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: 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: 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: 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.

Abstract: A fibrous, non-woven thermal insulation comprises synthetic polymeric resin microfibers, staple fibers and bonding fibers which are randomly oriented and randomly intermingled in a single layer. The microfibers comprise between 25% and 95% by weight virgin synthetic polymeric resin and between 5% and 75% by weight recycled polyethylene teraphthalate. The microfibers have an average diameter between 1 to 8 microns and comprise between 35% and 80% by weight of the insulation; the staple fibers have and average diameter between 10 and 30 microns and comprise between 15% and 60% by weight of the insulation; and the bonding fibers have an average diameter between 14 and 30 microns and comprise between 5% and 25% by weight of the insulation. The bonding fibers have thermoplastic surfaces with a lower temperature softening point than the microfibers and staple fibers and bond the fibers together to form the insulation material.

Abstract: A cylindrical polymer fiber filter cartridge for liquid filtration is formed by applying an acrylic latex binder, diluted with water, to a batt of thermoplastic polymer fibers and winding the batt onto a core to form a hollow fibrous cylinder while applying compression with a compression roll to an outer surface of the fibrous cylinder. After the batt is fully wound onto the core, the cylindrical cartridge is rotated at a speed sufficient to cause the acrylic latex binder to foam in-situ thereby fluidizing the cartridge to allow the polymer fibers in the cartridge to reorient to form a smooth outer surface on the cartridge and to evenly distribute the acrylic binder throughout the cartridge. The binder in the cartridge is then cured to bond the fibers together at their points of intersection and annular grooves are cut in the outer surface of the cartridge to increase the surface area of the filter.

Abstract: A furnace for melting and refining E glass comprises a melting and refining tank for melting and refining the glass batch materials into glass and a forehearth, downstream of the tank, for further refining the glass and delivering the glass to fiberizing means. The melting and refining tank is heated with oxygen fired burners. The oxygen fired burners in the melting and refining tank are located in the sidewalls at the upstream end of the tank and extend for about one-third the length of the tank. In one embodiment, burners are also located in the upstream end wall. This arrangement of the oxygen fired burners at the upstream end of the melting and refining tank moves the melter hot spot upstream for better refining of the glass and enables the furnace to produce a higher output of glass than can be obtained in a conventional E glass furnace of the same size.

Abstract: Described is an inorganic fiber comprising silica dioxide, calcium oxide, and alkali oxide having a free energy of hydration greater than (more positive than) -5.00 kcal/mol, an enthalpy of formation less than (more than negative than) -210.0 kcal/mol, a dissolution rate in simulated extra cellular fluid greater than 750 (calculated as nanograms of fiber/per square centimeter of fiber surface area/per hour) having an average fiber diameter not greater than 4.5 micrometers. Also described is a method of manufacturing the fibers.

Abstract: A rigid fiber glass air duct for conveying an airstream has an interior surface, adapted to be in contact with the airstream, which is coated with a polymeric coating with an organic biocide. The polymeric coating has a dry solids content of 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 duct can be cleaned by conventional industrial or commercial cleaning methods while in service without exposing glass fibers to the airstream.

Abstract: A vessel for use in the transportation of cryogenic liquids in over the road cryogenic tankers has a double wall with a highly efficient, relatively light weight fiber glass insulation in the cavity between the walls. The fiber glass insulation increases in density from the inner wall of the cavity to the outer wall of the cavity having the least density adjacent the cold inner wall of the vessel which contains the cryogenic liquid and the highest density adjacent the outer wall of the cavity which is exposed to ambient conditions. One or more layers of reflective septa can be incorporated into the fiber glass insulation to reduce radiant heat transfer.

Abstract: A synthetic microfiber blanket having a uniform thickness is formed from a nonuniform blanket having thin or feathered lateral edges. The nonuniform blanket is cut transversely into a plurality of discrete pieces of blanket of uniform length. The plurality of discrete pieces of blanket are arranged with the thin lateral edges in overlapping relationship to form a blanket of a desired width and thickness. The overlapped, discrete pieces of blanket are then joined into an integral blanket of uniform width and thickness by entangling together fibers of adjacent pieces of blanket. A scrim backing can be incorporated into the blanket for added strength and dimensional stability.

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: An oxygen-fuel firing system for a furnace comprising separate, spread apart nozzles for introducing gaseous streams of oxygen and fuel into the furnace at spaced apart locations. The gaseous streams merge within the furnace away from the furnace walls and crown. Thus, the main combustion within the furnace takes place in the central portion of the furnace where a broad flame cloud is created. The broad flame cloud provides a more uniform temperature profile within the furnace for a more efficient processing of materials being melted in the furnace.