Abstract: Apparatus for impregnating surfaces, including edge surfaces, of fiberglass insulation batts with synthetic fibers, comprising a conveyor for advancing the batts in a common direction and, initially, in a side-by-side orientation. Separators thereafter interrupt the side-by-side orientation, exposing the edges of the batts. Extrusion heads located in the area of side edge exposure impregnate the exposed edges with synthetic fibers while other extruder heads apply synthetic fibers to one or optionally both of the top and bottom surfaces.

Abstract: A method of directing extruded synthetic fibers toward at least one surface of a mineral fiber insulation batt, and corresponding apparatus and resulting product. In certain embodiments, a row of extrusion heads is provided for directing extruded synthetic fibers (e.g. fibers including ethyl vinyl acetate or EVA) toward a surface(s) of the batt(s) to be impregnated with same. Optionally, extrusion heads may be provided all around the batts so as to impregnate substantially all surfaces thereof with the extruded synthetic fibers. As the fibers exit the heads, they are hit with pressurized heated air streams which cause them to go into an insipid spin which increases directional tensile strength of the resulting batt in all directions. In certain embodiments, every other batt of a plurality of batts passes over an elongated member which extends over top of the conveyor in order to more efficiently impregnate edge surfaces of the batts.

Abstract: A method of directing extruded synthetic fibers toward at least one surface of a mineral fiber insulation batt, and corresponding apparatus and resulting product. In certain embodiments, a row of extrusion heads is provided for directing extruded synthetic fibers (e.g. fibers including ethyl vinyl acetate or EVA) toward a surface(s) of the batt(s) to be impregnated with same. optionally, extrusion heads may be provided all around the batts so as to impregnate substantially all surfaces thereof with the extruded synthetic fibers. As the fibers exit the heads, they are hit with pressurized heated air streams which cause them to go into an insipid spin which increases directional tensile strength of the resulting batt in all directions. In certain embodiments, every other batt of a plurality of batts passes over an elongated member which extends over top of the conveyor in order to more efficiently impregnate edge surfaces of the batts.

Abstract: A method of manufacturing/making mineral fiber (e.g. fiberglass) thermal insulation batt is disclosed wherein a base mineral fiber layer is impregnated with a two-layer layering system so as to produce a batt which is substantially vapor impermeable with a perm vapor rating less than about one. The first layer of the layering system is of a low melt material while the second layer is of a high melt material, the first layer being sandwiched between the base insulating layer and the second layer, and functioning to bond the layering system to the base. In certain embodiments, the first layer includes quick blooming ethyl vinyl acetate (e.g. from about 10-25% by weight) and a low density (e.g. 22-26 lbs. per cubic foot) polyethylene, and the second layer includes high density (e.g. 28-38 lbs. per cubic foot) polyethylene. The resulting insulation batt is vapor impermeable, less susceptible to cold-crack, easier to manufacture, fire retardant, more durable, and easier to handle.

Abstract: A mineral fiber (e.g. fiberglass) thermal insulation batt is disclosed wherein a base mineral fiber layer is impregnated with a two-layer layering system so as to produce a batt which is substantially vapor impermeable with a perm vapor rating less than about one. The first layer of the layering system is of a low melt material while the second layer is of a high melt material, the first layer being sandwiched between the base insulating layer and the second layer, and functioning to bond the layering system to the base. In certain embodiments, the first layer includes quick blooming ethyl vinyl acetate (e.g. from about 10-25%) and a low density (e.g. 22-26 lbs. per cubic foot) polyethylene, and the second layer includes high density (e.g. 28-38 lbs. per cubic foot) polyethylene. The resulting insulation batt is vapor impermeable, less susceptible to cold-crack, easier to manufacture, a better fire retardant, more durable, and easier to handle.

Abstract: A method and apparatus for molding foamed materials for use as carpet underpadding is disclosed. In one aspect, the process and apparatus involves pulling a sheet of a foamed material through a first set of pull rolls at a first pull rate followed by heating the foamed material in order to decompose blowing agent present in the sheet thereby causing the sheet to expand or thicken. The heated sheet is then pulled through a second set of pull rolls which pull the heated sheet at a faster rate than the first pull rate in order to stretch the expanded sheet so that it returns to its original thickness. The surface of one of the rolls of the second set is provided with dimples or indentations uniformly spread on the surface thereof for producing protrusions on one side of the heated sheet.

Abstract: A flexible insulating laminate including a heat insulating flameproof, soft, resilient and compressible polyester blanket bonded directly at one surface to a polymer surface of a vapor barrier formed by a metallized moisture impermeable, polymer film. The bond is formed by fusion of a heat softened surface of the polymer film and a heat softened surface of the blanket. There is a stiff, high tensile strength bonding layer between the blanket and the barrier. The preferred blanket is composed of heat fused polyester fibres.