Abstract: A melter apparatus includes a floor, a ceiling, and a substantially vertical wall connecting the floor and ceiling at a perimeter of the floor and ceiling, a melting zone being defined by the floor, ceiling and wall, the melting zone having a feed inlet and a molten glass outlet positioned at opposing ends of the melting zone. The melting zone includes an expanding zone beginning at the inlet and extending to an intermediate location relative to the opposing ends, and a narrowing zone extending from the intermediate location to the outlet. One or more burners, at least some of which are positioned to direct combustion products into the melting zone under a level of molten glass in the zone, are also provided.

Abstract: This invention relates to a process of making a fiber-reinforced composite. Glass fibers may be provided. These glass fibers may be treated with a sizing composition that has a coupling-activator compound with the formula: S—X-(A)n, where S represents a silicon-containing coupling moiety capable of bonding to the surface of glass fibers, X represents a linking moiety, and (A)n represents one or more polymerization activator moieties. The treated glass fibers may be combined with a resin to make a fiber-resin mixture. The resin may have a monomer, a catalyst, and an activator compound capable of initiating a polymerization of the monomer. The monomer may be a lactam or lactone having 3-12 carbon atoms in the main ring. The fiber-resin mixture may then be cured so that the monomer polymerizes to form a thermoplastic polymer matrix of the fiber-reinforced composite. The thermoplastic polymer matrix may be formed by in situ polymerization initiated from both the surface of the glass fibers and the resin.

Abstract: Fiberizing bushing assemblies, usually of rectangular shape, for fiberizing molten inorganic material like glass require cooling members located in the proximity of the orifices or tips forming the fibers. Cooling tubes carrying a cooling fluid like water are used by some fiber manufacturers and the cooling tubes have always been oriented with the length dimension of the bushing. It has now been discovered that orienting the cooling tubes to be substantially parallel to the width dimension, though more costly to fabricate because of the greater number required per bushing assembly, significantly reduce fiber break out rate and significantly increase productivity because they are easier to keep properly adjusted and result in a more uniform temperature of the fiberizing tips.

Abstract: Methods and systems for determining density or density gradient of molten foamed glass in a glass melter, an apparatus downstream of a glass melter, or both. A molten foamed glass is generated having molten glass and bubbles entrained therein and/or a layer of glass foam on a top surface thereof in a melter. At least a portion of the molten foamed glass is transferred into an apparatus positioned downstream of the melter, and the density or density gradient of the molten foamed glass in the melter or downstream apparatus is determined as a function of distance from a structural feature of the melter or downstream apparatus, or both, using one or more electromagnetic (EM) wave-based sensors.

Abstract: Embodiments of the invention provide apparatus and methods for insulating a structure. A method for insulating a structure may include providing a frame that comprises a plurality of frame members coupled together. Sheathing panels may be coupled to the frame members such that adjacent sheathing panels abut and directly contact each other at an interface to form a wall having a front surface and a rear surface. A spray insulation material may be applied to the front surface of the wall such that the insulation material forms a substantially continuous insulation layer atop the front surface and such that the insulation material directly contacts the interface between adjacent sheathing panels to restrict passage of air between the adjacent panels to at or below 0.2 L/m2/s at a differential pressure across the wall of 75 Pa.

Abstract: Sizing compositions to size fibers or particles used in plastic composites are described. The compositions may include a solution with a polymerization compound selected from: (a) at least one non-isocyanate-containing polymerization initiator (PI) for initiating the polymerization of caprolactam monomers; or (b) at least one precursor for a non-isocyanate-containing PI for initiating the polymerization of caprolactam monomers. Methods of making the sizing the composition, as well as methods of making reinforced thermoplastic composites from sized fibers or particles, are also described.

Abstract: According to one embodiment, a method for pressing roofing granules into a roofing membrane may include providing a roofing membrane and applying roofing granules atop a surface of the membrane. The method may also include adjusting a position of a second roller relative to a first roller so as to vary an amount of contact between the membrane and the first roller and pressing the roofing granules into the membrane via the first roller. In some embodiments, a line speed of the membrane may be determined and a contact value may be calculated based on the line speed of the membrane. The contact value may represent an effective amount of contact between the membrane and the first roller. The position of the second roller may be adjusted so that the amount of contact between the membrane and the first roller corresponds to the effective amount of contact.

Abstract: The subject invention is directed to a method for producing a pre-reacted clinker used in the manufacture of E glass. The clinker is fed into an E glass furnace, and melts down into a finished E glass product at high efficiencies and short production times. The clinker allows glass to be produced at a lower cost as compared with known methods.

Abstract: A bushing system includes a bushing having a bottom plate with a plurality of holes from which filaments are drawn. At least one elongated support extends through the bushing generally along a longitudinal axis to hold and stabilize the bushing. To handle the harsh conditions under which the bushing is subjected, the support comprises an alumina-based ceramic that generally resists sagging or excessive expansion and contraction during heating and cooling.

Abstract: Submerged combustion glass manufacturing systems include a melter having a floor, a roof, a wall structure connecting the floor and roof, and an exhaust passage through the roof. One or more submerged combustion burners are mounted in the floor and/or wall structure discharging combustion products under a level of material being melted in the melter and create turbulent conditions in the material. The melter exhausts through an exhaust structure connecting the exhaust passage with an exhaust stack. The exhaust structure includes a barrier defining an exhaust chamber having an interior surface, the exhaust chamber having a cross-sectional area greater than that of the exhaust stack but less than the melter. The barrier maintains temperature and pressure in the exhaust structure at values sufficient to substantially prevent condensation of exhaust material on the interior surface.

Abstract: The present invention relates to a filter medium, a method for the manufacture thereof and the use of the filter medium according to the invention. The filter medium according to the invention comprises at least two textile nonwoven layers which are joined to one another by needling. The needled composite is then subjected to an aftertreatment so that the holes present from he needling are reduced by at least 50%.

Abstract: A method of making a nonwoven fibrous mat that retains good strength and recovery after scoring and folding, properties making the mat useful in making collapsible ceiling tile. The mat comprises a majority of glass fibers and a minority of polymer fibers, the fibers being bound together with up to 35 wt. percent of a polyacrylic acid and polyol polymer binder based on the dry weight of the mat. The mat can be cured to “B stage”, thermoformed into the desired shape and then heated further to complete the cure of the binder.

Abstract: Provided are nonwoven polymeric fiber webs using an improved curable composition. Such curable composition comprises an aldehyde or ketone and an amine salt of an inorganic acid. The composition when applied to polymeric fibers is cured to form a water-insoluble polymer binder which exhibits good adhesion and thermodimensional stability.

Abstract: A process for making a glass product with reduced greenhouse gas emission, comprising: providing a raw material composition comprising at least one silicon dioxide or silicon dioxide-containing compound and at least one pre-reacted compound, wherein the pre-reacted compound comprises an atom of an alkaline earth metal chemically bonded to an oxygen atom, and a silicon atom chemically bonded to the oxygen atom; melting the raw material composition to produce a molten material; and forming the molten material into a glass product.

Abstract: According to one embodiment, a method for pressing roofing granules into a roofing membrane may include providing a roofing membrane and applying roofing granules atop a surface of the membrane. The method may also include adjusting a position of a second roller relative to a first roller so as to vary an amount of contact between the membrane and the first roller and pressing the roofing granules into the membrane via the first roller. In some embodiments, a line speed of the membrane may be determined and a contact value may be calculated based on the line speed of the membrane. The contact value may represent an effective amount of contact between the membrane and the first roller. The position of the second roller may be adjusted so that the amount of contact between the membrane and the first roller corresponds to the effective amount of contact.

Abstract: According to one embodiment, a self-adhesive insulation product is provided. The self-adhesive insulation product includes an elongated fibrous insulation blanket having a length, a width, a thickness, and a first major surface and a second major surface which each extend for the length and width of the fibrous insulation blanket. The self-adhesive insulation product also includes a coating of an adhesive applied to the first major surface of the fibrous insulation blanket. The adhesive includes an emulsion of a polymer material and water with the water evaporated so that the adhesive forms a dry layer atop the first major surface. The adhesive is nonbondable or nonadherable to other objects when in the dry state and is bondable or adherable to other objects upon the subsequent application of water.

Abstract: Compositions for binding organic or inorganic fibers is described. The compositions may include an aqueous solution having a pH of about 4.5 or more. The aqueous solution may include a polycarboxy polymer that is about 10%, by wt., to 100%, by wt., of a butenedioic acid or butenedioic anhydride; and a polyol. The compositions can maintain a pH of about 5 or more after being cured into a thermoset plastic with the fibers. Processes for preparing a binder composition for organic or inorganic fibers are also described. The processes may include providing an aqueous solution of polycarboxylic acid polymers, where the polymers comprise about 10%, by wt., to 100%, by wt., of a butenedioic acid or butenedioic anhydride; adding a polyol to the aqueous solution; and maintaining the pH of the aqueous solution at about 5 or more.

Abstract: According to one embodiment, a method of making a roofing membrane is provided. According to the method, an ethylene propylene diene monomer rubber (EPDM) material sheet is provided and a thermoplastic polyolefin (TPO) material sheet is extruded onto the EPDM material sheet. The EPDM material sheet and TPO material sheet are then pressed together via one or more rollers. The EPDM material is uncured and has a thickness of between about 50 mils and 70 mils. The extruded TPO sheet has a temperature of at least 150 degrees Celsius and a thickness of between about 15 mils and 35 mils. The heat of the TPO material sheet causes a top portion of the EPDM material sheet to cure such that crosslinking of the TPO and EPDM material sheets occurs at an interface of the sheets to bond the sheets together.

Abstract: Methods and systems produce a molten mass of foamed glass in a submerged combustion melter (SCM). Routing foamed glass to a fining chamber defined by a flow channel fluidly connected to and downstream of the SCM. The flow channel floor and sidewalls have sufficient glass-contact refractory to accommodate expansion of the foamed glass as fining occurs during transit through the fining chamber. The foamed glass is separated into an upper glass foam phase and a lower molten glass phase as the foamed glass flows toward an end of the flow channel distal from the SCM. The molten glass is then routed through a transition section fluidly connected to the distal end of the flow channel. The transition section inlet end construction has at least one molten glass inlet aperture, such that the inlet aperture(s) are positioned lower than the phase boundary between the upper and lower phases.

Abstract: Soy protein and carbohydrate containing binder compositions are described. The binder compositions may include a carbohydrate, a nitrogen-containing compound, and a soy protein. The binder compositions may also optionally include thickening agents such as modified celluloses and polysaccharides.