Abstract: A test method for measuring yarn and tuft or loop gripping strength characteristics and capability of tufted nonwoven primary backing mats for making tufted carpets, the tufted primary backing mat having no additional binder or adhesive on the backside of the mat prior to making tufted carpet is disclosed. The test apparatus and test method can be used for quality control purposes and for evaluation of experimental or new candidates for primary backing mats for making interim tufted products for carpets that are more resistant to tuft or loop defects. Revealed is a new and critical Quality Knee characteristic of primary backing mats that is crucial for minimizing tuft or loop defects during the tufting process and also the force magnitude on the yarn necessary to pop the tuft completely out of the primary backing mat sample.

Abstract: A prefabricated cover board has a high-density polymer or predominantly polymer material core layer having a density between 4 lbs/ft3 and 25 lbs/ft3. A prefabricated roofing panel composite includes the cover board and an insulation board that has a low-density polymer or predominantly polymer material foam core layer preferably having a density less than 2.5 lbs/ft3. The cover board may have a waterproofing membrane forming the top major surface of the cover board. When making the roofing panel composite, the low-density foam core layer of the insulation board may be formed with the high-density core layer of the cover board being currently or subsequently formed over and bonded to a top major surface of the low-density foam core layer in the same operation or preformed insulation boards may be fed into a production line with the high-density core layer of the cover board being formed over and bonded to top major surfaces of the low-density foam core layers of the insulation boards.

Abstract: An improved curable formaldehyde-free binding composition is provided. Such curable composition comprises the reaction product of a polyanhydride and a polyol crosslinker and a lower molecular weight anhydride. Initially, the polyanhydride is modified through reaction with a polyol (e.g., a glycol or an alkanolamine) and subsequently is grafted with the lower molecular weight anhydride (e.g., maleic anhydride) to form a water-soluble or water-dispersible curable reaction product. The composition is well suited for binding fibrous materials (e.g., a mat of glass fibers) or for bonding together non-fibrous materials. The binder composition displays an advantageous viscosity so as to facilitate a flowable application with ease combined with an adequately high molecular weight to satisfactorily undergo service as a binder following curing even when harsh environmental conditions (e.g., hot humid air) are encountered for a prolonged period of time.

Abstract: A polyester filament nonwoven ply is suitable for roofing and roof-sealing webs and has a latent shrinkage force which counteracts drafting forces which may subsequently occur as the result of stresses or during thermal processing operations. The roofing webs thus remain dimensionally stable even when exposed to heat. The shrinkage force is obtained according to the claimed process by drafting the ply accordingly in a drafting mechanism arranged after a dryer.

Abstract: A glass fiber composition comprises about 33-47 weight % SiO2; about 18-28 weight % Al2O3; about 5-15 weight % Fe2O3; greater than or equal to about 2 weight % and less than 10 weight % R2O; about 8-30 weight % CaO; and less than 4 weight % MgO; wherein R2O represents alkali metal oxides. Preferably, the glass fiber composition has a liquidus temperature of less than 2350° F.; and a viscosity at a liquidus temperature of the glass fiber composition of greater than 500 poise; and fire resistant glass fiber formed from the glass fiber composition has a biodissolution rate of greater than 50 ng/cm2/hr.

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: A pliable reinforcement carrier membrane for use in a coated membrane composite includes a pliable non-woven fibrous mat of entangled polymeric fibers and a hydrophobic binder. The membrane is made so that a first surface of the mat has portions of a portion of the polymeric fibers of the mat protruding therefrom in extent and in sufficient amounts to give the first surface of the mat a fuzzy characteristic to facilitate adhesion of a coating material and a second surface of the fibrous mat has a generally smooth, non-fuzzy surface. A pliable waterproof composite, including the membrane, has a bottom surface formed by a filled asphalt, modified bitumen, or non-asphaltic polymeric coating that overlies and is adhered to the first surface of the mat to provide a barrier against liquid water transmission through the composite and a top surface formed by the second surface of the mat.

Abstract: The invention includes a method and system for generating electricity using a drive for the electrical generator that is powered by an engine that uses high pressure hot gases produced by combustion of a fuel and an oxygen bearing gas, using at least a portion of the electricity generated to power manufacturing plant equipment and using the waste hot exhaust gases from the heat engine, such as a gas turbine, with or without a heat exchanger, in an oven in which the mat is carried through continuously on a belt, drum or with other conventional means to dry the wet fibrous mats. Optionally the fibrous mats can contain a binder and the hot waste gases can be optionally used to cure a binder.

Abstract: Self-adhering flashing cap strip and end lap connector cap sheet assemblies include a reinforcing layer encapsulated within self-adhering bitumen. The bottom major surfaces of the flashing cap strips and the connector end lap cap sheets are formed by the self-adhering bitumen and the top major surfaces of the flashing cap strips and the connector end lap cap sheets have lateral edge portions formed by the self-adhering bitumen and a coated central portion that extends between the lateral edge portions. The flashing cap strips are used to interconnect cap sheets at roof surface intersections in the formation of waterproof roofing layers and the connector end lap sheets are used to connect lengths of cap sheets at the job site.

Abstract: A process is described for treating a nonwoven fabric to improve the gripping ability of the fabric during the preparation of tufted carpets. The process includes the steps of applying an elastomeric binder to the fabric, treating the fabric to provide a series of depressions or holes in a pattern consistent with the tufting needle pattern to be subsequently applied, and then curing the binder. The resultant fabric has a pattern of holes or depressions which are essentially free of binder with excess binder squeezed from the depressions forming rings around the depressions. When the tufting needle is inserted into the depression or hole, the elastomeric ring surrounding the hole expands. Upon retraction of the needle, the elastomeric ring contracts and exerts a firm grip on the tuft in the hole.

Abstract: A vinyl floor covering is provided with reinforcement of segmented woven or non-woven glass fiber mat located on the underside of the vinyl floor covering or at or near the neutral axis of the vinyl floor covering. This segmented mat reinforcement increases the stiffness and mechanical properties of the vinyl floor covering. A polymeric binder separates the segments of the glass fiber mat from each other. Expansion or contraction of the installed vinyl floor covering is restricted to this polymeric binder region. The segments may be aligned with the vinyl floor covering's show surface patterns, thereby preserving pattern integrity. The segmented mat is manufactured by applying and curing a polymeric binder to a woven or non-woven glass fiber mat, and creating segments by the passing the woven or non-woven glass fiber mat with polymeric binder through a set of embossing rollers. The segmented woven or non-woven glass fiber mat with polymeric binder is easily handled by vinyl floor covering machinery.

Abstract: Inorganic fiber production processes and systems are disclosed. One process includes providing a molten inorganic fiberizable material, forming substantially vertical primary fibers from the molten material, and attenuating the primary fibers using an oxy-fuel fiberization burner. Other processes include forming a composition comprising combustion gases, aspirated air and inorganic fibers, and preheating a fuel stream and/or an oxidant stream prior to combustion in a fiberization burner using heat developed during the process. Flame temperature of fiberization burners may be controlled by monitoring various burner parameters.

Abstract: A glass fiber composition comprises about 52-65 weight % SiO2; less than or equal to 4 weight % Al2O3; about 7-16 weight % Fe2O3; greater than 6 weight % and less than or equal to about 14 weight % R2O; about 6-25 weight % CaO; less than or equal to 10 weight % MgO; and about 10-25 weight % RO; wherein R2O represents alkali metal oxides and RO represents alkaline earth metal oxides. Preferably, the glass fiber composition has a liquidus temperature of less than 2350° F.; and a viscosity at a liquidus temperature of the glass fiber composition of greater than 500 poise; and fire resistant glass fiber formed from the glass fiber composition has a biodissolution rate of greater than 50 ng/cm2/hr.

Abstract: A system for forming an insulation particle/air suspension suitable for use in a process for forming an insulation product is provided, comprising: a blowing machine for forming an insulation particle/air suspension, wherein the blowing machine comprises at least one outlet; a first hose in communication with the outlet, for transporting at least the suspension from the blowing machine; and a booster fan in communication with the first hose, wherein the booster fan is located downstream from the blowing machine.

Abstract: Provided is a coated nonwoven mat prepared by the process of passing a nonwoven mat over the surface of a binder or coating slurry to touch the bottom side of the mat sufficiently to fully wet the glass mat. The wetted nonwoven mat is then immersed in a slurry of the binder or coating material to fully saturate the mat with the slurry material. The process of the present invention allows one to control the porosity of the saturated fibrous nonwoven mat at high consistency with reduced scrap rate. The saturated mat will have improved tensile strength.

Abstract: The facing of a faced building insulation assembly includes a central field portion that is fungi growth resistant. The facing may include a fungi growth-inhibiting agent, be perforated to provide a selected water vapor permeance, and/or may include a heat activated bonding agent. The facing may have lateral tabs that are transparent, sufficiently open to enable wallboard to be directly bonded to framing members overlaid by the tabs, and/or of greater integrity than the field portion of the facing. The field portion of the facing may include a coating to stiffen the facing, inhibit fungi growth, and/or decrease flame spread and smoke formation.

Abstract: A prefabricated, faced roofing board composite includes a first board layer made of a polymeric material or a predominantly polymeric material and a fire and weather resistant fiberglass-based facer bonded to a top major surface of the first board layer and forming a top major surface of the composite. The fiberglass-based facer is substantially impervious to the passage of hot gases of combustion, water, and water vapor through the thickness of the fiberglass-based facer. The faced composite can be a cover board, an insulation board; can include cover board and insulation board layers; and can include cover board, insulation board, and baseboard layers. A second fiberglass-based facer that is substantially impervious to the passage of hot gases of combustion through its thickness can form a bottom major surface of the composite.

Abstract: A flexible nonwoven mat of polymeric fibers is liquid water transmission resistant and is particularly well suited for use as a prefabricated building construction underlayment. The polymeric fibers may be standard polymeric fibers or sheathed polymeric fibers that have fiber sheaths with a lower softening point temperature than the softening point temperature of the fiber cores. Preferably, the polymeric fibers are spunbond fibers and are bonded together through the application of heat and pressure. Where the fibers are sheathed fibers, interstices of the nonwoven mat are at least partially filled by a portion of the polymeric material of the sheaths that is dispersed into the interstices to reduce the porosity of the mat.

Abstract: A nonwoven fibrous mat or web forming or treating system is disclosed comprising a movable, permeable wire or belt for carrying the fibrous mat or web over at least one suction tube assembly comprising a primary suction tube having a suction slot at the top of the primary suction tube and an exit tube communicating with the primary suction tube mounted beneath the permeable belt to have the suction slot on or close to the bottom surface of the movable belt. The suction slot is at least 3.6 meters long and up to more than 5.3 meters long, and the exit tube of the suction tube assembly communicates with the primary suction tube through an opening in the primary suction tube, the opening being generally centered around a centerline of the suction slot. This primary suction tube assembly provides a more uniform suction distribution along the suction slot and reduces fouling of the suction slot compared with previous suction tube assemblies.

Abstract: A system for curing a binders applied to glass fibers is disclosed. The curing of the binder is accomplished by passing the binder coated glass fibers through a curing oven having one or more temperature zones. The temperature of the binder coated glass fibers is monitored and the temperature in the curing oven is adjusted to ensure proper heating of the glass fibers thereby ensuring uniform curing of the binder composition. Temperature measurements are made either as the product traverses the oven or as the cured product exits the curing oven. The invention is particularly useful for curing acrylic thermoset binders and formaldehyde-free binders.