Abstract: Disclosed is an apparatus and a method for at least partially encapsulating a fiber batt or other highly porous substrate by applying a polymeric foam layer to one or more surfaces of the fiber batt. The foam application assemblies are arranged and configured to extrude a polymeric foam or a foaming mixture onto the surface(s) of the fiber batt to be coated. A combination of foam application assemblies may be provided in either fixed or moveable configurations for coating one or more sides of the fiber batt. The encapsulation of the fiber batt may also include a premanufactured material layer on one or more surfaces that may be exposed or may also be encapsulated below the polymeric foam layer.

Abstract: The invention relates to an insulation product comprising an elongated fibrous batt with a polymeric encapsulating layer and, optionally, a vapor or other barrier layer on one or more surfaces of the fibrous batt and an apparatus for manufacturing such an insulation product.

Abstract: Disclosed is an apparatus and a method for at least partially encapsulating a fiber batt or other substrate by applying a polymer fiber layer to one or more surfaces of the fiber batt or substrate by melt-blowing. The melt-blowing assemblies are arranged and configured to extrude both a polymer melt and a hot gas stream whereby the hot gas stream attenuates the polymer melt to form polymer melt fibers and to direct the polymer melt fibers toward a surface to be coated. The melt-blowing assemblies are further of the fiber batt. A combination of melt-blowing assemblies may be provided in either fixed or moveable configurations for coating one or more sides of the fiber batt.

Abstract: Disclosed is an apparatus and a method for at least partially encapsulating a fiber batt or other highly porous substrate by applying a polymeric foam layer to one or more surfaces of the fiber batt. The foam application assemblies are arranged and configured to extrude a polymeric foam or a foaming mixture onto the surface(s) of the fiber batt to be coated. A combination of foam application assemblies may be provided in either fixed or moveable configurations for coating one or more sides of the fiber batt. The encapsulation of the fiber batt may also include a premanufactured material layer on one or more surfaces that may be exposed or may also be encapsulated below the polymeric foam layer.

Abstract: Disclosed is an apparatus and a method for at least partially encapsulating a fiber batt or other substrate by applying a polymer fiber layer to one or more surfaces of the fiber batt or substrate by melt-blowing. The melt-blowing assemblies are arranged and configured to extrude both a polymer melt and a hot gas stream whereby the hot gas stream attenuates the polymer melt to form polymer melt fibers and to direct the polymer melt fibers toward a surface to be coated. The melt-blowing assemblies are further of the fiber batt. A combination of melt-blowing assemblies may be provided in either fixed or moveable configurations for coating one or more sides of the fiber batt.

Abstract: The invention relates to an insulation product comprising an elongated fibrous batt with at least a partial polymeric encapsulating layer formed by melt-blowing or melt spraying a polymeric composition onto one or more surfaces of the fibrous batt and, optionally, a separate vapor retarding layer applied to one or more surfaces of the fibrous batt and an apparatus for manufacturing such an insulation product.

Abstract: The invention relates to an insulation product comprising an elongated fibrous batt with at least a partial polymeric encapsulating layer formed by melt-blowing or melt spraying a polymeric composition onto one or more surfaces of the fibrous batt and, optionally, a separate vapor retarding layer applied to one or more surfaces of the fibrous batt and an apparatus for manufacturing such an insulation product.

Abstract: The invention relates to an insulation product comprising an elongated fibrous batt with a polymeric encapsulating layer and, optionally, a vapor or other barrier layer on one or more surfaces of the fibrous batt and an apparatus for manufacturing such an insulation product.

Abstract: The invention relates to a method of forming a multicomponent mat, the multicomponent mat which is formed from glass fibers and natural fibers and methods of making a multicomponent mat. Initially in the method of forming a multicomponent mat, a natural fiber slurry is formed. The next step involves using a surfactant to disperse glass fibers in white water. The natural fiber slurry and the slurry of glass fibers are generally compatible and are combined to form a multicomponent slurry which is used to form a multicomponent mat.

Abstract: The invention relates to a method of forming a multicomponent mat, the multicomponent mat which is formed from glass fibers and natural fibers and methods of making a multicomponent mat. Initially in the method of forming a multicomponent mat, a natural fiber slurry is formed. The next step involves using a surfactant to disperse glass fibers in white water. The natural fiber slurry and the slurry of glass fibers are generally compatible and are combined to form a multicomponent slurry which is used to form a multicomponent mat.

Abstract: The present invention refers to multi-layered decorative laminates including a decorative layer, such as a wood veneer layer, and one or more reinforced polymer layer(s), such as a reinforced polyvinyl chloride (PVC) layer. Methods of making and using such laminates and of producing overly and underlay layers, which supplement the decorative layer, are described herein. The invention also relates to laminates of improved fire resistance including reinforced polymer layers.

Abstract: The present invention refers to multi-layered decorative laminates including a decorative layer, such as a wood veneer layer, and one or more reinforced polymer layer(s), such as a reinforced polyvinyl chloride (PVC) layer. Methods of making and using such laminates and of producing overly and underlay layers, which supplement the decorative layer, are described herein. The invention also relates to laminates of improved fire resistance including reinforced polymer layers.

Abstract: The invention relates to glass mats and their method of manufacture. In particular, the invention relates to a wet-laid method of making a glass mat and the mats formed by this method. The method includes combining a dispersant, water, glass fiber bundles, and a charged viscosity modifier to form a slurry, adding an oppositely charged viscosity modifier to the slurry, and removing the water from the slurry to form a wet glass mat. The present invention enables improved control of fiber dispersion and subsequent bundling of the fibers to form, for example, bundled glass mats with high porosity and a uniform weight. Mats produced by the present invention may be formed into a variety of products, such as in glass fiber paper, roofing shingles, and composite articles.

Abstract: The invention relates to a method of forming a bicomponent mat, the bicomponent mat which is formed from glass fibers and pulp fibers and methods of making a bicomponent mat. Initially in the method of forming a bicomponent mat, a pulp surface is treated with a cationic polymer in a pulp slurry. The next step involves using a surfactant to disperse glass fibers in a polyacrylamide (PAM)-based white water. The pulp slurry and the slurry of glass fibers are generally compatible and are combined to form a bicomponent furnish. The method has several advantages over conventional methods. First, conventional wet chop products typically cannot be used to form a bicomponent mat in a typical surfactant/PAM-based white water. Second, while some other fibers (such as glass fibers) may be used in the production of bicomponent mats in a typical PAM-based white water, the mat forming process is frequently interrupted and tends to produce very poor quality mats.