Faced fibrous insulation

Abstract

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

Description

CROSS REFERENCE TO RELATED APPLICATIONS [0001] This application is a Continuation-in-Part of U.S. patent application Ser. No. 10 / 858,666, entitled “Faced Fibrous Insulation” (Inventor Roy E. Shaffer), hereby incorporated by reference in its entirety.TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION [0002] The present invention relates to faced fibrous insulation. The faced insulation of the present invention provides improved thermal, acoustical properties as well as improved handling during installation of residential insulation. The faced insulation of the present invention also provides improved surface qualities for encapsulated insulation and improved facing adhesion qualities for during installation. BACKGROUND OF THE INVENTION [0003] Faced fibrous insulation is used in a variety of thermal, acoustical and residential applications. Conventional insulation typically include a facing layer adhered to a fibrous insulation layer. The facing layer is useful in preventin...

AI Technical Summary

Benefits of technology

[0012] The present invention provides a facing on one or more surfaces of a fibrous insulation material. The facing provides improved surface quality, high and controlled adhesion, and is easily manufactured. The facing of the present invention includes a pre-applied adhesive that is heat activated. The facing may be input into the glass fiber forming section of a fibrous insulation production line. Alternatively, the facing may be applied to an uncured pack prior to curing or applied to cured fibrous insulation. The facing may be applied to one or more surfaces of the insulation and may be applied in conjunction with a standard vapor barrier facing such as a kraft asphalt facing. It is an object of the present invention to provide a facing on one or more surfaces of a fibrous insulation material to provide improved surface quality, high and controlled adhesion, and is easily processed. It is a further object of the present invention to provide a faced fibrous insulation that may be reliably manufactured through a wide variety of process parameters without adversely affecting the surface quality or the adhesion of the facing to the fibrous insulation.

Problems solved by technology

However, this method tends to result in poor adhesion of the mat facing to the fibrous insulation due to the inherent difficulty in controlling the amount of binder at the surface.

The method also tends to increase manufacturing costs because the process of curing the fibrous insulation must be optimized to provide a suitable bond between the mat facing and the glass fibers rather than optimizing for improved efficiency in curing the binder in the pack of fibers.

This method tends to saturate the fibers on the surface of the finished board that causes a brashy surface on the fibrous insulation due to the fiber ends that are fixed in place by the high amount of binder at the surface.

The high amount of binder on the mat also may cause discoloration of the mat facing causing a spotty or mottled surface on the fibrous insulation.

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