Abstract: An under carpet heat shield/floor pan insulator is provided for a vehicle. The shield/insulator includes an acoustical and thermal insulating layer of polymer fiber that shows no signs of any thickness increase, delamination, deterioration or any undesirable effect which may affect performance for at least 330 hours when maintained at a temperature of at least approximately 150° C. The shield/insulator may include a relatively high density, nonlaminate skin of polymer fiber and/or one or more facing layers constructed from polymer material.

Abstract: A method for containing fibrous material within muffler comprises the initial step of providing an internal assembly of a muffler. In the next method step, a sheet is placed about the internal assembly to form an enclosure about a compartment. In the next method step, the compartment is filled with a fibrous material. A muffler according to the invention comprises a muffler having an outer shell having an internal cavity and outer edges. An internal assembly is inserted within the internal cavity. The internal assembly comprises partitions and a sheet about the internal assembly and extending between the partitions from an enclosure between the partitions. The enclosure is filled with fibrous material. End plates are joined to the outer edges of the outer shell.

Abstract: A method for depositing granules (48) onto a substrate (14) comprises providing a hopper (36) for granules with a discharge slot (46), moving a gate (50) across the slot to open and close the slot so that when the slot is open granules fall from the hopper and when the slot is closed granules are prevented from falling from the hopper, and detecting the speed of the substrate and controlling the extent of opening of the slot by the gate to meter the granules falling from the hopper in response to the speed of the substrate.

Abstract: A mold for molding fibrous molding media includes upper and lower mold bodies defining a mold cavity, the upper and lower mold bodies being movable relative to each other to close the mold. The upper and lower mold bodies have respective upper and lower mold surfaces for contacting the fibrous molding media positioned within the mold, and have gas flow openings configured to direct gases into contact with the fibrous molding media. The mold also includes a source of gas connected to the gas flow openings.

Abstract: A recyclable tufted carpet meeting EPA recyclable content standards and having improved dimensional stability that reduces skew, bow, and wrinkles during manufacture and installation is formed by combining prior art primary and secondary backings into a single, fiber-reinforced primary backing layer. Consolidating either a glass fiber fabric layer, a glass veil, or a glass mat with a fiber-reinforced extruded film forms the fiber-reinforced primary backing layer. An additional glass fabric fiber layer can also be introduced to the primary backing to provide additional dimensional stability.

Abstract: A fiberglass insulation binder composition made from a polycarboxy polymer, a polyhydroxy crosslinking agent, and a cationic surfactant, amphoteric surfactant, nonionic surfactant, or mixture thereof. Also, a process for manufacturing a fiberglass insulation product, which involves a step of applying the binder composition onto a fiberglass substrate and curing the fiberglass substrate so treated. Binders produced in accordance with the present invention are characterized by improved atomization, improved binder dispersion and fiber wetting properties, and improved protection of individual fibers during processing.

Abstract: Disclosed is an apparatus and a corresponding method for producing a continuous foamed extrudate product in which the extrusion and initial expansion of the foamed extrudate is conducted within a chamber under a partial vacuum. The foamed extrudate is then removed from the chamber through an orifice submerged within a liquid baffle. The dimensions of the foamed extrudate are monitored as it approaches the orifice and, if necessary, the effective sizing of the orifice is adjusted through the movement of a pair of side gates and a single vertical gate arranged external the orifice to match opening to the foamed extrudate and impede the flow of liquid into the chamber through the orifice.

Abstract: A fabric-retaining structure includes: a body; and a fabric-gripping jaw arrangement coupled to the body. The jaw arrangement includes: a crenated jaw having crenated teeth and a serrated jaw having serrated teeth. The crenated jaw is arranged in opposition to the serrated jaw.

Abstract: Methods are provided for forming a plurality of air diffusers from a single fiberglass and foil blank. At an automated pre-forming station upstream of a molding station, a blank has pressed therein two air diffuser patterns at a middle portion, two patterns at a first catercorner portion and two patterns at a second catercorner portion and the pressing of each set of two patterns occurs substantially simultaneously to prevent the foil from delaminating from the fiberglass. Thereafter, the blank is fed to a molding station that applies a significantly larger pressing force and heats the blank to form six air diffusers. Perforations are cut in the blank to facilitate separation of the air diffusers in a trimming station downstream of the molding station. Preferred pressing of air diffuser patterns occurs with pneumatic actuated male and female air diffuser pattern molds that are sequentially operated in accordance with a desired pattern.

Abstract: An insulated duct-wrap insulating product for an air duct that incorporates a wicking media to transport condensed water on the duct surface to be evaporated into the atmosphere. A wicking fabric, or fibrous media, incorporated as part of the insulating duct wrap is in contact with the metal air duct surface. A portion of the wicking fabric extends into the interior of the air duct, typically through joints in the duct system. When water vapor condenses on the air duct surface it is transported by the wicking fabric and evaporated from the wick surface within the air stream being transported by the ducting system.

Abstract: A process for forming thermoplastic composites that uses wet use chopped strand glass is provided. Wet reinforcement fibers such as wet chopped strand glass fibers are opened by passing the fibers consecutively through a first opener, a condenser, and, optionally, a second opener. The opened reinforcement fibers are mixed with a resin and transferred to a first sheet former. The resin is preferably polypropylene fibers. An optional second sheet former may be used to form a final composite having high structural integrity. The resulting sheet may be optionally passed through a needle felting machine for mechanical strengthening. The sheet is then passed through a thermal bonder to thermally bond the reinforcement glass fibers and resin. The composite product that exits the thermal bonder can be subsequently used as a reinforcement in a molding process to produce composite articles.

Abstract: An apparatus and method are provided for forming a densified surface layer on a thermoplastic blanket. The apparatus includes first and second continuous belts, a treatment zone defined between those belts, first and second heating and densifying units and a cooler downstream from the heating and densifying units. The method includes the steps of continuously forming a densified surface layer on a face of a thermoplastic blanket and making the thermoplastic blanket with the densified surface layer to a desired thickness within strict dimensional tolerances. A densified thermoplastic blanket product is also disclosed.

Abstract: A method of recycling building materials is described, including the steps of introducing the building material into a cement kiln or a boiler, and combusting a combustible portion of the building material as a fuel within the kiln or boiler. The noncombustible portion of the building material is incorporated into a clinker material within the kiln or used to reduce emissions form the boiler.

Abstract: Provided are a method and apparatus for fabricating a panel product including a board, panel or substrate having at least one surface on which a decorative image and alignment marks corresponding to an image data file are applied. The alignment marks and the image data file are then used to align an intermediate product with one or more cutting devices. Once aligned, the original image data file or a transformed version of the image data file is used to control cutters or other tools for removing waste portions of the panel product. The panel product may then be subjected to additional processing, particularly with regard to edge treatments, to obtain a final panel product.

Abstract: Panels for a suspended ceiling of the torsional spring type are disclosed. Such panels can include: a circumferential edge configuration that preserves a very tight tolerance between a surface bearing against a foot portion of a T-bar and a face of the panel; and/or reinforcing ribs in the form of T-bars whose foot portions are inserted between the laminae of a typical ceiling panel. Each circumferential side edge configuration is multifaceted and includes: a first surface intersecting the back surface; a second surface intersecting the first surface and substantially parallel to the face surface; a third surface intersecting the second surface and substantially orthogonal to the face surface; and a fourth surface intersecting, and being beveled relative to, the third surface. The length of the first surface will vary in close proportion to the variations in the thickness of a new panel, which makes the machined back-to-face distance very uniform.

Abstract: A formulation for controlling the thickening profile for sheet molding compositions to a lower viscosity for use in low pressure molding conditions is provided. The B side addition of a modified alkaline earth oxide thickening system using a combination of oxides results in a sheet molding compound that is tack free at lowered viscosities. These sheet molding compounds exhibit extended shelf lives, good flowability, and excellent handling characteristics.

Abstract: By utilizing a pH indicator having known color change characteristics, an accurate determination of the pH of a binder surface, and hence the amount of cure of a polycarboxylic acid based binder on the fiberglass fibers, can be easily determined for polycarboxylic binder based fiberglass materials used in insulation and composite applications. Based on these results, the manufacturing line used to make these bindered materials may be adjusted to ensure adequate curing at maximum efficiency while minimizing operating costs and reducing waste.

Abstract: In a method of reinforcing and waterproofing a paved surface, a layer of liquefied asphalt is applied on a paved surface. A reinforcement mat is then applied over the liquefied asphalt. The reinforcement mat includes a first layer comprising a nonwoven mat produced from fibers selected from the group consisting of mineral fibers, polymer fibers, and mixtures thereof. The reinforcement mat also includes a second layer of mineral fibers attached to the first layer. The liquefied asphalt penetrates and soaks the reinforcement mat to form a water barrier. A layer of paving material is then applied a over the reinforcement mat. The first layer and the second layer of the reinforcement mat are attached to each other by any one of sewing, knitting, needling, heat treating, and adhering with an adhesive, or combinations thereof.

Abstract: The invention relates to an insulation product comprising an elongated fibrous batt with a polymeric encapsulating layer and, optionally, a vapor or other barrier layer on one or more surfaces of the fibrous batt and an apparatus for manufacturing such an insulation product.

Abstract: Disclosed is an apparatus and a method for at least partially encapsulating a fiber batt or other substrate by applying a polymer fiber layer to one or more surfaces of the fiber batt or substrate by melt-blowing. The melt-blowing assemblies are arranged and configured to extrude both a polymer melt and a hot gas stream whereby the hot gas stream attenuates the polymer melt to form polymer melt fibers and to direct the polymer melt fibers toward a surface to be coated. The melt-blowing assemblies are further of the fiber batt. A combination of melt-blowing assemblies may be provided in either fixed or moveable configurations for coating one or more sides of the fiber batt.