Abstract: A non-woven fabric includes flame retardant fibers and binding fibers mixed with the flame retardant fibers. The binding fibers set a thickness of the fabric. Application of a flame to the fabric causes the binding fibers to degrade and the flame retardant fibers to expand such that the thickness of the fabric increases, for example by a factor of two or more. The non-woven fabric can be used in a wide variety of different applications. For example, the non-woven fabric may be used to make seals of a drier, heat shields, fire barriers, and/or vents.

Abstract: An enclosure for a recessed light in an attic is transformable between a first configuration in which the enclosure is flat and a second configuration in which the enclosure defines a housing. The housing has an opening at a bottom end for receiving the recessed light and an upwardly-facing surface opposite the opening. The upwardly-facing surface has a variable height relative to the bottom end.

Abstract: Appliance (w) having a housing, a moveable tub (T) member inside the housing, and a dampening portion is provided. The housing includes, at least one side wall and the dampening portion disposed at least partially between the moveable tub member and the at least one side wall. The dampening portion includes, for example, a resilient material having at least one surface extending at least partially along the side wall or tub member. Methods of shipping and operation dampening an appliance are also disclosed.

Abstract: Various embodiments of apparatuses and methods relating to appliances are provided. In one embodiment, an appliance having a housing, one or more moveable components inside the housing, a drive assembly, and a dampening portion is provided. The housing includes, for example, at least one side wall and the dampening member is disposed at least partially between the drive assembly and the at least one side wall. The dampening portion includes, for example, a resilient material having at least one surface extending at least partially along the side wall and the drive assembly. The dampening member is configured to limit movement of the drive assembly during shipping and handling to prevent damage to the appliance. The dampening member stays with the appliance after shipping and handling to enhance performance of the appliance, protect the moveable component, or both.

Abstract: An insulation element is provided for installation in a gap of thickness G provided between two objects. The insulation element includes a body made from a thermoplastic polymer material. The body has a first face, a second face and a thickness defined between the first and second faces. The body is characterized by a semi permanently pre-installation thickness T1 where T1 is less than G. The body swells upon heating to a thickness T2 where T2 is greater than or equal to G so that the insulation element bridges the gap, engages the two objects and provides a spring rate of between 4.0 and 275.0 grams per square inch.

Abstract: An expandable insulation blanket includes a body of insulation material having a first edge and a second edge wherein the first and second edges are opposite one another. A first slit defines a first hinge point between a first end of the first slit and the first edge, a second hinge point between a second end of the first slit and the second edge and a third hinge point between a third end of the first slit and the first edge. A first hinge body is outlined by the first slit, the first hinge point and the third hinge point. A second slit extends across the first hinge body and defines a fourth hinge point between the second slit and the first slit. When expanded the insulation body includes a substantially triangular shaped opening.

Abstract: A siding panel assembly includes an ornamental facing and a first insulation layer made from fibrous insulating material. That fibrous insulating material includes polymer fibers and glass fibers, polymer fibers, natural fibers and mixtures thereof. A method for making the siding panel assembly includes the steps of cutting a groove in and molding a first surface of a sheet of the insulation layer to match in profile a concavity in the ornamental facing and assembling the insulation layer and the ornamental facing.

Abstract: Washing machine shipping systems that inhibit movement of one or more moveable component with respect to one or more stationary component of a washing machine during shipping and handling of the washing machine. The shipping systems engage a moveable component, such as a motor or a basket, to substantially prevent side-to-side and/or vertical movement of the moveable component with respect to a stationary component, such as a cabinet or frame, during shipment. In an exemplary embodiment, the shipping system is removed from the washing machine for installation of the washing machine at the consumer's residence. In some exemplary embodiments, the washing machine system engages an outer surface of an external rotor of a motor to substantially prevent side-to-side and/or vertical movement of the motor with respect to the washing machine cabinet.

Abstract: Densified non-woven materials having acoustic and thermal properties are provided. The non-woven material is formed of a thermoplastic material or fibers and a thermoplastic material. The fibers may be an organic, inorganic, or thermoplastic fiber and are desirably devoid of conventional sizing compositions. The densified portion of the non-woven material is formed by applying a moisture additive and subsequently applying heat. Heating the non-woven material causes the water in the moisture additive to turn to steam, which causes a molecular change in the polymer based thermoplastic material(s) of the non-woven material that was treated with the moisture additive. The moisture additive is preferably water, but may include a dilute alkali, a dilute acid, or additives to enhance surface, fire, or mold release characteristics. The water additive may be utilized to surface treat, partially treat, or completely treat the air-laid mat to achieve desired acoustic or thermal properties and/or stiffness.

Abstract: A shipping capsule for an electrical appliance comprises a blanket of insulating material and a layer of stretch wrap. Together these materials function as a durable shipping container eliminating the need for a corrugated cardboard outer carton currently in use. The invention further includes a method of reducing shipping costs and shipping waste associated with shipping an electrical appliance. The method includes the steps of covering at least a portion of the electrical appliance with insulation material that will remain with the electrical appliance after installation and providing a layer of stretch wrap over the insulation material whereby the combination of insulation material and stretch wrap form a shipping capsule.

Abstract: In accordance with embodiments of the present invention described herein, a shipping capsule is provided comprising a lattice blanket that is expandable and contractible so as to allow size adjustability and a covering layer. In one particularly embodiment, the lattice blanket forms an expandable and contractible sleeve that is received around a product being shipped in the shipping capsule and the covering layer is a polymer film such as stretch wrap. Methods of shipping and packaging a product are also disclosed.

Abstract: A building product includes a thermoplastic polymer mat impregnated with a cementitious material. The thermoplastic polymer mat has a front face and a rear face. A stiffening layer is laminated to the rear face of the thermoplastic polymer mat. A finishing layer covers the front face of the thermoplastic polymer mat. A method of producing the building product is also provided.

Abstract: A blanket is provided including a first panel of material having a honeycombed portion that is expanded to form a second, projecting panel from the first panel material. The invention also includes a method of reducing the material needed to construct a multipanel structure. The method includes the steps of providing a first panel of material; honeycombing a portion of that first panel and expanding the honeycombed portion of the first panel to form a second panel projecting from the first panel. Advantageously, the second panel is formed from material of the first panel and no additional material is required.

Abstract: An enclosure for a recessed light in an attic is transformable between a first configuration in which the enclosure is flat and a second configuration in which the enclosure defines a housing. The housing has an opening at a bottom end for receiving the recessed light and an upwardly-facing surface opposite the opening. The upwardly-facing surface has a variable height relative to the bottom end.

Abstract: A roofing shingle comprising a mat having regions of various thicknesses. A layer of asphalt-based material coats the mat and a layer of granules is deposited on the asphalt-coated mat. The variations in the thickness of the regions of the mat give the shingle differences in thickness corresponding to the thickness variations in the regions of the mat, thereby giving the shingle an appearance of depth.

Abstract: A dishwasher tub includes a main body having opposing side walls that are interconnected by a rear wall, all formed from a multi-layered composite material. A cap member is joined atop the opposing side and rear walls, a base member is joined to lower edge portions of the opposing side walls and rear wall, and a frontal halo member is mounted between the cap and base member to define an overall washing chamber having a front opening. Preferably, the multi-layered composite material includes an inner stainless layer, a rigid layer and an outer protective layer, such as a layer of stainless steel, a rigid polyester mat, and a protective layer of hard plastic or aluminum foil. The outer layer also preferably serves as a shipping container for the dishwasher, enabling components of the dishwasher to be transported to a designated location for final assembly.

Abstract: An insulation element is provided for installation in a gap of thickness G provided between two objects. The insulation element includes a body made from a thermoplastic polymer material. The body has a first face, a second face and a thickness defined between the first and second faces. The body is characterized by a semi permanently pre-installation thickness T1 where T1 is less than G. The body swells upon heating to a thickness T2 where T2 is greater than or equal to G so that the insulation element bridges the gap, engages the two objects and provides a spring rate of between 4.0 and 275.0 grams per square inch.

Abstract: A siding panel assembly includes an ornamental facing and a first insulation layer made from fibrous insulating material. That fibrous insulating material includes polymer fibers and glass fibers, polymer fibers, natural fibers and mixtures thereof. A method for making the siding panel assembly includes the steps of cutting a groove in and molding a first surface of a sheet of the insulation layer to match in profile a concavity in the ornamental facing and assembling the insulation layer and the ornamental facing.

Abstract: The instant invention includes a flexible fire-resistant thermally insulated composite structure designed in some embodiments to pass through an opening. The structure may be self-supporting due to the stiffness of various layers, and battens may contribute to the self-supporting capacity of the structure. The flexible composite structure may have a collapsed transit configuration, allowing the structure to be compressed to more easily pass it through an opening, a rotable attachment to allow the structure to rotate away from the opening, and a releasable attachment for attaching the structure around an opening periphery. In another embodiment, the structure may also include a bottom and such a structure could provide shelter in conditions ranging from ambient environmental conditions to the extreme heat of certain fires. The insulative structures of the instant invention are not limited to embodiments designed to rest on generally horizontal surfaces.