Abstract: A process and apparatus for manufacturing fiberglass-reinforced panels are provided. The apparatus includes a guide mechanism and drive mechanism to drive individual elongate molds through a gel coating spraying section and thereafter through an oven to cure the gel coat. The elongate molds are thereafter driven through first and second resin/fiberglass application stations to apply a composite of resin and fiberglass strands. The apparatus also includes a station whereby wooden boards may be placed over the top of the resin and the fiberglass strands, and thereafter to a vacuum station whereby a vacuum can be placed over the wooden boards, such that when a vacuum is drawn on the composite, the resin is drawn into the wooden boards to form an integrated deposit panel.

Abstract: A trilaminate a trilaminate shingle, having a horizontal longitudinal orientation, includes an overlay sheet having series of tabs and cutouts extending horizontally across the shingle. The shingle also includes a middle sheet having a series of tabs and cutouts extending horizontally across the shingle. The middle sheet cutouts are narrower horizontally than the overlay cutouts. The shingle also includes an underlay sheet beneath the middle sheet. The middle sheet is laminated beneath the overlay so that portions of the middle sheet, including at least some of the middle sheet cutouts, are exposed through the overlay cutouts. The underlay is laminated beneath the middle sheet so that portions of the underlay are exposed through the middle sheet cutouts and through the overlay cutouts. The exposed portions of the underlay sheet are generally darker than the middle sheet.

Abstract: A wet-formed permeable mat composed of wet use chopped strands (WUCS), chopped roving, and potentially unidirectional roving coupled with an alkaline resistant binder are combined to create an randomly oriented open mat structure with a high degree of openness that can be used in cement backerboard applications. The cement backerboard that is subsequently formed from the wet-formed permeable mat has lower binder content, superior decorative finish, and better permeability control than known glass scrim systems and can be produced in a single continuous step.

Abstract: An acoustical liner with integral water barrier is provided. The liner includes a pad of fibrous material having a lofty, acoustically insulating portion and at least one heat-seared face of relatively higher density to provide water barrier protection. The acoustical liner is a non-laminate made from polyester, fiberglass, polypropylene and any mixtures thereof. A method of insulating a door including an exterior body panel and an interior fascia panel as well as a door for a vehicle are also disclosed and claimed.

Abstract: A method of co-texturizing glass fibers and thermoplastic fibers comprises passing a glass fiber strand through a texturizing gun, simultaneously passing a thermoplastic fiber strand through the texturizing gun with the glass fiber strand and injecting pressurized air into the texturizing gun concurrently with the glass fiber strand and thermoplastic fiber strands. This method produces a co-texturized fiber material comprising between 20-85% by weight glass fiber and 15-80% by weight thermoplastic fiber having an overall density of from about 20 grams/liter to about 200 grams/liter, and preferably from about 20 grams/liter to less than about 30 grams/liter.

Abstract: A structurally enhanced, insulating sheathing (10) and method of sheathing a frame of the type used in constructing a building are disclosed. In one embodiment, the sheathing includes an insulating layer of material (14) attached to a structural layer of material (12) formed of a plurality of fibers (12al-12an), preferably biased in first and second directions (D1, D2) relative to a common axis, such as the longest centerline of the sheathing. The fibers form a grid (12c) having a plurality of openings (12d) that are capable of receiving an adhesive (A3) for attaching the sheathing to a stable mounting structure, such as a frame. Preferably, the adhesive is capable of penetrating at least partially into the openings to ensure that a secure, lasting bond is formed. In a second embodiment the sheathing includes a multilayer polymer film with a low melting point adhesive thereon.

Abstract: An automated assist apparatus is provided in a system for forming a molded article from a composition comprised of a plurality of chopped mineral fibers and a binder applied to at least one portion of a perforated mold and initially held in place by a vacuum drawn through the perforations before undergoing a curing process. The assist apparatus includes at least one device for holding the composition applied to at least one portion of the perforated mold in place prior to and during the curing process and a motive device for automatically moving the holding device from a first retracted position away from the mold to a second position for holding the composition in place. The vacuum is released when the holding device is in the second position. The composition undergoes curing and the holding device is automatically moved to the first retracted position for removing the cured molded article.

Abstract: A construction beam includes a pair of lateral members and a resilient web extending therebetween, so as to present a cross-sectional profile corresponding to commonly used construction beam members (e.g., 2″×4″ or 2″×6″). The resilience of the web helps to attenuate sound transmission through the beam from one lateral member to the other. In particular, in a wall frame, the lateral members are mounted at opposite ends thereof to end plates consisting of other construction beams according to the present invention (i.e., a pair of lateral members with resilient web extending therebetween).

Abstract: An adhesive for a roof covering comprises asphalt, polymer and crosslinker. The crosslinker is a phenolic resin or a phenol-aldehyde resin. In another embodiment, the adhesive comprises asphalt, polymer and crosslinker, and it excludes polyfunctional amine having at least two amino groups.

Abstract: An asphalt-based roofing material includes a substrate coated with an asphalt coating, a protective coating adhered to the upper surface of the asphalt coating, a layer of granules adhered to the protective coating, and a web bonded to the lower region of the asphalt coating. A method of manufacturing a roofing material includes coating a substrate with an asphalt coating, applying a protective coating to the upper surface of the asphalt coating, applying a layer of granules to the protective coating, and applying a web to the lower region of the asphalt coating.

Abstract: The presently disclosed invention relates to a phenolic binder comprising a premix of a urea modified phenol-formaldehyde resole resin, a curing agent, and an additive selected from the group consisting of ammonium lignosulfonate, melamine and a melamine derivative. A method for reducing gaseous emissions in the manufacture of fibrous insulation materials is also disclosed.

Abstract: A screen comprises an electrically conductive elongate inner screen plate. The inner screen plate has at least one elongate fold therein and at least two elongate divergent surfaces on opposing sides of the fold. Each divergent surface has an upper end and opposing edges tapering downward from the upper end. The upper ends of the divergent surfaces diverge from one another. Each of the divergent surfaces has a plurality of holes therein. The screen further comprises at least two electrically conductive outer screen plates. The outer screen plates are attached to the edges of the divergent surfaces and extend between the divergent surfaces. Each of the outer screen plates has a plurality of holes therein. Another embodiment of the invention is directed toward a glass fiber bushing system comprising a bushing body and a screen within the bushing body. The bushing body has opposing end plates. The screen comprises opposing ends. Each of the ends has an upper portion and a lower portion.

Abstract: A formaldehyde free co-binder solution formed by using a polyol to crosslink polycarboxylic acid and a polyacid monomer is provided. In forming the co-binder solution, the polyacid monomer and the polyol are mixed in any conventional device with heat and agitation for a period of time sufficient for the chemicals to react and form a reaction product. The resultant product is then admixed with polycarboxylic acid to form a co-binder solution. In a preferred embodiment, the polyacid is maleic anhydride and the polyol is triethanolamine.

Abstract: A laminated shingle simulates a tiled roof when placed with other similar shingles on a roof deck. The laminated shingle includes an overlay member and an underlay member fixedly attached to each other. The overlay member includes an upper or headlap portion and a lower or exposed butt portion with one or more substantially identically shaped tabs with a cutout between each tab. The lower edge of the tabs may have a curving or negative contour. The tabs may taper in width from the butt edge to the lower edge of the headlap portion. The upper edge of the cutouts may have a generally straight contour or a generally curved contour. The lower edge of the underlay member may have a generally straight contour or a portion of the lower edge may have a generally curving contour. The overlay member and/or underlay member may include a darker shading area to enhance the tile simulating aspect of the shingle.

Abstract: A method of making shingles includes coating a shingle mat with roofing asphalt to make an asphalt-coated sheet, and covering the asphalt-coated sheet with granules to form a granule-covered sheet along a longitudinal axis, the granule-covered sheet having a shadow patch thereon, the shadow patch having a first width along the longitudinal axis. The granule-covered sheet is divided into an overlay sheet and an underlay sheet, the shadow patch being on the underlay sheet. A pattern of tabs and cutouts is cut in the overlay sheet, one of the tabs of the pattern being a select tab having a second width along the longitudinal axis, the second width of the select tab being less than the first width of the shadow patches. The relative longitudinal positions of the shadow patch and the select tab are synchronized.

Abstract: A drainage mat and mortar blocker system including a panel and polymeric drainage mat which includes protrusions on the front side and indentations on the back side of the mat. A filter fabric is affixed to the side of the mat containing the protrusions. The top portion of the back side of the drainage mat is affixed to the panel and the bottom portion of the mat is folded upward so as to form a U-shape. The U-shape is held in place by connections extending from the back side of the bottom portion of the drainage mat and into the front side of the drainage mat.

Abstract: A bumper/muffler assembly is provided comprising a bumper; and a muffler having an outer shell. The outer shell may be formed from a non-high impact resistant material, such as a thin metal or a composite material. The muffler may comprise a separate element from the bumper, which is coupled thereto, or is formed as an integral part of the bumper.

Abstract: A liner/insulator includes a pad of fibrous material having a lofty, acoustically insulating portion and a relatively higher density skin along a first face thereof that may function as a water barrier. The acoustical liner is a non-laminate made from polyester, polyethylene, polypropylene, polyethylene terephthalate, glass fibers, natural fibers and any mixtures thereof. For certain applications the liner/insulator may incorporate a facing on one or even two opposing faces thereof. A method of insulating a door including an exterior body panel and an interior fascia panel as well as a door for a vehicle are also provided.

Abstract: Apparatus for unloading a load from a container having a floor, includes a floor sheet placed on the floor of the container, the floor sheet having a top surface with a coefficient of static friction less than about 0.3. A pull sheet placed on the top surface of the floor sheet, the pull sheet having a bottom surface with a coefficient of static friction less than about 0.5. The pull sheet has a tensile strength sufficient to enable the pull sheet to be pulled from the container while maintaining the load on the top surface of the pull sheet to unload the load from the container.

Abstract: In a process to control the heating of a coating material for a roof covering, the coating material is heated using a heat exchange medium in a continuous process. The heat exchange medium is cooled in response to a slowdown or stoppage of the continuous heating process to maintain the temperature of the coating material below a predetermined level.