Abstract: A method of forming a needled fiberglass glass insulation product is provided. The formation of the needled insulation product may be conducted in a process in which the fibers are formed, a binder is sprayed onto the fibers, the fibers are collected and formed into a fiberglass pack, the fiberglass pack is passed through the oven, and at least partially cured insulation blanket is passed through a needling apparatus. The reduction in thickness and increased density caused by the needling process permits the production of lower thickness and high density insulation products.

Abstract: A method of forming a needled fiberglass glass insulation product is provided. The formation of the needled insulation product may be conducted in a process in which the fibers are formed, a binder is sprayed onto the fibers, the fibers are collected and formed into a fiberglass pack, the fiberglass pack is passed through the oven, and at least partially cured insulation blanket is passed through a needling apparatus. The reduction in thickness and increased density caused by the needling process permits the production of lower thickness and high density insulation products.

Abstract: A method of forming a needled rotary fiberglass glass insulation product is provided. The formation of the needled insulation product may be conducted in a continuous in-line process in which the fibers are rotary formed, a binder is sprayed onto the hot fibers, the fibers are collected onto a conveyor and formed into a fiberglass pack, the fiberglass pack is passed through the oven, and the cured insulation blanket is passed through a needling apparatus. The reduction in thickness and increased density caused by the needling process permits the production of lower thickness and higher density insulation products. In particular, the needled insulation product may have a thickness of less than about 0.75 inches and a density from about 1 pcf to about 10 pcf. The needled insulation product may be utilized in household appliances, water heaters, and HVAC equipment.

Abstract: Insulation for high temperature applications includes glass fibers having an average diameter of between about 2.7 to about 3.8 microns. In one possible embodiment the insulation includes a polyacrylic acid binder. Such insulation has about 98 weight percent glass fibers and about 2 weight percent binder.

Abstract: A method of forming a needled rotary fiberglass glass insulation product is provided. The formation of the needled insulation product may be conducted in a continuous in-line process in which the fibers are rotary formed, a binder is sprayed onto the hot fibers, the fibers are collected onto a conveyor and formed into a fiberglass pack, the fiberglass pack is passed through the oven, and the cured insulation blanket is passed through a needling apparatus. The reduction in thickness and increased density caused by the needling process permits the production of lower thickness and higher density insulation products. In particular, the needled insulation product may have a thickness of less than about 0.75 inches and a density from about 1 pcf to about 10 pcf. The needled insulation product may be utilized in household appliances, water heaters, and HVAC equipment.

Abstract: A needled rotary fiberglass glass insulation product including (1) a plurality of single component rotary glass fibers where at least a portion of the fibers are entangled and mechanically bonded and (2) a binder applied to at least a portion of the glass fibers is provided. The needled insulation product may have a thickness less than about 0.75 inches and a density from about 1 pcf to about 10 pcf. In exemplary embodiments, the thickness may be from about 0.25 to about 0.5 inches and the density may be from about 3 pcf to about 5 pcf. Additionally, a fire-retarding layer may be positioned on the insulation product. The needled rotary glass insulation product has a thermal conductivity that is equivalent to or less than conventional, lofty insulation blankets and may be utilized in household appliances, water heaters, and HVAC equipment.

Abstract: Insulation for high temperature applications includes glass fibers having an average diameter of between about 2.7 to about 3.8 microns. In one possible embodiment the insulation includes a polyacrylic acid binder. Such insulation has about 98 weight percent glass fibers and about 2 weight percent binder.

Abstract: A rotary fiberglass needled glass insulation product is provided. The formation of the needled insulation product may be conducted in a continuous in-line process in which the fibers are rotary formed, a binder is sprayed onto the hot fibers, the fibers are collected onto a conveyor and formed into a fiberglass pack, the fiberglass pack is passed through the oven, and the cured insulation blanket is passed through the needling apparatus. The needled insulation product may have a thickness of less than about 0.75 inches. The reduction in thickness and increased density caused by the needling process permits the production of lower thickness and higher density final insulation products. Thin insulation products made in accordance with the present invention can be manufactured using current manufacturing lines, thereby saving time and money. The needled insulation product may be utilized in household appliances, water heaters, and HVAC equipment.

Abstract: A method for translating a decorative surface of an acoustic substrate to an edge of the finished acoustical product is provided. A portion of an acoustical substrate having a decorative surface on a first side is compressed to form a void having at least one adjacent region of compressed material having an increased density. The acoustical substrate is then manipulated to close the void and place at least a portion of the decorative surface on a side of the substrate. The manipulation of the acoustical substrate also places the region of compressed material at the edges of the acoustical substrate, thereby reinforcing the edges of the acoustical product. A decorative non-woven acoustic panel that has at least one peripheral edge with a density greater than the density of the main body is also provided.

Abstract: The present invention provides a mat adapted to reinforce a thermosetting matrix material to form a composite, composites formed therefrom, and methods related thereto. The mat includes a primary, supporting layer having a plurality of randomly oriented essentially continuous glass fiber strands. The primary layer has about 1 to about 10 weight percent of the mat on a total solids basis. The mat also includes a secondary layer positioned upon and supported by a surface of the primary layer, the secondary layer including a plurality of glass fiber strands. The mean average length of the glass fiber strands of the secondary layer ranges from about 20 to about 125 millimeters. The strands of the primary layer are entangled with the strands of the secondary layer by needling the primary layer and the secondary layer together.

Abstract: A needled mat adapted to reinforce a thermoplastic matrix material to form a composite, the mat including: (a) a plurality of discontinuous glass monofilaments present in an amount ranging from at least about 30 weight percent to about 99 weight percent of the mat on a total solids basis and having a filament coating composition thereon which is compatible with a thermoplastic matrix material; and (b) a plurality of discontinuous glass fiber strands and having a strand coating composition thereon which is compatible with the thermoplastic matrix material, wherein the glass monofilaments and glass fiber strands are essentially uniformly distributed throughout the mat.