Abstract: A fibrous, non-woven thermal insulation comprises synthetic polymeric resin microfibers, staple fibers and bonding fibers which are randomly oriented and randomly intermingled in a single layer. The microfibers comprise between 25% and 95% by weight virgin synthetic polymeric resin and between 5% and 75% by weight recycled polyethylene teraphthalate. The microfibers have an average diameter between 1 to 8 microns and comprise between 35% and 80% by weight of the insulation; the staple fibers have and average diameter between 10 and 30 microns and comprise between 15% and 60% by weight of the insulation; and the bonding fibers have an average diameter between 14 and 30 microns and comprise between 5% and 25% by weight of the insulation. The bonding fibers have thermoplastic surfaces with a lower temperature softening point than the microfibers and staple fibers and bond the fibers together to form the insulation material.

Abstract: A cylindrical polymer fiber filter cartridge for liquid filtration is formed by applying an acrylic latex binder, diluted with water, to a batt of thermoplastic polymer fibers and winding the batt onto a core to form a hollow fibrous cylinder while applying compression with a compression roll to an outer surface of the fibrous cylinder. After the batt is fully wound onto the core, the cylindrical cartridge is rotated at a speed sufficient to cause the acrylic latex binder to foam in-situ thereby fluidizing the cartridge to allow the polymer fibers in the cartridge to reorient to form a smooth outer surface on the cartridge and to evenly distribute the acrylic binder throughout the cartridge. The binder in the cartridge is then cured to bond the fibers together at their points of intersection and annular grooves are cut in the outer surface of the cartridge to increase the surface area of the filter.

Abstract: A furnace for melting and refining E glass comprises a melting and refining tank for melting and refining the glass batch materials into glass and a forehearth, downstream of the tank, for further refining the glass and delivering the glass to fiberizing means. The melting and refining tank is heated with oxygen fired burners. The oxygen fired burners in the melting and refining tank are located in the sidewalls at the upstream end of the tank and extend for about one-third the length of the tank. In one embodiment, burners are also located in the upstream end wall. This arrangement of the oxygen fired burners at the upstream end of the melting and refining tank moves the melter hot spot upstream for better refining of the glass and enables the furnace to produce a higher output of glass than can be obtained in a conventional E glass furnace of the same size.

Abstract: Described is an inorganic fiber comprising silica dioxide, calcium oxide, and alkali oxide having a free energy of hydration greater than (more positive than) -5.00 kcal/mol, an enthalpy of formation less than (more than negative than) -210.0 kcal/mol, a dissolution rate in simulated extra cellular fluid greater than 750 (calculated as nanograms of fiber/per square centimeter of fiber surface area/per hour) having an average fiber diameter not greater than 4.5 micrometers. Also described is a method of manufacturing the fibers.

Abstract: A rigid fiber glass air duct for conveying an airstream has an interior surface, adapted to be in contact with the airstream, which is coated with a polymeric coating with an organic biocide. The polymeric coating has a dry solids content of between 10 and 20 grams per square foot of duct board surface and retains its abrasion strength and puncture resistance whereby the interior surface of the duct can be cleaned by conventional industrial or commercial cleaning methods while in service without exposing glass fibers to the airstream.

Abstract: A vessel for use in the transportation of cryogenic liquids in over the road cryogenic tankers has a double wall with a highly efficient, relatively light weight fiber glass insulation in the cavity between the walls. The fiber glass insulation increases in density from the inner wall of the cavity to the outer wall of the cavity having the least density adjacent the cold inner wall of the vessel which contains the cryogenic liquid and the highest density adjacent the outer wall of the cavity which is exposed to ambient conditions. One or more layers of reflective septa can be incorporated into the fiber glass insulation to reduce radiant heat transfer.

Abstract: A synthetic microfiber blanket having a uniform thickness is formed from a nonuniform blanket having thin or feathered lateral edges. The nonuniform blanket is cut transversely into a plurality of discrete pieces of blanket of uniform length. The plurality of discrete pieces of blanket are arranged with the thin lateral edges in overlapping relationship to form a blanket of a desired width and thickness. The overlapped, discrete pieces of blanket are then joined into an integral blanket of uniform width and thickness by entangling together fibers of adjacent pieces of blanket. A scrim backing can be incorporated into the blanket for added strength and dimensional stability.

Abstract: Described is an acidic glass fiber binding composition comprising an aqueous soluble phenol formaldehyde resin having low free formaldehyde, an effective amount of a formaldehyde scavenger, and an effective amount of a strong aqueous soluble acid, wherein the composition has an acidic pH and the solids content ranges from about 1 to about 30% by weight of the total composition. Also described is a method of binding glass fibers such as newly formed warm glass fibers at junctions of the fibers by applying the composition as described above to the fibers and then drying the composition. Also described are B-staged and C-staged glass fiber compositions having a alkylamine content less than 5 ppm.

Abstract: An oxygen-fuel firing system for a furnace comprising separate, spread apart nozzles for introducing gaseous streams of oxygen and fuel into the furnace at spaced apart locations. The gaseous streams merge within the furnace away from the furnace walls and crown. Thus, the main combustion within the furnace takes place in the central portion of the furnace where a broad flame cloud is created. The broad flame cloud provides a more uniform temperature profile within the furnace for a more efficient processing of materials being melted in the furnace.

Abstract: A method of and apparatus for continuously foaming a polyimide prepolymer powder which is not susceptible to heating by microwave energy utilize a preheated conveyor belt to heat the powder in contact with and adjacent the surface of the conveyor belt to commence the reaction and foaming of the powder as it enters an oven which further heats the powder by convection and infrared radiation to form a continuous foam bun. The conveyor belt is cooled as it exits the oven to cool a bottom surface of the foam product to enable the foam product to be removed from the conveyor before interior portions of the foam product have cooled. Foam adhering to the conveyor belt, after the product has been removed, is cleaned from the conveyor belt, collected and mixed with and used as a filler in the prepolymer powder used in the process. In addition the mass of the powder entering the oven and the density and degree of cure of the foam bun exiting the oven are monitored to continuously control the process.

Abstract: Apparatus for producing organic fibers by means of a centrifugal spinning process. The fiberizing disc and the molten material introduction nozzle are designed to prevent the molten material from escaping the disc prior to being fiberized. The heater for heating the material in the disc is designed to accommodate the lower melt temperature of the material to be fiberized. Also, means are provided for diverting the flow of fibers from the disc to cause the fibers to be more precisely or uniformly deposited. The fibers are substantially immediately cooled upon exiting the fiberizing disc, resulting in a fiber structure that is at least about 60% amorphous.

Abstract: A method and apparatus for forming spiral wound rolls from strips of compressible material uses a first endless belt conveyor to deliver the strips of compressible material into a winding space. As the strip enters the winding space, the strip is compressed by a compression and slider plate to the desired thickness for the layers of strip material in the spiral roll. Then, the leading portion of the strip successively contacts: an inclined, second endless belt conveyor, a compression roll, and a third endless belt conveyor which together with the first conveyor define the winding space. The second conveyor extends upwardly at an acute angle to the first conveyor and as the strip of compressible material contacts the second conveyor it maintains the strip in compression and starts to turn the strip back upon itself to form the spiral roll. The strip next contacts the compression roll which is located intermediate the first and second conveyors.

Abstract: A flexible closure system seals off and insulates openings in external building walls or roofs where structures such as ducts penetrate the walls or roofs. The flexible closure system also isolates the structures from the walls or roofs by absorbing rather than transmitting vibrations. The flexible closure system includes an exterior rubber closure sheet and an interior silicone coated fiber glass fabric closure sheet which are both coextensive with the opening, secured to the structure and wall or roof, and form a cavity which is filled with glass fiber insulation.

Abstract: A method of manufacturing a fiber glass blanket encapsulated within an air-permeable sheet on one major face and a non-porous film extending over the other major face and the two side edges. The film is applied by being wrapped around the edges of the backed blanket and preferably being heat sealed to the backing sheet. The air-permeable sheet is preferably applied to the blanket before curing of the binder in the blanket, and in a preferred method the glass fibers are deposited directly on the sheet while the sheet is supported on a collection chain.

Abstract: A method and apparatus for expanding the fiber column produced by a rotary fiber manufacturing unit and intermingling additive particles with the fibers. A rotating bell-shaped shell is mounted beneath the rotary disc of the manufacturing unit so that the lower portion of the shell is in the path of the fiber column, causing the column to be outwardly deflected. Additive particles are introduced from within or beneath the shell and are radially directed into the fiber column. Liquid binder may be introduced to the fibers and water may be directed onto the inner surface of the shell to cool the shell to prevent curing of binder coming in contact with the shell. The fibers may be glass fibers and the particles may be foamed resin, fibers or particles of various types.