An improved apparatus for curing fibrous insulation material includes an oven, and a lower conveyor mounted to travel through the oven. The lower conveyor includes a plurality of flights having a support surface for supporting fibrous insulation material. An upper conveyor is mounted to travel through the oven and has a plurality of flights opposite the flights of the lower conveyor. Each flight of the upper conveyor includes a support surface. The upper and lower conveyors are arranged to press the fibrous insulation material between the respective support surfaces as the conveyors carry the fibrous insulation material through the oven. A plurality of molding members are configured to mold a shape into a surface of the fibrous insulation material, and are releasably retained on the flights by a plurality of retaining members. The retaining members are automatically releasable when the flights are moving, such that the releasing of the retaining members unlocks the molding members from the flights.

A method of forming a box-like acoustical substrate is provided. Portions of an acoustical substrate having a decorative surface are compressed to form a flange, a first compressed region, a second compressed region, and a third compressed region. First, second, central, and third uncompressed regions are positioned respectively adjacent to the compressed regions. A left first surface and a right first surface of the acoustical substrate may be folded toward the back surface of the substrate until the second compressed region and the third compressed regions are flush with the central uncompressed region. An outer portion of the left surface may then be folded towards the back surface until the flange is flush with the right edge. The acoustical product may be used as an acoustical trap or duct. When the acoustical product is utilized as a duct, an air impermeable sheet may be positioned on the external surface.

Provided is an air duct suitable for conducting a flow of air. The air duct includes a central layer formed from a fiber glass. The central layer has an inner surface and an outer surface. The air duct also includes a liner layer arranged adjacent to the inner surface of the central layer. The liner layer is formed from an organic material and is substantially free of fiber glass, or is formed from polyester and rayon. The central layer and liner layer are arranged to define a channel for conducting a flow of air.

A faced fibrous insulation having a mat facing on one or more surfaces of a fibrous insulation material is provided. The mat facing provides improved surface quality, high and controlled adhesion, and is easily manufactured. The mat facing of the present invention includes a pre-applied adhesive that is heat activated to provide adhesion to the fibrous insulation. The mat facing may be input into the glass fiber forming section of a fibrous insulation production line. Alternatively, the mat facing may be applied to the uncured pack prior to curing or applied to the cured fibrous insulation.

A method of making an insulation product is provided. An uncured or partially cured mat containing randomly oriented inorganic fibers and a heat curable binder agent is formed. The mat has a pair of side portions and a first and second major surfaces thereon. A nonwoven sheet is applied to the first major surface. The nonwoven sheet comprises randomly oriented glass fibers. The uncured or partially cured mat is heated with the nonwoven sheet, wherein the mat is cured to form a low density mat and the nonwoven sheet is bonded to the first major surface by the heat curable binder agent.