Abstract: [Object] To provide a building material having excellent durability. [Solution] A building material has a convex part formed on a surface thereof, the convex part including a first lateral surface part and a second lateral surface part corresponding to the first lateral surface part. The building material is formed from a mixture containing a hydraulic material, an admixture, and a plant-based reinforcing material, and the plant-based reinforcing material at least in the convex part is distributed in the mixture with the hydraulic material and the admixture attached to the plant-based reinforcing material. A distribution of the plant-based reinforcing material in the first lateral surface part and a distribution of the plant-based reinforcing material in the second lateral surface part are substantially the same.

Abstract: Synergy between component parts of desiccants is disclosed that teaches how to augment performance of desiccants in the reduction of humidity. Single component desiccants lack the synergistic effect. The problem of single component deficiency is solved by the disclosed methods that generally engage the synergy between humidity attracting substances and polymeric substances. Synergy is observed in the improved desiccation being greater than the sum of the desiccating effects of the component parts. Resultant products are dual purpose in that they can be used both as desiccants and component parts of packaging materials.

Abstract: An integral canister filter having multiple layers, including a prefiltration layer. The prefiltration layer may filter oil and/or water from an airflow to protect downstream components. The prefiltration layer may be treated with a water and/or oil repelling or absorbing material. The second layer may be a porous membrane filter positioned downstream of the prefiltration layer. The third layer may provide structural support for the first and/or second layers.

Abstract: Formaldehyde-free binder compositions are described that include an aldehyde or ketone, a reaction product between a polyamine and an organic anhydride, and an acidic compound. The acidic compound may be an organic acid, an acidic catalyst, or both. The acidic compound is supplied in quantities that lower the pH of the binder composition to about 5 or less. The binder compositions may be used in methods of binding fiberglass and the resulting fiberglass products have an improved tensile strength due to the addition of the acidic compound.

Abstract: A water-dispersed coating composition comprising an amino resin, and a dispersion of latex polymer particles comprising from 0.1 to 2 weight percent of a multi-ethylenically unsaturated monomer and from 0.1 to 2 weight percent of (meth)acrylamide.

Abstract: Inorganic fiber paper including bio-soluble inorganic fibers which have been subjected to a heat treatment and a binder. A method for producing inorganic fiber paper including: the first step of subjecting amorphous bio-soluble inorganic fibers to a heat treatment; and the second step of making paper comprising the heat-treated bio-soluble inorganic fibers and a binder. Equipment for heating and/or thermal insulation which includes the inorganic fiber paper.

Abstract: The invention relates to asphalt emulsions comprising an asphalt component selected from the group consisting of a solvent extracted asphalt, an oxidized asphalt, and combinations thereof. The invention also relates to products made therefrom, including fibrous mats comprising a fiber component, such as glass fibers, and a binder component comprising an asphalt emulsion. The invention further relates to wet-laid processes for manufacturing fibrous mats and that employ the use of an amphoteric surfactant, which is applied to a wet fiber web prepared from a dispersion of fiber components, such as glass fibers.

Abstract: The invention discloses a cellulose or glass fibre paper for preservation of biological samples, which comprises 4-30 wt % of a hydrophilic branched carbohydrate polymer. It also discloses a method for preservation of biological samples by applying and drying them on the paper.

Abstract: A pyrophoric sheet that comprises oxidizable iron, non-combustible fibers, stiction-reducing coating where the sheet has a water content<2%.

Abstract: A wet laid basemat for an acoustical ceiling tile comprising on a dry weight basis, 50% or more mineral wool fiber, including shot, less than 9% binder, and between 5 and 20% chopped strand glass fiber, and, optionally, minor amounts of other constituents, whereby the chopped strand glass fibers serve to promote and/or maintain voids in the mat such that the dry basemat has a density of between about 7½ to about 10½ lbs. per cubic foot and an NRC substantially greater than 0.55.

Abstract: Inorganic fiber paper includes first biosoluble inorganic fibers having an average fiber diameter of 3 to 7 ?m, second biosoluble inorganic fibers having an average fiber diameter of 2 to 3 ?m, and a binder, the average fiber diameter of the second biosoluble inorganic fibers being smaller than that of the first biosoluble inorganic fibers.

Abstract: Coated and uncoated fibrous mats, and laminates containing the mat, having one or more surfactants on the fibers and binder holding the fibers together in only a portion of the thickness of the mat are disclosed. The mat contains a major portion of non-cellulosic fibers and a minor portion of cured resinous binder with the most typical fibers being glass fibers. The surfactant on the surface of the fibers causes a slurry or other liquid applied to the mat in a later process to form a board or laminate like faced gypsum board, a faced foam board, etc. to uniformly penetrate the mat to the desired distance. Also disclosed are methods of applying the surfactant(s) to the hot, coated or uncoated, mat soon after the coated or uncoated mat exits a drying oven used in the process of making, or coating, the mat.

Abstract: Methods of making the burnthrough resistant non-woven mat include forming the mat from glass fibers and at least two binders, a first binder having a vinyl component and a second binder having a strengthening component. The vinyl component may be, for example, ethylene vinyl chloride, and the strengthening component may be, for example, melamine formaldehyde. In one method, the vinyl component is added to the glass fibers by a beater addition process and the strengthening component is sprayed onto the glass fibers. The burnthrough resistant non-woven mat may be used in conjunction with an insulation blanket, and may be especially suited to use in insulating aircraft.

Abstract: Sulfopolyester thermoplastic resins provide advantages in papermaking processes and in paper products including paperboard. Improvements in wet strength and dry strength of paper products are achieved by addition of sulfopolyester thermoplastic resins and cationic strength additives during the paper making process. The use of sulfopolyester thermoplastic resins in paper products also significantly enhances the repulpability of the paper.

Abstract: The invention relates to asphalt emulsions comprising an asphalt component selected from the group consisting of a solvent extracted asphalt, an oxidized asphalt, and combinations thereof. The invention also relates to products made therefrom, including fibrous mats comprising a fiber component, such as glass fibers, and a binder component comprising an asphalt emulsion. The invention further relates to wet-laid processes for manufacturing fibrous mats and that employ the use of an amphoteric surfactant, which is applied to a wet fiber web prepared from a dispersion of fiber components, such as glass fibers.

Abstract: A coarse separator (10) for a power tool (2) is used for separating, at least partially, from an air flow (L), material particles (M) produced during operation of the power tool (2) and aspirated by a suction device (8), and includes an inlet opening (48) connectable with the suction head (6) of a suction device (8) that aspirates the particles, an outlet opening (40) for letting a purified air flow (L) out, and a lamella separator arranged between the inlet opening (48) and the outlet opening (40).

Abstract: A cementitious board and a reinforcement sheet for the board includes, a water vapor porous layer of glass fibers bonded together by a cured binder, and a hydrophilic coating material being mobile in slurry water to wet the binder coated glass fibers and spread a slurry of a cementitious compound, and the hydrophilic coating material being volatile to dissipate by evaporation at an elevated temperature at which the cementitious compound dries to form a dried cementitious board having both the cementitious compound and the binder coated glass fibers essentially free of the hydrophilic coating material.

Abstract: A multilayer fibrous nonwoven mat containing at least one transition zone comprised of a mixture of the slurries used to form the layers on each side of the transition zone, the transition zone having a thickness of at least 1 percent of the thickness of the mat. At least one of the layers contains glass fibers. The multilayer mats are particularly useful as facers on gypsum wall board, insulating foam, a wood material and a broad range of other materials. The multilayer mats are made by a method that involves using a lamella in the forming box on a wet laid mat machine, between slurries, the lamella ending a significant distance prior to a moving forming wire. The transition zone or zones provide superior interlaminar shear strength and other properties compared to multilayer fibrous mats produced on wet laid machines having two or more separate forming boxes.

Abstract: The invention relates to asphalt emulsions comprising an asphalt component selected from the group consisting of a solvent extracted asphalt, an oxidized asphalt, and combinations thereof. The invention also relates to products made therefrom, including fibrous mats comprising a fiber component, such as glass fibers, and a binder component comprising an asphalt emulsion. The invention further relates to wet-laid processes for manufacturing fibrous mats and that employ the use of an amphoteric surfactant, which is applied to a wet fiber web prepared from a dispersion of fiber components, such as glass fibers.

Abstract: Cured non-woven fibrous mats, UF-based resinous binders, asphalt coated roofing material and processes for making cured non-woven fibrous mats are provided. A cured non-woven fibrous mat comprising randomly disposed fibers bound together with a resinous adhesive is provided. The mat has a caliper of less than 30 mil, an LOI of less than 18 wt. %, a hot tensile strength of at least about 60 lbs for a sample width of 2.5 inches, and an areal weight of equal to or less than about 1.8 lbs/100 ft2.

Abstract: A thermal insulation core material and a vacuum insulation panel and a manufacturing process thereof are disclosed. The process for manufacturing a thermal insulation core material comprises: A) stirring and dispersing a mixture of glass fiber cotton and water to obtain a slurry; B) adding water and dilute sulfuric acid into the slurry to obtain a concentration of 0.1% and a pH value in a range of 2.5-3.0; C) removing residue from the slurry to obtain a qualified slurry, the residue comprising unmelted glass fibers; D) transporting the qualified slurry from a high-level tank to a head box, through which the qualified slurry flows onto a forming mesh where the qualified slurry is dehydrated to obtain a plate-shaped core material; E) transporting the plate-shaped core material into a vacuum box for compression and dehydration; and F) drying the plate-shaped core material.

Abstract: Glass-fiber composites are described that include a substrate containing glass fibers and particles in contact with the glass fiber substrate. The particles may include an alkali-metal containing compound. In addition, batteries are described with an anode, a cathode, and an electrolyte. The cathode may include alkali-metal containing nanoparticles in contact with glass fibers. Also describe are methods of making a glass-fiber composite. The methods may include the steps of forming a wet laid non-woven glass fiber substrate, and contacting alkali-metal containing particles on the substrate.

Abstract: Provided is thermosetting urea-formaldehyde (UF) resin binder formulation, preferably prepared with modified styrene-maleic anhydride. The formulation has a viscosity in the range of from 3 to 10 cP and a surface tension of from 35 to 50 mN/m, and is prepared using a UF resin composition exhibiting a viscosity of from 175 to 250 cP.

Abstract: Provided is thermosetting urea-formaldehyde (UF) resin binder formulation modified with a thickener. The formulation preferably has a viscosity in the range of from 3 to 10 cP and a surface tension of from 35 to 50 mN/m, and is preferably prepared from a binder composition exhibiting a viscosity of from 175 to 250 cP.

Abstract: Methods for improving the tear strength in non-woven chopped strand mats during the manufacturing process of the mats are provided. In particular, the tear strength of the mat can be improved as the mat is being formed in response to current manufacturing conditions by the addition of a water soluble polyol, such as polyvinyl alcohol, or a cationic dispersant to the binder seal pit. Alternatively, a cationic dispersant may be added to the white water chest to improve the tear strength of the chopped strand mat. The addition of polyvinyl alcohol or a cationic dispersant to the binder seal pit results in an immediate or nearly immediate improvement of the tear strength of the chopped strand mat. Both the polyvinyl alcohol and the cationic dispersant can be utilized to improve the tear strength of a chopped strand mat regardless of the type of binder or components in the white water.

Abstract: A composite sheet material, useful as a component of roofing shingles, and a process of making same, which includes a glass fiber web bound with a thermosetting resin which includes a fatty acid amide having the structural formula RCOONH2, where R is a C8-C25 alkyl.

Abstract: This invention is to provide a sheet product that is excellent in moisture absorption amount, moisture absorption speed and moisture release speed and is capable of keeping a powder from falling off and that can have a large content of a moisture adsorbent, and the sheet product of this invention contains (a) a moisture adsorbent formed of a tubular or fibrous metal oxide, (b) a cellulosic fibrillated fiber, and (c) an organic fiber having a fineness of 0.01 dtex to 0.45 dtex and is characteristically produced by a paper-making method.

Abstract: Sulfopolyester thermoplastic resins provide advantages in papermaking processes and in paper products including paperboard. Improvements in wet strength and dry strength of paper products are achieved by addition of sulfopolyester thermoplastic resins and cationic strength additives during the paper making process. The use of sulfopolyester thermoplastic resins in paper products also significantly enhances the repulpability of the paper.

Abstract: The invention includes a method and system for generating electricity using a drive for the electrical generator that is powered by an engine that uses high pressure hot gases produced by combustion of a fuel and an oxygen bearing gas, using at least a portion of the electricity generated to power manufacturing plant equipment and using the waste hot exhaust gases from the heat engine, such as a gas turbine, with or without a heat exchanger, in an oven in which the mat is carried through continuously on a belt, drum or with other conventional means to dry the wet fibrous mats. Optionally the fibrous mats can contain a binder and the hot waste gases can be optionally used to cure a binder.

Abstract: This specification is generally related to reinforced, parchmented paper, composite, reinforced parchmented paper and methods of manufacture thereof. The reinforced, parchmented paper may be used to form a sausage casing.

Abstract: A flexible fibrous material comprises inorganic fibers and a binder and methods of making the same. The binder comprises at least one of: a first organic polymer having anionic groups and a flocculent, the flocculent comprising a second organic polymer having cationic groups; or a reaction product of the first organic polymer and the flocculent. Flexible fibrous material according to the present invention may be used as components in certain pollution control devices.

Abstract: Provided is thermosetting urea-formaldehyde (UF) resin binder formulation, preferably prepared with modified styrene-maleic anhydride. The formulation has a viscosity in the range of from 3 to 10 cP and a surface tension of from 35 to 50 mN/m, and is prepared using a UF resin composition exhibiting a viscosity of from 175 to 250 cP.

Abstract: Provided is thermosetting urea-formaldehyde (UF) resin binder formulation, preferably prepared with modified styrene-maleic anhydride. The formulation has a viscosity in the range of from 3 to 10 cP and a surface tension of from 35 to 50 mN/m, and is prepared using a UF resin composition exhibiting a viscosity of from 175 to 250 cP.

Abstract: A shake mechanism is provided for shaking a breast roll at the wet end of a conventional glass mat machine. A method of producing a glass fiber mat is provided, the method involving combining glass fibers with a dispersant medium to form an aqueous slurry, and shaking the aqueous slurry to redistribute fibers from areas of high concentration to areas of lower concentration. A glass fiber mat production line is also provided, the production line comprising a slurry formation station for combining glass fibers with a dispersant medium to form an aqueous slurry, and a hydroformer for shaking the slurry to redistribute glass fibers from areas of high concentration to areas of lower concentration.

Abstract: Making mats using glass fibers having a diameter of about 13+/?3 microns, bound with a binder formed from a homopolymer or a copolymer of polyacrylic acid and a polyol produces fibrous nonwoven mats having high tensile strength and also an unexpected high flame resistance considering the amount of oxygen in the binder. Mats of the present invention pass the National Fire Protection Association's (NFPA) Flammability Test. Tabor stiffness of these mats is greater than about 40, preferably greater than about 50 and most preferably greater than about 55. Air permeability of the mats is preferably within the range of about 500 to about 800 CFM/sq. ft. Methods of making the mat are also disclosed.

Abstract: A gypsum board which comprises a set gypsum core sandwiched between and faced with fibrous mats, wherein a free surface of one of said mats is pre-coated with a combination of a mineral pigment, optionally an inorganic adhesive binder and an organic binder, preferably a hydrophobic, UV resistant polymer latex adhesive binder applied to said surface as an aqueous coating composition, said aqueous coating composition upon drying and setting providing a pre-coated mat satisfying certain morphology requirements.

Abstract: Methods for improving the tear strength in non-woven chopped strand mats during the manufacturing process of the mats are provided. In particular, the tear strength of the mat can be improved as the mat is being formed in response to current manufacturing conditions by the addition of a water soluble polyol, such as polyvinyl alcohol, or a cationic dispersant to the binder seal pit. Alternatively, a cationic dispersant may be added to the white water chest to improve the tear strength of the chopped strand mat. The addition of polyvinyl alcohol or a cationic dispersant to the binder seal pit results in an immediate or nearly immediate improvement of the tear strength of the chopped strand mat. Both the polyvinyl alcohol and the cationic dispersant can be utilized to improve the tear strength of a chopped strand mat regardless of the type of binder or components in the white water.

Abstract: The present invention provides a wet-spun non-woven fabric composed of inorganic fibers containing bundled inorganic fibers and a binder component for binding the fibers, wherein the average number of the fibers in each bundle is 1.5 to 20 and the average Z/X value represented by the following formula in the cross section of the non-woven fabric is 0.9 or below: (number of adjacent fibers in the thickness direction in each bundle)/(number of adjacent fibers in the plane direction in each bundle)=Z/X, and a method for producing a wet-spun non-woven fabric, which comprises the steps of dispersing inorganic fibers in an aqueous medium in the presence of an anionic dispersion stabilizer, adding a cationic compound to the obtained fiber dispersion to bundle the fibers and thereby preparing a fiber dispersion containing the resultant fiber bundles, making a sheet from the obtained fiber dispersion containing the fiber bundles by wet method and applying a binder to the obtained sheet.

Abstract: New coated nonwoven fibrous mats having properties particularly suited for a facer on gypsum wallboard and other substrates and in laminates of various types, and the method of making the coated mat is disclosed. The mat preferably contains a major portion of glass fibers and a minor portion of a resinous binder. The coating is preferably permeable and reduces fiber dust and abrasion experienced in the past with relatively coarse, relatively inexpensive glass fibers in the mat. Contrary to previous coating methods, the coated fibrous mat is made in-line on a wet mat forming production line by applying a wet foam binder onto a wet, fibrous web followed by drying and curing in-line.

Abstract: The process according to the invention comprises: a step in which chopped filaments and discontinuous PVOH fibers are dispersed in a process water, followed by a step in which a bed is formed in a forming device by passing the dispersion over a forming cloth through which the process water is drained, the filaments and fibers being retained on said cloth, followed by a heat treatment step in a stoving device. The PVOH fibers impart rigidity to the bed of fibers being formed. This process provides a veil with a very high tensile strength for low proportions of binder.

Abstract: A non-woven mat of inorganic fiber is disclosed having a substance which is lower at the edges of the mat than in the remainder of the mat. Apparatus for making such a mat includes: a source of a slurry of inorganic fiber in a liquid; a forming wire disposed to move past the source, the liquid passing through the forming wire to deposit the inorganic fiber on the forming wire; a mask across a part of the width of the forming wire to hinder passage of the liquid through the forming wire over the part, the effectiveness of the mask varying in the direction of movement of the forming wire past the slurry source.

Abstract: A shoe press 1 for applying pressure to a fibrous web W has a concave press shoe 2 adapted to be juxtaposed with a backing member 6. A plurality of articulated hydraulic actuators 5 are spaced apart in the cross-machine direction along the press shoe 2 to press the shoe toward a backing member. The actuators have first and second cylinders and a piston. The pistons and the cylinders have spherical surfaces adapted to be able to cooperate with each other.

Abstract: A head-box for depositing slurry upon a moving web including a main metering roll, a companion roll disposed in closely spaced relation to the metering roll and a vibrating gate which forms a nip between the metering roller and the gate. The nip is arranged to retain a supply of the slurry, and the rolls are driven so slurry retained in the nip progresses over an upper outer peripheral surface of the metering roll to be deposited upon the web. Also, preferably included is a doctor blade disposed in operational relationship to the metering roll for directing the slurry downwardly from the outer metering roll surface to a point above the surface of a carrier for a fiberglass layer upon which the slurry layer is deposited. The vibrating gate and doctor blade may be pivotally mounted to either side of the surfaces of the head-box.

Abstract: Resinous coatings can be applied to glass, exhibiting improved adhesion thereto, by including in the coating composition a sulfonic acid derived compound such as 2-acrylamido-2-methylpropanesulfonic acid or a salt thereof. Alternatively, the glass can be first coated with the sulfonic acid derived compound and thereafter the film-forming resin applied.

Abstract: Wet laid, nonwoven, fibrous mats suitable for making MERV 6 or higher, filters, and methods of making the nonwoven mats filter media are disclosed. The mats include a blend comprising a major portion of glass fibers, a minor portion of man-made polymer fibers, such as polyester fibers and about 0-30 wt. percent of chemically cross linked bleached Kraft pulp the fibers, and optionally fully bleached softwood Kraft pulp, the fibers being bound together with a cured binder having a Tg in the range of about minus 30 to about 50 degrees C. The mats are pleated prior to assembling the filter in conventional manner. The only fibrous mat in the filters is wet laid fibrous nonwoven mat and the pleated filter media needs no other means of support in the filter frame.

Abstract: A binderless glass fiber mat suitable for use as a separator for valve regulated (“recombinant”) lead acid (“VRLA”) batteries is disclosed. The separator is produced by a dry process by collecting the fibers from fiberizing apparatus, without subjecting them to a wet paper making or other post forming process, and selecting portions of the collected fibers which are sufficiently uniform in thickness and grammage for use as battery separators. The fibers can be entwined to produce a superior separator material. Additives can be introduced during the collection process to enhance the properties of the separator. A battery comprises at least one stack of alternating positive and negative plates, with the separator between adjacent plates. Separators according to the invention are significantly more resilient and have longer fibers than otherwise identical separators made from different samples of the same glass fibers, but by a conventional wet paper making process.

Abstract: A new foam coated nonwoven fibrous mat having properties particularly suited for a facer on gypsum wallboard, laminates made therefrom and the method of making the mat is disclosed. The mat preferably contains a major portion of glass fibers and a minor portion of a resinous binder. The foam coating is permeable and reduces fiber dust and abrasion experienced in the past with relatively coarse, relatively inexpensive glass fibers in the mat. Contrary to previous methods, the foam coated fibrous mat is made in-line on a wet mat forming production line by applying a wet foam binder onto a wet, fibrous web followed by drying and curing in-line.

Abstract: A glass adhesion composition containing a copolymer having an acid and a substituted amide, silanol, or amine oxide functionality. The substituted amide, silanol, or amine oxide functionality provide excellent adhesion of the copolymer to glass, silica, sand and other silicon-based substances. The copolymer is useful as a fiberglass binder, and also useful in providing protective coatings on glass sheets. A fiberglass sizing composition is also provided having a copolymer that includes at least one acid group derived from at least one acid monomer, a hydrophobic comonomer, and a crosslinker.

Abstract: A method of forming a molding mat formed bundles of reinforcing fibers and bonding materials is provided. The reinforcing fibers are preferably wet use chopped strand glass fibers (WUCS). The bonding materials may be any thermosetting material having a melting point less than the reinforcing fiber. The molding mat may be formed by partially opening the wet use chopped strand glass fibers and filamentizing the bonding materials, blending the reinforcement and bonding fibers, forming the reinforcement and bonding fibers into a sheet, and bonding the sheet. During bonding, the sheet is heated to a temperature above the melting point of the bonding fibers but below the temperature of the glass fibers. The molding mat thus formed may be used as a reinforcement material in sheet molding compounds.

Abstract: A composite sheet material, useful as a component of roofing shingles, and a process of making same, which includes a glass fiber web bound with a thermosetting resin which includes a fatty acid amide having the structural formula RCOONH2, where R is a C8–C25 alkyl.