Abstract: Molded fibrous workpieces of various cross sectional configurations are coated with a polymeric latex foam coating material to encapsulate fibers and dust within the exterior surfaces of the workpieces. The foam coating is applied by passing the workpieces through a coating chamber filled with the polymeric foam so that the workpieces are totally immersed in the foam coating as the workpieces pass through the chamber. Openings for introducing the workpieces into and discharging the workpieces from the chamber have a configuration complementary to the transverse configuration of the workpieces. The foam coating is introduced into the chamber both above and below the path of the workpieces through the coating chamber to assure that the coating chamber remains fully charged with the foam coating. Brushes or wiper blades spread the foam coating over the exterior surfaces of the workpieces.

Abstract: A plasma arc melter which is equipped with at least two transferred arc plasma torches of opposite polarities is used to melt normal batch materials for producing glass, ceramics, refractories and other such materials and for the recycling, combustion and/or vitrifying incineration of waste materials. To enhance the stability of the plasma jets, the anode torch is positioned farther above the surface of the materials being processed than the cathode torch and the materials being processed are introduced into the melter so that the materials first pass beneath the cathode torch. An oxidizing gas can be introduced into the zone between the torches in the region of the plasma jets to enhance the combustion process. For waste materials with a high organic content, a plasma arc afterburner can be used to further treat the exhaust gases from the melter.

Abstract: The present invention relates to furan resins having low levels of VOCs. The claimed furan resins are the reaction product of a source of ammonia and a first reaction product, said first reaction product being derived from the reaction between a source of reactable formaldehyde, a formaldehyde scavenger, and an acidic furan resin resulting from the polymerization reaction wherein at least one reagent is selected from the group consisting of the furan containing molecule having the general formula ##STR1## and its saturated analogs thereof having zero to one carbon-carbon double bonnets, wherein X and Y are independently comprised of organic molecular groups.

Abstract: Emissions of formaldehyde and ammonia from urea-extended alkaline phenol/formaldehyde resole fiberglass binders are sharply reduced by using as a catalyst an emission-reducing effective amount of an acidifying agent which is a hydrolyzable inorganic salt, mineral acid, monomeric carboxylic acid or partial ester of a polycarboxylic acid such that the instantaneous pH of the binder solution is lower than 5.5. Use of the catalysts of the subject process also allow for additional urea-extension without degradation of fiberglass product physical properties. The preferred catalyst is aluminum sulfate in an amount of from 2.0 weight percent to about 4.0 weight percent based on the resin solids.

Abstract: The present invention relates to a glass fiber binding composition having an effective binding amount of an aqueous compatible furan resin mixed with sufficient water to result in a binding composition having from 0.5 to 80% nonvolatile. The aqueous compatible furan resin is the reaction product of a source of ammonia and a first reaction product, the first reaction product being derived from the reaction of an acidic furan resin, a source of reactable formaldehyde, and a formaldehyde scavenger. The invention further pertains to a process of binding glass fibers at junctions of the fibers comprising the steps of providing glass fibers, applying an effect binding amount of the binding composition of the invention to the glass fibers such that the binder is present at a portion of the junctions, and curing the resin at the junctions of the glass fibers.

Abstract: Molded fibrous workpieces of various cross sectional configurations are coated with a polymeric latex foam coating material to encapsulate fibers and dust within the exterior surfaces of the workpieces. The foam coating is applied by passing the workpieces through a coating chamber filled with the polymeric foam so that the workpieces are totally immersed in the foam coating as the workpieces pass through the chamber. Openings for introducing the workpieces into and discharging the workpieces from the chamber have a configuration complementary to the transverse configuration of the workpieces. The foam coating is introduced into the chamber both above and below the path of the workpieces through the coating chamber to assure that the coating chamber remains fully charged with the foam coating. Brushes or wiper blades spread the foam coating over the exterior surfaces of the workpieces.

Abstract: An apparatus for continuously foaming a polyimide prepolymer powder which is not susceptible to heating by microwave energy utilize a preheated conveyor belt to heat the powder in contact with and adjacent the surface of the conveyor belt to commence the reaction and foaming of the powder as it enters an oven which further heats the powder by convection and infrared radiation to form a continuous foam bun. The conveyor belt is cooled as it exits the oven to cool a bottom surface of the foam product to enable the foam product to be removed from the conveyor before interior portions of the foam product have cooled. Foam adhering to the conveyor belt, after the product has been removed, is cleaned from the conveyor belt, collected and mixed with and used as a filler in the prepolymer powder used in the process. In addition the mass of the powder entering the oven and the density and degree of cure of the foam bun exiting the oven are monitored to continuously control the process.

Abstract: Described is an acidic glass fiber binding composition comprising an aqueous soluble phenol formaldehyde resin having low free formaldehyde, an effective amount of a formaldehyde scavenger, and an effective amount of a strong aqueous soluble acid, wherein the composition has an acidic pH and the solids content ranges from about 1 to about 30% by weight of the total composition. Also described is a method of binding glass fibers such as newly formed warm glass fibers at junctions of the fibers by applying the composition as described above to the fibers and then drying the composition. Also described are B-staged and C-staged glass fiber compositions having a alkylamine content less than 5 ppm.

Abstract: A spiral core comprises successive convolutions of a rigidifying layer which are spaced with respect to each other and maintained in a spiral spaced relationship. Preferably, a spiral insulation layer, having convolutions intermediate the convolutions of the rigidifying layer and forming a laminate with the rigidifying layer, is also present in the spiral core. The insulation layer and the rigidifying layer are bonded together to maintain the laminate spirally wound. The rigidifying layer can be a sheet material that is bonded to the insulation layer or a bonding material that hardens to both form the rigidifying layer and bond the rigidifying layer to the insulation layer. The insulation layer is a flexible insulation material such as, fiber glass blanket, a mineral wool fiber blanket, a ceramic fiber blanket, a polyimide fiber blanket or a foam sheet.

Abstract: An air/liquid polymeric latex foam coating generator includes a static splash plate mixer for forming a coarse foam coating and a conventional static refining mixer which further refines and homogenizes the coarse foam produced by the static splash plate mixer before delivering a refined foam to application heads or nozzles for application to a workpiece. The static splash plate mixer comprises a housing which is divided into two chambers by a splash plate. A stream of pressurized air and a stream of pressurized polymeric latex coating material are introduced into the upstream chamber where the streams intersect each other, impinge upon the splash plate and are mixed into a coarse foam in the upstream chamber. The foam passes through openings in the splash plate to the downstream chamber where the foam is further refine before being discharged from the static splash plate mixer.

Abstract: A rigid, glass fiber airduct for conveying an airstream has an interior surface, adapted to be in contact with the airstream, which is coated with a polymeric coating comprising an organic or inorganic biocide. The polymeric coating has a dry solids content between 10 and 20 grams per square foot of duct board surface and retains its abrasion strength and puncture resistance whereby the interior surface of the airduct can be cleaned by conventional industrial or commercial cleaning procedures while in service without exposing glass fibers to the airstream.

Abstract: An air filtration media comprises a single layer of randomly oriented and randomly intermingled synthetic, polymeric resin microfibers, staple fibers and bonding fibers. The microfibers, taken as a whole, have an average fiber diameter no greater than 5 microns and comprise between 50% and 90% by weight of the filtration media; the staple fibers, taken as a whole, have an average fiber diameter between 10 and 30 microns and comprise between 5% and 45% by weight of the filtration media; and the bonding fibers, taken as a whole, have an average fiber diameter between 10 and 30 microns and comprise between 5% and 25% by weight of the filtration media. The bonding fibers have thermoplastic surfaces with a lower temperature softening point than the microfibers and the staple fibers and bond the fibers together to form the air filtration media.

Abstract: Described is a flame retarded asphalt composition comprising: a) a bituminous composition; b) a thermoplastic elastomer; c) an inert filler; d) a halogenated flame retardant; and e) an effective flame retardant amount of a nitrogen heterocyclic composition having at least six members and containing at least three nitrogen atoms.

Abstract: An apparatus for compressing bulky materials, like microfibers having a bulk density of less than about 0.2 PCF, to a much higher density, e.g. about 10.8 PCF, and packaging the compressed mass without damaging the material. The apparatus comprises a hopper having a pivoting wall wherein one edge of the pivoting wall is tapered and cooperates with a curved extension of one wall of an adjoining compression chamber to prevent the material from being pinched or scarffed which would damage the material. The compression chamber is long enough that when the compression means is withdrawn to accept another charge (each package requires a plurality of charging and compressing cycles) the compressed material cannot expand into the opening the compression chamber leading to the hopper. Finally, one end portion of a wall of the compression chamber has a movable retaining wall that also forms a portion of a wall of an adjoining packaging chamber.

Abstract: The present invention relates to furan resins having low levels of VOCs. The claimed furan resins are the reaction product of a source of ammonia and a first reaction product, said first reaction product being derived from the reaction between a source of reactable formaldehyde, a formaldehyde scavenger, and an acidic furan resin resulting from the polymerization reaction wherein at least one reagent is selected from the group consisting of the furan containing molecule having the general formula ##STR1## and its saturated analogs thereof having zero to one carbon-carbon double bonnets, wherein X and Y are independently comprised of organic molecular groups.

Abstract: A sound absorption laminate comprises a porous insulation substrate, such as, a thermoplastic glass or polymeric fiber blanket or a foamed polymeric resin sheet and a facing sheet with a high air flow resistance. The facing sheet is adhered to a surface of the porous insulation substrate to augment the acoustical properties of the substrate. With the facing sheet the air flow resistance of the laminate is greater than the air flow resistance of the substrate and the laminate exhibits a higher sound absorption coefficient than the sound absorption coefficient of the substrate. Thus, the laminate exhibits better sound absorption properties than the substrate and is suitable for sound absorption applications for which the substrate alone would not be suitable.

Abstract: Disclosed are an improved apparatus for collecting fine fibers, such as glass fibers, having a mean diameter of less than two microns from a gaseous stream, a method of collecting fine fibers using the apparatus and the novel new product produced by this method. The improvement lies mainly in the way in which the collection drum is supported and sealed which allows the collection to take place at relatively high partial vacuums. The fiber is also consolidated in the gaseous stream by passing it through a duct having at least one approximately ninety degree turn therein.

Abstract: A fiber glass air filtration media comprises a blanket of glass fibers with about 25% to 35% by weight of the glass fibers being fine glass fibers having an average diameter of less than 3.5 microns and about 65% to 75% by weight of the glass fibers being coarse glass fibers having an average diameter of more than 3.5 microns. The fine and coarse glass fibers are randomly intermingled throughout the blanket. The blanket is formed by producing the fine glass fibers on a first set of fiber generators and the coarse glass fibers on a second set of fiber generators. The fiber generators are laterally aligned across the width of and direct gaseous streams of the glass fibers at a moving collection surface where the blanket is formed. The fiber generators of the first set alternate with the fiber generators of the second set and the glass fibers produced by the two sets of fiber generators are mixed together before being deposited on the collection surface.

Abstract: A method and apparatus for accumulating and densifying microfibers such as glass fibers having mean fiber diameters below 1-2 microns is disclosed. A fine fiber blanket having been collected on a collection surface is removed and wound up on a mandrel having a permeable surface while a partial vacuum, preferably exceeding one hundred inches of water column, is maintained in the interior of the mandrel.

Abstract: A process for providing a relatively smooth, tough, elastomeric coating over one surface of a fibrous batt employs a heated ironing surface which engages an uncured coating of a composition of cross-linkable elastomeric aqueous emulsion applied as a foam or froth to an exposed surface of a fibrous batt. The heated belt causes dewatering and cure of a film of the coating which is in contact with the ironing surface. The fibrous batt thereafter is heated in a curing oven to drive off substantially all of the moisture and substantially cure all of the elastomeric coating composition. The resulting coated fibrous batt has a smoother and tougher surface than similar batts formed from similar compositions without the interposed ironing treatment. A preferred ironing element comprises a continuous stainless steel belt.