby the blanket can be handled as a unit for insulating a cavity having a width about equal to the width of the blanket or easily separated or torn apart by hand at a separable connector for insulating a cavity having a lesser width. A major surface of the blanket may have a facing bonded thereto that is separable by hand along the cut(s) in the major surface to facilitate separating the blanket by hand.

Abstract: Fibrous sorbent media or pads are formed from non-woven mats of thermoplastic fibers, preferably polypropylene fibers, having a mean diameter between about 0.5 microns and about 25 microns. The mats have a weight between about 2 ounces/yd2 and about 25 ounces/yd2; a thickness of at least {fraction (1/20)} of an inch; an oil absorbency ratio of at least 5 to 1 or a water absorbency ratio of at least 5 to 1. The sorbent media have first and second major surfaces with abrasion resistant, liquid permeable, integral skins and fibrous cores. The liquid permeable skins of the media are formed by melting fibers at and immediately adjacent the major surfaces of the mats to form thermoplastic melt layers which are subsequently solidified into the skins on the major surfaces of the mats. For many applications, the thermoplastic fibers of the mats are point bonded together at spaced apart locations to increase the integrity of the mats.

Abstract: An insulation sheet for insulating a wall, floor, ceiling or roof cavity is flexible, compressible and resilient and has lateral edges extending the length of the sheet. The lateral edges of the sheet are formed with contours along the lengths of the lateral edges, which with the flexibility, compressibility and resilience of the insulation sheet, increase the effective width of the sheet, relative to a conventional insulation sheet of the same length, width, thickness and density with straight lateral edges extending perpendicular between the major surfaces of the conventional sheet, with no or substantially no increase in the amount of insulation material forming the sheet relative to the insulation material used in the conventional insulation sheet.

Abstract: An elongated fibrous insulation blanket is pre-cut for custom fitting the insulation blanket into wall, floor, ceiling and roof cavities of different widths formed by the framework of a building. The blanket has at least one, preferably two or three, series of cuts extending between major surfaces of the blanket with successive cuts of each series of cuts being separated by a series of separable connectors located intermediate the major surfaces of the blanket. Each series of separable connectors hold together adjacent sections of the blanket for handling, but are separable by hand so that the blanket can be handled as a unit for insulating a cavity having a predetermined width or easily separated by hand into two or more sections at one or more of the series of separable connectors for insulating a cavity having a lesser width.

Abstract: A method of making a spinner disc for a rotary fiberization process, such as but not limited to a glass fiberization process, includes: forming a spinner disc from an alloy that forms a protective oxide film on surfaces of the spinner disc exposed to the atmosphere; forming fiberizing holes in an annular peripheral sidewall of the spinner disc; and applying a plasma to a surface of the spinner disc to remove hydrocarbons and sulfurous compounds from the surface of the spinner disc which would otherwise reduce and/or react with and degrade the protective oxide film forming on the surface of the spinner disc when the spinner disc is exposed to the atmosphere.

Abstract: A fibrous insulation media is formed from a non-woven mat of thermoplastic fibers having a mean diameter of less than about 15 microns. Preferably, when used as an acoustical insulation, the media is formed of fibers having a mean diameter of less than about 13 microns; the media has a density of less than about 60 Kg/m3; and the media has a Fraiser air permeability of less than 75 cubic feet per minute per square foot of surface area. The media has first and second major surfaces and a fibrous core with at least one of the major surfaces having an integral skin thereon. The skin is formed by melting fibers at and immediately adjacent the major surface of the mat formed into the media to form a thermoplastic melt layer which is subsequently solidified into a skin on the major surface of the mat. The thermoplastic fibers of the mat are point bonded together at spaced apart locations to increase the integrity of the mat.

Abstract: A process for manufacturing an insulation board comprising a rigid polyisocyanurate foam core having two major surfaces and a facing material on at least one of the major surfaces, comprising (a) conveying a facing material along a production line for attachment to one major surface of the core; (b) applying a foam-forming mixture of polyisocyanurate to the facing material such that the mixture is applied along the entire width of the facing material; (c) optionally conveying a second facing material along the production line for attachment to the other major surface of the core; (d) conveying the facing material with applied foam-forming mixture into a laminator which comprises a gap for foam expansion and allowing the mixture to foam and expand to fill the gap within the laminator; and (e) curing the foam. The process provides excellent boardstock thickness control, minimal wasted densification at the foam/facer interface, greater compressive strength and high line speed.

Abstract: A hinged vent chute, for providing ventilation to an open attic space, includes an elongated chute segment and an insulation dam segment. The elongated chute segment has one or more upwardly open channels, extending from a lower end to an upper end of the chute segment, that provide an air passage from a soffit region of a roof, over an interior surface of the roof, up into an open attic space beneath the roof. The hinged vent chute has a hinge or fold line joining the elongated chute segment to the insulation dam segment which permits the vent chute to be folded downward at the hinge to position the insulation dam segment for securement to form an insulation dam which prevents loose fill insulation in an attic from flowing down into a soffit region of a roof and blocking air flow.

Abstract: A sized staple fiber product that disperses quickly, thoroughly and uniformly in water is particularly useful in the manufacture of gypsum board by the slurry process. An aqueous chemical size composiiton on the surface of the fibers contains a high level of surfactant and can contain a polymer film former and a biocide. Preferably, the fiber is chopped glass fiber. Novel sizing composition and methods of making and using the fiber are also disclosed.

Abstract: Fibrous sorbent media or pads are formed from non-woven mats of thermoplastic fibers, preferably polypropylene fibers, having a mean diameter between about 0.5 microns and about 25 microns. The mats have a weight between about 2 ounces/yd2 and about 25 ounces/yd2; a thickness of at least {fraction (1/20)} of an inch; an oil absorbency ratio of at least 5 to 1 or a water absorbency ratio of at least 5 to 1. The sorbent media have first and second major surfaces with abrasion resistant, liquid permeable, integral skins and fibrous cores. The liquid permeable skins of the media are formed by melting fibers at and immediately adjacent the major surfaces of the mats to form thermoplastic melt layers which are subsequently solidified into the skins on the major surfaces of the mats. For many applications, the thermoplastic fibers of the mats are point bonded together at spaced apart locations to increase the integrity of the mats.

Abstract: A method of making a fiber glass mat especially useful for bonding to wood contains glass fibers and a “B” staged resin is disclosed. A substantial portion of the resin binder can be a furfuryl alcohol formaldehyde, phenol formaldehyde, melamine formaldehyde, or any other resin that can be “B” staged. Also, a method of making wood and wood product laminates using this new mat without any other adhesives, and the resultant laminates are disclosed.

Abstract: Provided is a fiberglass binder which contains a polycarboxy polymer and a polyol, with a pH of the binder being no greater than 3.5. It is further preferred that the polycarboxy polymer has a molecular weight of less than 10,000, and more preferably about 5000 or less. The binder also preferably includes a catalyst which is an alkali metal salt of a phosphorus polyol is preferably triethanolamine. The binder also preferably includes a catalyst which is an alkali metal salt of a phosphorus-containing organic acid. The resultant binder, particularly when used in preparing fiberglass products, provides minimal processing difficulties and a product with excellent recovery and rigidity.