Abstract: Disclosed are fiber coating sizing applicator apparatus having a member to remove unused sizing and foreign objects from the fiber coating element of the applicator on a continuous or intermittent basis. Also disclosed are sizing applicators having as part of the drive, a servo motor for reduced variation in sizing application. Unused sizing is filtered to remove foreign objects and returned the applicator right away, or stored in a temperature controlled area until ready to feed back to a sizing applicator. Also disclosed are methods of using the sizing applicator apparatus to produce sized fibers. The apparatus and methods of the invention produce a substantial reduction in the fiber break rate, sizing usage and applicator maintenance.

Abstract: Provided is a roofing system comprising a thermoplastic roofing membrane and one or more raised metal profiles attached to the thermoplastic roofing membrane. In an embodiment, provided is a method of improving a roofing system comprising a thermoplastic roofing membrane. The method comprises installing one or more thermoplastic coated raised metal profiles on the roofing system. A side of the one or more thermoplastic coated raised metal profiles comprises a thermoplastic layer. Installing the one or more thermoplastic coated raised metal profiles on the roofing system comprises welding the thermoplastic layer to the thermoplastic roofing membrane. The presently disclosed raised profiles provide not only desirable aesthetics to thermoplastic roofing systems, but can also provide structural benefits to the roofing system.

Abstract: A method of applying thermal and acoustical insulation by spraying an air entrained stream of high velocity pils onto an overhead surface in concert with a liquid-based adhesive is disclosed.

Abstract: The invention relates to products and processes employing coupling activator compounds represented by the following formula I: S—X-A??(I) wherein S represents a silane coupling moiety capable of bonding with the surface of an inorganic substrate, A represents a ring-opening polymerization activator moiety, or blocked precursor thereof, and X represents a linking moiety. Substrates containing the coupling activator compounds are useful in preparing reinforced resins.

Abstract: A roofing system includes a plurality of insulation boards adapted for overlying a roof deck to form a layer of insulation, and a plurality of cover boards adapted for overlying the layer of insulation. Each insulation board includes a foam material that includes polyisocyanurate or polyurethane, the foam material having a first density. Each cover board includes a material including polyisocyanurate or polyurethane, the material having a second density greater than the first. The roofing system may further include a waterproofing membrane adapted for overlying the cover boards. The insulation boards and cover boards may include facers on top or bottom surfaces.

Abstract: Methods of making nonwoven mats having good strength after being scored and folded and particularly useful in making lightweight, compressible ceiling panels are disclosed. The mats also have excellent flame resistance. The mats include a blend comprising a major portion of glass fibers and a minor portion of man-made polymer fibers, the fibers being bound together with a cured binder containing a homopolymer or copolymer of polyacrylic acid and a polyol. The binder bonding the mat together can be cured to only a “B” stage to produce thermoformable mats or more fully cured to produce mats having the properties described above.

Abstract: A system and method for applying de-dusting agents to fibrous mats, webs, and/or blankets requiring a lower usage of the de-dusting agents, and producing fibrous products having improved dust suppression are disclosed. The dedusting agent or agents are first reduced to very fine particles or droplets and then, in an air suspension, are passed through the fibrous mat, web and/or blanket to deposit the very fine particles or droplets onto the surfaces of the fibers.

Abstract: A spinner for fiberizing glass has fiberizing holes formed in the spinner sidewall by a process utilizing an electron beam perforating process. A backing material used in the process is deposited on the walls of the fiberizing holes for increasing the corrosion resistance of the fiberizing holes. With regard to the formation of each fiberizing hole, an interaction of the backing material with an electron beam during the electron beam perforating process creates a gaseous backing material that expands through a hole created by the electron beam in the spinner sidewall to eject molten alloy material of the spinner sidewall made molten by the electron beam from the hole and deposit a thin substantially uniform coating layer of the backing material on the wall of the hole to increase the corrosion resistance of the fiberizing hole thus formed.

Abstract: A curable formaldehyde-free binding composition for use with fiberglass is provided. Such curable composition comprises an acid-catalyzed reaction product of an aldehyde or ketone with a multihydric alcohol. When heated, the composition forms polyacetal or polyketal that undergoes curing to form a water-insoluble resin binder which exhibits good adhesion to glass. In a preferred embodiment, maleic anhydride initially serves as a catalyst and subsequently enters into a cross-linking reaction during curing to form a poly(ester-acetal). Also, in a preferred embodiment, the fiberglass is in the form of building insulation. In other embodiments the product can be a microglass-based substrate for use in a printed circuit board, battery separator, filter stock, or reinforcement scrim.

Abstract: A process for securely binding the adjoining fibers of a fibrous material in the absence of the use of phenol-formaldehyde reaction product is provided. A curable binding composition comprising an intermediate reaction product capable of undergoing free-radical polymerization as well as an esterification crosslinking reaction is provided. The intermediate reaction product is formed by the reaction of (i) at least one anhydride having at least one unsaturated double bond capable of undergoing free-radical polymerization, and (ii) at least one polyol crosslinker. When applied to a fibrous material, the binding composition comprising the intermediate reaction product is cured in the presence of a free-radical initiator and a polyol crosslinker wherein the double bonds present in the intermediate reaction product undergo free-radical polymerization and hydroxyl and carboxylic acid end groups undergo crosslinking to form a cured binder.

Abstract: Inorganic fiber production burner apparatus and methods of use are disclosed. One burner includes a refractory block adapted to be in fluid connection with sources of primary oxidant and fuel, the refractory block having a fuel and primary oxidant entrance end and a flame exit end, the flame exit end having a substantially rectangular flame exit having a width greater than its height, the refractory block defining a combustion chamber and a second chamber fluidly connecting the combustion chamber and the flame exit end; and an oxygen manifold fluidly connected to the combustion chamber and adapted to route oxygen to the combustion chamber through a plurality of passages through the refractory block. This abstract allows a searcher or other reader to quickly ascertain the subject matter of the disclosure. It will not be used to interpret or limit the scope or meaning of the claims. 37 CFR 1.72(b).

Abstract: A multilayer fibrous nonwoven mat containing at least one transition zone comprised of a mixture of the slurries used to form the layers on each side of the transition zone, the transition zone having a thickness of at least 1 percent of the thickness of the mat. At least one of the layers contains glass fibers. The multilayer mats are particularly useful as facers on gypsum wall board, insulating foam, a wood material and a broad range of other materials. The multilayer mats are made by a method that involves using a lamella in the forming box on a wet laid mat machine, between slurries, the lamella ending a significant distance prior to a moving forming wire. The transition zone or zones provide superior interlaminar shear strength and other properties compared to multilayer fibrous mats produced on wet laid machines having two or more separate forming boxes.

Abstract: A process for securely binding the adjoining fibers of a fibrous material in the absence of the use of a phenol-formaldehyde reaction product is provided. A curable binding composition comprising a water-soluble intermediate reaction product having hydroxyl and carboxylic acid end groups that is capable of undergoing an esterification crosslinking reaction is provided. The intermediate reaction product is formed by the reaction of (i) a polyanhydride, and (ii) certain polyol crosslinkers other than an alkanolamine. Such crosslinkers have been found to yield a bound product that displays improved color (i.e., lighter color). Particularly preferred crosslinkers are triethylene glycol and tripropylene glycol. When applied to a fibrous material, the intermediate reaction product is reacted with crosslinking to form a cured reaction product. In a preferred embodiment the securely bound fibrous product is building insulation of good color that well resists water.

Abstract: The present invention relates to a filter composed of a multi-ply filter medium, which comprises at least one non-woven stiffening layer, at least one filtration layer, at least one covering layer and where necessary at least one non-woven microfibre layer, the non-woven stiffening layer comprising fibers of synthetic polymers and the fibers being both partially oriented and oriented fibers.

Abstract: Provided is a method of forming a self supporting fibrous nonwoven filter media comprising dispersing glass fibers, crimped polymer fibers, and cellulosic fibers in a fluid dispersion. The dispersion is subjected to a moving forming wire to form a fibrous web. Binder is applied to the web. The web is dried and cured/melted and later pleated in a subsequent operation. Inclusion of crimped polymer fibers in filter media improves dust holding characteristics of the filter media.

Abstract: A pipe insulation product including a core of insulating material and a roughly rectangular laminate. The core may include an outer surface; an inner surface; and a wall extending between the outer and inner surfaces. The laminate may include a foil or metallized polymeric film sheet, a scrim, a paper media sheet, and a polymeric film sheet bonded together via an adhesive. The laminate may include a closure flap that adhesively seals opposite ends of the laminate together to form a cylindrical tube with the core enclosed therein. The paper media sheet may be between the range of 20 and 40 pounds per 3000 square feet to provide greater closure flap seal integrity without significantly reducing one or more beneficial properties of the laminate.

Abstract: A gypsum board comprises a set gypsum layer having a first face and a second face. A fibrous mat is affixed to at least one of the faces. The mat comprises a non-woven web bonded together with a resinous binder. The web is composed of chopped continuous glass fibers having an average fiber diameter ranging from about 9.5 to 12.5 ?m. The board is exceedingly durable. It has a smooth surface that is readily finished in an aesthetically pleasing way, using paint or other wall covering systems.

Abstract: A system and method for applying de-dusting agents to fibrous mats, webs, and/or blankets requiring a lower usage of the de-dusting agents, and producing fibrous products having improved dust suppression are disclosed. The dedusting agent or agents are first reduced to very fine particles or droplets and then, in an air suspension, are passed through the fibrous mat, web and/or blanket to deposit the very fine particles or droplets onto the surfaces of the fibers.

Abstract: A facing laminate for insulation products includes: a foil or metallized polymeric film sheet layer forming an inner layer of the laminate that is adapted be bonded directly to a surface of an insulation product; a paper composite sheet layer, which may include synthetic and/or inorganic fibers, forming an outer exposed layer of the laminate; and a scrim intermediate and bonded to the foil or metallized polymeric film sheet and paper composite sheet layers. The facing laminate may include a humectant and/or a water, oil, and/or grease repellant component. The paper composite sheet layer of the laminate exhibits greater dimensional stability and reduced wrinkling when the laminate is exposed to conditions of high humidity. Insulation products to be faced with this facing laminate include pipe insulation, duct board, duct wrap insulation, metal building insulation, and other building insulation products.

Abstract: A pipe insulation product including a core of insulating material and a roughly rectangular laminate. The core may include an outer surface; an inner surface; and a wall extending between the outer and inner surfaces. The laminate may include a foil or metallized polymeric film sheet layer, a scrim, a porous media sheet layer, and a polymeric film sheet layer bonded together via an adhesive. The polymeric film sheet layer may also include a closure flap that adhesively couples opposite ends of the laminate together to form a cylindrical tube with the core enclosed therein. A charge dissipator may be applied to the polymeric film sheet layer in an amount sufficient to reduce generation of a static charge on the laminate's exterior surface without affecting the closure flap's ability to adhesively couple the opposite ends of the laminate.