U.S. patent application number 12/167285 was filed with the patent office on 2010-01-07 for pre-applied waterless adhesive on hvac facings with sealable flange.
Invention is credited to Jerry M. Parks.
Application Number | 20100000170 12/167285 |
Document ID | / |
Family ID | 41258721 |
Filed Date | 2010-01-07 |
United States Patent
Application |
20100000170 |
Kind Code |
A1 |
Parks; Jerry M. |
January 7, 2010 |
Pre-Applied Waterless Adhesive On HVAC Facings With Sealable
Flange
Abstract
A fibrous insulation product having at least one facing material
adhered thereto is provided. The facing includes a pre-applied
waterless, thin-film adhesive that is thermoplastic and heat
activated. Accordingly, the facing may be repaired or repositioned
in the field with the use of a hot applicator. In at least one
embodiment, the fibrous insulation product is a duct board formed
of an insulation layer with a vapor barrier adhered to a first
major surface and a fibrous web adhered to a second major surface.
The vapor barrier is preferably wider than the insulation layer to
form a sealing flange. The waterless, thin-film adhesive may be
placed on a sealing flange and heat sealed without the use of hand
applied foil tape. The waterless, thin-film adhesive reduces odor
potential and improves fiberglass recovery. In addition, the
waterless, thin-film adhesive requires less energy to cure than a
water-based adhesive, thereby reducing cost.
Inventors: |
Parks; Jerry M.; (Granville,
OH) |
Correspondence
Address: |
OWENS CORNING
2790 COLUMBUS ROAD
GRANVILLE
OH
43023
US
|
Family ID: |
41258721 |
Appl. No.: |
12/167285 |
Filed: |
July 3, 2008 |
Current U.S.
Class: |
52/411 ;
52/746.1 |
Current CPC
Class: |
B32B 2262/101 20130101;
B32B 5/024 20130101; B32B 5/08 20130101; B32B 2405/00 20130101;
B32B 7/12 20130101; B32B 2262/06 20130101; B32B 2262/0253 20130101;
B32B 11/06 20130101; B32B 27/12 20130101; B32B 2262/02 20130101;
B32B 2250/20 20130101; B32B 2262/12 20130101; B32B 2262/04
20130101; B32B 7/06 20130101; B32B 15/14 20130101; B32B 19/06
20130101; B32B 2262/0276 20130101; F16L 59/026 20130101; B32B
2260/046 20130101; F16L 59/14 20130101; F24F 13/0263 20130101; B32B
2262/14 20130101; B32B 3/30 20130101; B32B 2307/7246 20130101; B32B
2260/021 20130101; B32B 2419/00 20130101; B32B 2250/44 20130101;
B32B 2307/304 20130101; B32B 3/06 20130101; B32B 5/26 20130101;
B32B 2262/108 20130101; D04H 1/4218 20130101; B32B 5/022 20130101;
B32B 2262/10 20130101; F16L 59/029 20130101; B32B 2262/0261
20130101; B32B 29/02 20130101; B32B 2307/748 20130101; B32B 11/10
20130101; B32B 2250/03 20130101 |
Class at
Publication: |
52/411 ;
52/746.1 |
International
Class: |
E04B 1/00 20060101
E04B001/00 |
Claims
1. A faced fibrous insulation product comprising: a fibrous
insulation layer having first and second opposed major surfaces;
and a first facing layer adhered to said first major surface, said
first facing layer having thereon a first pre-applied waterless,
thin-film adhesive, wherein said first facing layer is adhered to
said first major surface of said fibrous insulation layer by
heating said fibrous insulation layer and said first facing layer
to a temperature at or above the melting point of said first
pre-applied waterless, thin-film adhesive.
2. The faced insulation product of claim 1, wherein said first
pre-applied waterless, thin-film adhesive is selected from the
group consisting of a polyethylene copolymer, polyurethane,
ethylene vinyl acetate, amorphous polyolefin, polyethylene, low
density polyethylene, cellophane, polyethylene terephthalate,
polyvinyl chloride, nylons, polypropylene, polystyrene, polyamides
and cellulose acetate.
3. The faced insulation product of claim 1, wherein said first
facing layer is a vapor barrier and said first facing layer extends
beyond said fibrous insulation layer to form a sealing flange.
4. The faced insulation product of claim 3, wherein said insulation
product contains a plurality of grooves to permit folding of said
insulation product into one of a duct liner or a duct wrap.
5. The faced insulation product of claim 3, wherein said first
pre-applied thin-film adhesive is thermoplastic and said first
facing layer and said sealing flange may be repaired or
repositioned with the application of heat.
6. The faced insulation product of claim 3, wherein said first
pre-applied waterless, thin-film adhesive is substantially evenly
applied to said fibrous insulation layer.
7. The faced insulation product of claim 1, further comprising a
second facing layer adhered to said second major surface of said
fibrous insulation layer, said second facing layer having thereon a
second pre-applied waterless, thin-film adhesive.
8. The faced insulation product of claim 7, wherein said first and
second facing layers are selected from the group consisting of a
vapor barrier, a nonwoven mat, web and veil.
9. A fibrous duct board comprising: a fibrous insulation layer
having a first and second opposing major surfaces; a first facing
layer adhered to said first major surface, said first facing layer
having thereon a first pre-applied waterless, thin-film adhesive,
wherein said first facing layer is wider than said insulation layer
such that said first facing layer extends beyond an edge of said
fibrous insulation layer to form a sealing flange; and a second
facing layer adhered to said second major surface, said second
facing layer having thereon a second pre-applied waterless,
thin-film adhesive, wherein said first and second facing layers are
adhered to said fibrous insulation layer by heating said fibrous
insulation layer, said first facing layer, and said second facing
layer a temperature at or above the melting points of said first
and second waterless, thin-film adhesive.
10. The fibrous duct board of claim 9, further comprising male and
female shiplap edges, said sealing flange extending from said male
shiplap edge.
11. The fibrous duct board of claim 9, wherein said first and
second pre-applied waterless, thin-film adhesive are substantially
evenly applied to said fibrous insulation layer
12. The fibrous duct board of claim 9, wherein said first and
second pre-applied waterless, thin-film adhesive is selected from
the group consisting of a polyethylene copolymer, polyurethane,
ethylene vinyl acetate, amorphous polyolefin, polyethylene, low
density polyethylene, cellophane, polyethylene terephthalate,
polyvinyl chloride, nylons, polypropylene, polystyrene, polyamides
and cellulose acetate.
13. The fibrous duct board of claim 9, wherein said first and
second pre-applied thin-film adhesives are thermoplastic and said
first and second facing layers may be repaired or repositioned with
the application of heat.
14. The fibrous duct board of claim 9, wherein said first facing
layer is a vapor barrier and said second facing layer is selected
from the group consisting of a nonwoven fibrous web, veil and
mat.
15. A method of forming a faced fibrous insulation product
comprising: pre-applying a first waterless, thin-film adhesive to a
first facing material to form a first facing layer; forming a pack
of fibers having an uncured binder thereon; applying said first
facing layer to a first major surface of said pack of fibers;
heating said first facing material and said pack of fibers to cure
said binder and at least partially melt said first waterless,
thin-film adhesive to form a faced insulation product.
16. The method of claim 15, further comprising: pre-applying a
second waterless, thin-film adhesive to a second facing material to
form a second facing layer; applying said second facing layer to a
second major surface of said pack of fibers; at least partially
melting said second waterless, thin-film adhesive to adhere said
second facing layer to said pack of fibers, wherein said first and
second waterless, thin-film adhesives may be the same or
different.
17. The method of claim 16, wherein said step of applying said
first facing layer positions said first facing layer to extend
beyond said pack of fibers to form a sealing flange.
18. The method of claim 17, further comprising: forming grooves in
said faced insulation product; folding said insulation product
along said grooves into a duct liner; and heating said sealing
flange to seal said sealing flange against a first portion of said
insulation product to secure the formation of said duct liner.
19. The method of claim 16, wherein said first and second
waterless, thin-film adhesives are selected from the group
consisting of a polyethylene copolymer, polyurethane, ethylene
vinyl acetate, amorphous polyolefin, polyethylene, low density
polyethylene, cellophane, polyethylene terephthalate, polyvinyl
chloride, nylons, polypropylene, polystyrene, polyamides and
cellulose acetate.
20. The method of claim 16, wherein said first and second thin-film
adhesives are thermoplastic and said first and second facing layers
may be repaired or repositioned with the application of heat.
Description
TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION
[0001] The present invention relates generally to rotary fiberglass
insulation, and more particularly, to fibrous insulation products
faced with one or more facing materials having thereon a waterless,
pre-applied thin-film adhesive, including UVAC product facings with
a sealable flange.
BACKGROUND OF THE INVENTION
[0002] Ducts and conduits are used to convey air in building
heating, ventilation, and air conditioning (HVAC) systems. Often
these ducts are formed of sheet metal, and, as a result, do not
possess good thermal or acoustical properties. In order to enhance
these properties, the ducts are lined with a flexible thermal and
sound insulating material. Duct insulation used in HVAC systems
typically includes a facing layer adhered to an insulation layer.
Often the facing layer acts as, or is, a vapor barrier. The fibrous
duct insulation is typically formed of a suitable organic or
inorganic material such as fiberglass. Typical fiberglass duct
boards or duct liners are constructed of a fiberglass insulation
layer having a density from about 1.0 to about 7.0 pounds per cubic
foot (pcf) and a thickness from about 0.5 to about 3.0 inches. The
facing material is commonly affixed to the fibrous insulation by an
adhesive. Non-limiting examples of adhesive materials used in
conjunction with fibrous insulation are set forth below.
[0003] U.S. Pat. No. 4,738,998 to Uffner, et al. discloses thermal
insulating articles that include a laminate of thermal insulation
and a flexible jacket material. The insulation and the jacket
material are adhered to each other by a hot melt adhesive that
consists essentially of an asphalt an ethylene-vinyl acetate
copolymer, and a wax.
[0004] U.S. Pat. No. 5,106,446 to DiRado, et al. teaches a hot melt
adhesive for insulation assemblies for HVAC systems that includes
(1) 10-50% of an isotactic thermoplastic polybutylene-1/ethylene
copolymer containing from about 5.5-10% by weight ethylene, (2)
20-50% of a tackifier, (3) 15-50% of an amorphous diluent having a
softening point greater than 90.degree. C., (4) 0-2% of an
antioxidant, and (5) 0-5% of a wax.
[0005] U.S. Pat. No. 5,277,955 to Schelhorn, et a., discloses an
insulation assembly for insulating buildings. The insulation
assembly includes a low density, binderless mineral fiber batt
enclosed by an exterior layer or cover. In one embodiment, the
exterior layer is a heated polyethylene layer that is applied
directly to the fibrous glass batt. The heated polyethylene serves
as an adhesive layer that joins the film to the mineral fiber
batt.
[0006] U.S. Pat. No. 6,986,367 to Toas, et al. discloses an
insulation product for installing around ducts that includes a
fibrous insulation board and a reinforcement fabric. The insulation
board and reinforcement fabric are laminated together using an
adhesive material. The adhesive material may be a removable
adhesive, a permanent adhesive, or a repositionable adhesive.
Examples of suitable adhesives include water-based adhesives, hot
melt glues, a liquid adhesive, or a tape.
[0007] U.S. Patent Publication No. 2005/0031819 to Mankell, et al
discloses a duct board or duct liner that is formed of (1) a
fibrous material bound by a resinous binder, (2) an outer facing
layer adhered to an outer surface of the insulating layer, and (3)
a water repellant mat facer adhered to an interior surface of the
insulating layer opposite the outer surface. A liquid adhesive is
utilized to adhere the outer facing layer and the mat facer to the
insulation layer.
[0008] U.S. Patent Publication No. 2005/0272338 to Shaffer teaches
a faced fibrous insulation product that has a mat on one or more
surfaces of a fibrous insulation. The mat facing includes a
pre-applied adhesive that is heat activated to provide adhesion to
the fibrous insulation. A low melting point adhesive and a
relatively higher temperature melting point adhesive are
distributed on a surface of the mat facing and heated to a
temperature above the melting point of the low melting adhesive to
adhere the high melting point adhesive to the mat facing. Suitable
low melting point adhesives include polyethylene, ethylene vinyl
acetate, and other polymer adhesives. Examples of high melting
point adhesives include polyamide adhesives and phenolic
powders.
[0009] U.S. Patent Publication No. 2005/0272338 to Shaffer
discloses a faced fibrous insulation product that has a fibrous web
on one or more surfaces of a fibrous insulation layer. The mat
facing includes a pre-applied adhesive that is heat activated to
provide adhesion to the fibrous insulation layer. Particles of the
adhesive are distributed on a surface of the fibrous web and heated
to a temperature above the temperature of the melting point of the
adhesive to adhere the adhesive powder to the fibrous nonwoven web.
Examples of suitable adhesives include polyethylene, polypropylene,
ethylene vinyl acetate, polyamides, epoxies, urethane, melamine,
and phenolic powders.
[0010] U.S. Patent Publication No. 2006/0083889 to Schuckers
discloses a duct board that is formed of a fibrous duct board
layer, an adhesive material, and a second insulating board layer.
The adhesive material may be any adhesive material that adheres the
fibrous duct board and the second insulating board layer. Examples
of suitable adhesives include a hot melt glue or a water-based
adhesive.
[0011] Although there are numerous types of adhesives known in the
art water-based adhesives are conventionally utilized to adhere the
facing layer to the fibrous insulation. However, water-based
adhesives present numerous problems, such as surface foil corrosion
and the stimulation of trimethylamine (TMA), which produces an
undesirable odor. In addition, an enormous amount of energy is
required to remove the water and cure the water-based adhesive.
Accordingly, there exists a need in the art for a fibrous
insulation product that can be utilized as a duct liner and which
is formed using an adhesive that is easy to use, is inexpensive,
requires minimal energy to cure, and eliminates the need for
expensive foil tape.
SUMMARY OF THE INVENTION
[0012] It is an object of the present invention to provide a faced
insulation product that includes at least one facing layer adhered
to a major surface of an insulation layer. The facing layer is
formed of a facing material that has thereon a pre-applied
waterless, thin-film adhesive. The waterless, thin-film adhesive is
thermoplastic and heat activated. In at least one embodiment, the
waterless, thin-film adhesive is a polyethylene copolymer. Due to
the thermoplastic nature of the waterless, thin-film adhesive, the
facing material may advantageously be repositioned or repaired in
the field by the application of heat. The facing material may be
any facing material that is suitable for a fibrous insulation
product, such as a nonwoven mat, web, or veil, or a vapor barrier.
Application of the waterless, thin-film adhesive to the facing
layer(s) reduces the time associated with curing the adhesive. In
particular, the waterless, thin-film adhesive requires much less
energy to cure than conventional water-based adhesives, which, in
turn, may result in a reduction in manufacturing costs.
Additionally, the lack of water in the waterless, thin-film
adhesive helps to reduce or eliminate detrimental effects to the
insulation product typically caused by water-based adhesives, such
as surface foil corrosion and the stimulation of trimethylamine
(TMA) and its associated odor.
[0013] It is another object of the present invention to provide a
fibrous duct board that has facing materials on first and second
major surfaces of an insulation layer, a sealing flange, and
optionally, male and female shiplap edges. In one exemplary
embodiment, a first facing material is a vapor barrier positioned
on a first major surface of a fibrous insulation layer and a second
facing material is a non-woven fibrous web positioned on a second,
opposing major surface of the fibrous insulation layer. Desirably,
the first facing layer is wider than the insulation layer and
projects beyond the insulation layer along a transverse edge
thereof to form a sealing flange. In addition, the first facing
layer may be applied to the fibrous insulation layer in an offset
manner such that a transverse edge of the first facing layer
extends beyond a corresponding transverse edge of the fibrous
insulation layer to form a male shiplap edge, from which the
sealing flange extends. The facing materials have thereon a
pre-applied waterless, thin-film adhesive. In a preferred
embodiment, the waterless, thin-film adhesive is a polyethylene
copolymer. The waterless, thin-film adhesive seals the sealing
flange and thus reduces, or even eliminates, the need for foil tape
or staples, which are conventionally used in the industry. Because
foil tape is expensive and time consuming to apply, the use of the
waterless, thin-film adhesive saves both time and money.
Additionally, the sealing flange may be securely and easily bonded
in the field, such as with a hot iron, and may be repositioned due
to the thermoplastic nature of the waterless, thin-film
adhesive.
[0014] It is yet another object of the present invention to provide
a method of forming a fibrous insulation product such as a duct
board, duct liner, or duct wrap. A waterless, thin-film adhesive is
pre-applied to a facing material to form a facing layer. The facing
layer having the pre-applied waterless, thin-film adhesive thereon
is adhered to a major surface of a fibrous insulation layer by
heating the facing material and the fibrous insulation layer to a
temperature at or above the melting point of the waterless,
thin-film adhesive for a time sufficient to adhere the facing to
the fibrous insulation layer. In exemplary embodiments, a first
facing layer is adhered to a first major surface of the fibrous
insulation layer and a second facing layer is adhered to a second
major surface of the fibrous insulation layer. The first facing
layer may be wider than the insulation layer to project beyond the
insulation layer along a transverse edge thereof to form a sealing
flange. The waterless, thin-film adhesive is thermoplastic and heat
activated. In preferred embodiments, the waterless, thin-film
adhesive is a polyethylene copolymer.
[0015] It is an advantage of the present invention that the
waterless, thin-film adhesive may be pre-applied to a sealing
flange of a duct board and sealed by the application of heat
without the use of tape or staples.
[0016] It is another advantage of the present invention that less
energy is required to cure the waterless, thin-film adhesive
compared to water-based adhesives.
[0017] It is yet another advantage of the present invention that
the waterless, thin-film adhesive may reduce or eliminate the use
of foil tape conventionally used to seal duct sealing flanges.
[0018] It is also an advantage of the present invention that the
waterless, thin-film adhesive reduces surface foil corrosion and
permits a better adhesion of foil tape and duct board foil if such
foil tape is utilized.
[0019] It is still another advantage of the present invention that
the waterless, thin-film adhesive may be evenly or substantially
evenly applied to the facer material.
[0020] It is a further advantage of the present invention that the
facing material having thereon the pre-applied waterless, thin-film
adhesive may advantageously be repaired or repositioned in the
field with the use of a hot applicator.
[0021] It is yet another advantage of the present invention that
the waterless, thin-film adhesive exhibits a constant or nearly
constant weight distribution across the facing.
[0022] It is a feature of the present invention that the waterless,
thin-film adhesive is thermoplastic and heat activated.
[0023] It is another feature of the present invention that the lack
of water in the waterless, thin-film adhesive reduces odors that
commonly occur with water-based, liquid adhesives.
[0024] It is a further feature of the present invention that facing
materials having thereon a pre-applied layer of the waterless,
thin-film adhesive may be adhered to one or more surfaces of a
fibrous insulation layer.
[0025] It is yet another feature of the present invention that the
waterless, thin-film adhesive may be positioned on the facing
material and adhered thereto via the application of heat.
[0026] The foregoing and other objects, features, and advantages of
the invention will appear more fully hereinafter from a
consideration of the detailed description that follows. It is to be
expressly understood, however, that the drawings are for
illustrative purposes and are not to be construed as defining the
limits of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The advantages of this invention will be apparent upon
consideration of the following detailed disclosure of the
invention, especially when taken in conjunction with the
accompanying drawings wherein:
[0028] FIG. 1 is a schematic illustration of a facing layer formed
of a fibrous web having thereon a waterless, thin-film adhesive
according to one embodiment of the present invention;
[0029] FIG. 2 is a schematic illustration of a manufacturing line
for producing a faced fibrous insulation product in which the faced
insulation product is rolled by a roll-up device according on an
exemplary embodiment of the present invention;
[0030] FIG. 3 is a schematic illustration similar to that of FIG.
2, but showing an alternate embodiment of the manufacturing line of
FIG. 2 where the faced insulation product is cut into panels
according to another exemplary embodiment of the present
invention;
[0031] FIG. 4 is a schematic illustration depicting an alternate
embodiment of the manufacturing line of FIG. 3 in which the facer
is applied to a top surface of an uncured pack of glass fibers;
[0032] FIG. 5 is a perspective view, partially cut away, of a faced
insulation product having a facing material on one major surface
thereof according to at least one embodiment of the present
invention;
[0033] FIG. 6A is a schematic illustration of a faced fibrous
insulation product having a sealing flange extending beyond a
transverse edge of the fibrous insulation layer;
[0034] FIG. 6B is a schematic illustration of the insulation
product depicted in FIG. 6A being folded and used as a duct
wrap;
[0035] FIG. 6C is a schematic illustration of a faced fibrous
insulation product similar to that of FIG. 6A, but having a thinner
insulation layer;
[0036] FIG. 6D is a schematic illustration of the insulation
product depicted in FIG. 6C being folded into a duct liner;
[0037] FIG. 7 is a schematic illustration of a manufacturing line
for producing a faced fibrous insulation product in which the faced
insulation product has a facing material on a first and second
major surface according on one exemplary embodiment of the present
invention;
[0038] FIG. 8 is a perspective view, partially cut away, of a faced
insulation product having a facing material on two major surfaces
thereof according to at least one embodiment of the present
invention;
[0039] FIG. 9 is a schematic illustration depicting an alternate
embodiment of the manufacturing line of FIG. 7 in which the faced
insulation product is bisected and rolled into two separate rolls
by roll-up devices;
[0040] FIG. 10A is schematic illustration depicting an alternative
process of forming a faced fibrous insulation product in a
post-curing oven or off-line process using a heated platen to
adhere the facing material to the fibrous insulation;
[0041] FIG. 10B is a schematic illustration of an alternative
process of forming a faced fibrous insulation product in a
post-curing oven or off-line process using a heated roller to
adhere the facing material to the fibrous insulation;
[0042] FIG. 11 is a schematic illustration of an alternative
process of forming the faced fibrous insulation product in a
post-curing oven or off-line process using a heated caterpillar to
adhere the facing to the fibrous insulation;
[0043] FIG. 12 is a perspective view of a duct board according to
at least one exemplary embodiment of the present invention;
[0044] FIG. 13 is a schematic illustration of a duct board similar
to that of FIG. 12 but including grooves to permit folding of the
duct board into a predetermined shape according to at least one
exemplary embodiment of the present invention;
[0045] FIG. 14 is a schematic illustration of a duct board folded
into an air duct according to at least one exemplary embodiment of
the present invention;
[0046] FIG. 15 is a perspective view of a duct board according to
at least one exemplary embodiment of the present invention, the
duct board incorporating male and female shiplap edges and a
sealing flange;
[0047] FIG. 16 is a schematic illustration of a duct board similar
to that shown in FIG. 15 but incorporating grooves to facilitate
folding of the duct board into a predetermined shape; and
[0048] FIG. 17 is a schematic illustration of a duct board as
depicted in FIG. 16 but folded into an air duct with the shiplap
edges engaging at the joint between the opposing ends of the duct
board.
DETAILED DESCRIPTION AND PREFERRED EMBODIMENTS OF THE INVENTION
[0049] Unless defined otherwise, all technical and scientific terms
used herein have the same meaning as commonly understood by one of
ordinary skill in the all to which the invention belongs. Although
any methods and materials similar or equivalent to those described
herein can be used in the practice or testing of the present
invention, the preferred methods and materials are described
herein. All references cited herein, including published or
corresponding U.S. or foreign patent applications, issued U.S. or
foreign patents, and any other references, are each incorporated by
reference in their entireties, including all data, tables, figures,
and text presented in the cited references.
[0050] In the drawings, the thickness of the lines, layers, and
regions may be exaggerated for clarity. It is to be noted that like
numbers found throughout the figures denote like elements. It will
be understood that when an element is referred to as being "on,"
another element, it can be directly on or against the other element
or intervening elements may be present. The terms "facing" and
"facing material" may be used interchangeably herein.
[0051] The present invention relates to a waterless, thin-film
adhesive that is pre-applied to a facing material. The facing with
the pre-applied adhesive may subsequently be adhered to surfaces of
fibrous insulation materials to form duct boards for HVAC systems.
In addition, the waterless, thin-film adhesive may be placed on a
sealing flange of a duct board and heat sealed without the use of
hand applied foil tape. The waterless, thin-film adhesive reduces
odor potential, improves fiberglass recovery, and reduces
manufacturing and production costs.
[0052] The facing material is not particularly limited, and may be
any facing material that is suitable for a fibrous insulation
product, such as a nonwoven mat, web, or veil, or a vapor barrier
such as a foil/skrim/Kraft (FSK), Kraft/asphalt, or polymer and
foil/scrim/Kraft layers. FIG. 1 depicts a facer with a waterless,
thin-film adhesive adhered thereto according to one embodiment of
the present invention. As shown in FIG. 1, the facer 12 may include
a fibrous web 5 and a waterless, thin-film adhesive 7 adhered to a
major surface of the fibrous web 5. The fibrous web 5 may be formed
from fibers such as, but not limited to, glass fibers, mineral
wool, rock wool, polymer fibers, synthetic fibers, and/or natural
fibers. As used in this application, the term "natural fiber" is
meant to indicate plant fibers extracted from any part of a plant,
including, but not limited to, the stein, seeds, leaves, roots, or
bast. Desirably, the fibrous web 5 is formed of organic fibers such
as rayon, polyethylene, polypropylene, nylon, polyester, and
mixtures thereof. Continuous fibers and/or multi-component fibers
such as bicomponent or tricomponent polymer fibers may also be
utilized in forming the web 5. The bicomponent fibers may be formed
in a sheath-core arrangement in which the sheath is formed of first
polymer fibers that substantially surround a core formed of second
polymer fibers. Although the web 5 is preferably a non-woven web
formed by conventional dry-laid processes, other materials such as
point bonded, woven, and other non-woven materials such as needled,
spunbonded, or meltblown webs may be used. A binder,
flame-retardants, pigments, and/or other conventional additives may
also be included in the fibrous web 5. Optionally, the web 5 may be
treated with a fungicide and/or bactericide either during or after
manufacturing. Similarly, the waterless, thin-film adhesive may be
heat bonded to a vapor barrier (e.g., FSK layer) and subsequently
applied to a fibrous insulation product.
[0053] The waterless, thin-film adhesive is thermoplastic and heat
activated. The thickness of the waterless, thin-film adhesive is
desirably as small as possible so long as the adhesive has
sufficient bond strength and meets such required standards such as
ASTM E84 Flame and Smoke certifications. In exemplary embodiments,
the waterless, thin-film adhesive has a thickness less than or
equal to about 60 microns, from about 6.0 to about 30.0 microns, or
from about 10 microns to about 15 microns. The waterless, thin-film
adhesive is applied to the facing material via the application of
heat. For instance, the waterless, thin-film adhesive may be
positioned on the facing material and then adhered to the facing
material by heating the facing material with a hot plate or other
suitable heating device (e.g., an oven). The facing material may
similarly be adhered to a fibrous insulation layer by heating the
facing material and the fibrous insulation to a temperature at or
above the melting point of the waterless, thin-film adhesive for a
time sufficient to adhere the facing to the fibrous insulation
layer. Non-limiting examples of suitable adhesives include an
ethylene copolymer, polyturethane, ethylene vinyl acetate (EVA),
amorphous polyolefin, polyethylene, low density polyethylene
(LDPE), cellophane, polyethylene terephthalate (PETP), polyvinyl
chloride (PVC) nylons, polypropylene, polystyrene, polyamides, and
cellulose acetate. Additionally, the waterless, thin-film adhesive
may incorporate pre-engineered components to address requirements
set forth according to ASTM E184 (Flame and Smoke certification),
color pigmentation, static guards, and/or pre-designed
scavengers.
[0054] The lack of water in the thin-film adhesive helps to reduce
odors that commonly occur with water-based, liquid adhesives.
Because the thin-film adhesive is thermoplastic and heat activated,
the facing may advantageously be repaired or repositioned in the
field with the use of a hot applicator. Conventional adhesives are
thermoset and do not allow for easy re-application of the facing
layer(s). In addition, the thin-film adhesive may be evenly or
substantially evenly applied to the facing material, unlike
conventional liquid adhesives which are commonly unevenly applied
to the facing material. Further, there is a reduction in down time
due to the optimization of the application of the waterless,
thin-film adhesive. Unlike the waterless, thin-film adhesive,
water-based adhesives require constant monitoring. Further, the
waterless, thin-film adhesive may reduce or eliminate the use of
foil tape conventionally used to seal duct sealing (closing)
flanges.
[0055] The facing with the pre-applied waterless, thin-film
adhesive may be applied to one or more surfaces of a fibrous
insulation layer to form a faced insulation product. The facing
provides improved surface quality, high and controlled adhesion,
and is easily manufactured. The pre-applied facing may be input
into the glass fiber forming section of a fibrous insulation
production line as shown in FIG. 2. It is to be appreciated that
although glass fiber insulation is discussed herein, mineral wool,
rock wool, polymer fibers, synthetic fibers, and/or natural fibers
may alternatively or additionally be utilized in forming the
insulation. Fibrous glass insulation products are generally formed
of matted glass fibers bonded together by a cured thermoset
polymeric material. The manufacture of glass fiber insulation
products may be carried out in a continuous process by fiberizing
molten glass and immediately forming a fibrous glass batt on a
moving conveyor.
[0056] Turning to FIG. 2, glass may be melted in a tank (not shown)
and supplied to a fiber forming device such as a fiberizing spinner
15. The spinners 15 are rotated at high speeds. Centrifugal force
causes the molten glass to pass through the holes in the
circumferential sidewalls of the fiberizing spinners 15 to form
glass fibers. Single component glass fibers of random lengths may
be attenuated from the fiberizing spinners 15 and blown generally
downwardly, that is, generally perpendicular to the plane of the
spinners 15, by blowers 20 positioned within a forming chamber 25.
The blowers 20 turn the fibers downward to form a veil or curtain
30. Non-limiting examples of glass fibers that may be utilized in
the present invention are described in U.S. Pat. No. 6,527,014 to
Aubourg; U.S. Pat. No. 5,932,499 to Xu et al.; U.S. Pat. No.
5,523,264 to Mattison; and U.S. Pat. No. 5,055,428 to Porter, the
contents of which are expressly incorporated by reference in their
entirety.
[0057] The glass fibers, while in transit in the forming chamber 25
and while still hot from the drawing operation, are sprayed with an
aqueous binder composition by suitable spray applicators 35 so as
to result in a distribution of the binder composition throughout
the formed uncured pack 40. Water may also be applied to the glass
fibers in the forming chamber 25, such as by spraying, prior to the
application of the binder composition to at least partially cool
the glass fibers. Although any conventional binder such as
phenol-formaldehyde and urea-formaldehyde may be used, the binder
is desirably a low formaldehyde binder composition, such as a
polycarboxylic based binder, a polyaciylic acid glycerol (PAG)
binder, or a polyaciylic acid triethanolamine (PAT binder).
Suitable polycarboxy binder compositions for use in the instant
invention include a polycarboxy polymer, a crosslinking agent, and,
optionally, a catalyst. Such binders arc known for use in
connection with rotary fiberglass insulation. Examples of such
binder technology are found in U.S. Pat. Nos. 5,318,990 to Straus;
5,340,868 to Straus et al.; 5,661,213 to Arkens et al.; 6,274,661
to Chen et al.; 6,699,945 to Chen et al; and 6,884,849 to Chen et
al., each of which is expressly incorporated entirely by reference.
The binder may be present in an amount from about 2% to about 25%
by weight of the total product, and preferably from about 5% to
about 20% by weight of the total product, and most preferably from
about 10% to about 18% by weight of the total product.
[0058] The glass fibers having the uncured resinous binder adhered
thereto may be gathered and formed into an uncured pack 40 on the
facer 12 on an endless forming conveyor 45 within the forming
chamber 25 with the aid of a vacuum (not shown) drawn through the
insulation pack 40 from below the forming conveyor 45. It is to be
noted that throughout this application, facers 12, 16 are facing
materials having thereon a pre-applied waterless, thin-film
adhesive as described herein. The facer 12 is supplied to the
conveyor 45 by roll 90. The residual heat from the glass fibers and
the flow of air through the insulation pack 40 and facer 12 during
the forming operation are generally sufficient to volatilize a
majority of the water from the binder before the glass fibers exit
the forming chamber 25, thereby leaving the remaining components of
the binder on the fibers as a viscous or semi-viscous high-solids
liquid.
[0059] The coated uncured pack 40, which is in a compressed state
due to the flow of air through the pack 40 in the forming chamber
25, and the facer 12 are then transferred out of the forming
chamber 25 under exit roller 50 to a transfer zone 55 where the
insulation pack 40 vertically expands due to the resiliency of the
glass fibers. The expanded uncured pack 40 and facer 12 are then
heated, such as by conveying the pack 40 through a curing oven 60
where heated air is blown through the insulation pack 40 and facer
12 to evaporate any remaining water in the binder, cure the binder
and the adhesive, rigidly bond the fibers together in the
insulation pack 40, and adhere the facer 12 to the insulation pack
40. The facer 12 and the insulation pack 40 are heated to a
temperature at or above the temperature of the above the waterless,
thin-film adhesive for a time period sufficient to at least
partially melt the waterless, thin-film adhesive and bond the
adhesive to the insulation pack 40. Specifically, heated air is
forced though a fan 75 through the lower oven conveyor 70, the
insulation pack 40 and the facer 12, the upper oven conveyor 65,
and out of the curing oven 60 through an exhaust apparatus 80. The
cured binder imparts strength and resiliency to the faced
insulation product 10. It is to be appreciated that the drying and
curing of the binder and the waterless, thin-film adhesive may be
carried out in either one or two different steps. Also, in the
curing oven 60, the uncured pack 40 may be compressed by upper and
lower foraminous oven conveyors 65, 70 to form the faced fibrous
insulation product 10 having a predetermined thickness.
[0060] The faced fibrous insulation 10 then exits the curing oven
60 and may be rolled by roll-up device 82 for storage and/or
shipment. The faced fibrous insulation product 10 may subsequently
be unrolled and cut or die pressed to form fibrous insulation parts
(e.g., duct boards). Alternatively, as depicted in FIG. 3, the
faced fibrous insulation product 10 may be cut to a predetermined
length by a cutting device such as a blade or knife 83 to form
panels 84 of the faced fibrous insulation. The panels 84 may be
stacked or bagged by a packaging apparatus 86 If desired, channels
or grooves, such as v-shaped grooves, may be formed in the inner
surface of the fibrous insulation product 10 for folding or bending
the fibrous insulation product 10 into a duct liner, as is
discussed in more detail below.
[0061] In an alternate embodiment depicted in FIG. 4, an uncured
pack 40 is formed as described in detail above with respect to FIG.
2. Once the uncured pack 40 is formed and exits the forming chamber
25, a facer 12 is applied to a top surface of the uncured pack 40
from roll 90. The facer 12 and the uncured pack 40 enter the curing
oven 60 where heated air is forced though a fan 75 through the
lower oven conveyor 70, the insulation pack 40 and the facer 12,
the upper oven conveyor 65, and out of the curing oven 60 through
an exhaust apparatus 80. As the faced fibrous insulation product 10
exits the oven 60, it may be cut into panels 84 by the cutting
device 83 and collected by the gathering apparatus 86.
Alternatively, the faced fibrous insulation product 10 may be
rolled by a roll-up device (not illustrated) for storage and/or
shipment. As illustrated in FIG. 5, the faced insulation product 10
formed by the processes depicted in FIGS. 2, 3, and 4 include a
fibrous insulation layer 14 and a facing material 12 affixed to a
major surface of the insulation layer 14. In a related embodiment,
the facer 12 may be applied to one surface of the fibrous
insulation 14 where the facer 12 is larger than the fibrous
insulation 14 and drapes over the edges of the insulation layer 14
to face one or more of the minor surfaces of the fibrous insulation
14.
[0062] In one or more exemplary embodiment, the faced insulation
product 10 may be utilized as a duct liner or duct wrap. For
example, a duct liner or duct wrap may be formed from the
insulation products described above where the insulation layer 14
has thereon a single facer 12 that is wider than the insulation
layer 14 along a transverse edge to form a flange 134. In preferred
embodiments, the facer 12 is a foil/scrim/Kraft layer. As shown in
FIGS. 6a and 6b, the duct wrap 145 may be formed of a facer 12
including a flange 134 adhered to an insulation layer 14 by a
waterless, thin-film adhesive 125. The duct wrap 145 may be wrapped
around a sheet metal duct 137 and the edges of the duct wrap 145
sealed by the seating flange 134. Specifically, the sealing flange
134 may be adhered or bonded to the adjoining surface of the facing
layer 12 (e.g., a foil/scrim/Kraft layer) by heat and pressure due
to the pre-applied waterless, thin-film adhesive 125. Although the
flange 134 is depicted at the middle of a wall of the metal duct
137, one skilled in the art will recognize that the location of the
sealing flange 134 on the final assembly, including the duct liner
147 described below, could be at a corner of the duct 137, or at
other locations, depending on the location of the grooves 144
within the insulation product 10.
[0063] Turning to FIGS, 6c and 6d, a duct liner 147 having a facing
12 with a flange 134 adhered to a fibrous insulation layer 14 is
illustrated. The duct liner 147 may be folded into a shape
substantially similar to the shape of the duct into which it is to
be inserted (e.g. a substantially square shape as shown in FIG. 6d)
and inserted into a sheet metal to form a duct assembly (not
illustrated). The duct wrap 145 and duct liner 147 enhance the
thermal efficiency of duct work in a building and reduce noise
associated with the movement of air through the air duct.
[0064] Alternatively, facing materials may be applied to both major
surfaces of the fibrous insulation 14, as shown in FIG. 7. In one
exemplary embodiment, molten glass (not illustrated) is supplied to
fiberizing spinners 15 that are rotated at high speeds to force the
molten glass through holes in the circumferential sidewalls of the
fiberizing spinners 15 and form glass fibers. Blowers 20 direct a
gas stream in a substantially downward direction to impinge the
attenuated fibers, turning them downward, to form a veil or curtain
30. The fibers may be sprayed with an aqueous binder by suitable
spray applicators 35. The glass fibers having the uncured resinous
binder adhered thereto may then be gathered and formed into an
uncured pack 40 on a perforated endless conveyor 45 within the
forming chamber 25. The coated uncured pack 40, which is in a
compressed state due to the flow of air through the pack 40 in the
forming chamber 25 is then transferred out of the forming chamber
25 under exit roller 50 to a transfer zone 55 where the insulation
pack 40 vertically expands due to the resiliency of the glass
fibers.
[0065] As the uncured pack 40 exits the forming chamber 25, facing
materials 12, 16 are positioned on the top and bottom major surface
of the uncured pack. It is to be appreciated that the facing
materials 12, 16 may be the same or different. For example, one of
the facing layers may be a fibrous web and the other facing layer
may be a vapor barrier. The facing materials 12, 16 are fed to the
uncured pack 40 from rolls 90 and 92, respectively. The expanded
uncured pack 40 and facers 12, 16 are then heated in a curing oven
60 where heated air is blown through the insulation pack 40 and
facers 12, 16. It is contemplated that facer 12 may alternatively
be supplied to the conveyor 45 prior to the formation of the
uncured pack 40 such that the fibers formed from the spinners 15
are deposited onto the facer 12. Heated air is forced though a fan
75 through the lower oven conveyor 70, the insulation pack 40 and
the facers 12, 16, the upper oven conveyor 65, and out of the
curing oven 60 through an exhaust apparatus 80. Also, in the curing
oven 60, the uncured pack 40 may be compressed by upper and lower
foraminous oven conveyors 65, 70 to form a faced fibrous insulation
product 10 having a predetermined thickness. The double-faced
fibrous insulation product 10 then exits the curing oven 60 and may
be rolled by roll-up device 82 for storage and/or shipment. The
faced fibrous insulation product 10 may subsequently be unrolled
and cut or die pressed to form fibrous insulation parts. Channels
or grooves, such as v-shaped grooves, may optionally be formed in
the inner surface of the fibrous insulation product 10 for folding
or bending the fibrous insulation product 10 into a duct liner.
[0066] FIG. 8 depicts such a double-faced fibrous insulation
product 10 in which a facer 12 is positioned on a first major
surface of the fibrous insulation 14 and a second facing material
16 is positioned on a second major surface of the fibrous
insulation 14.
[0067] The presence of water, dust, and/or other microbial
nutrients in the faced insulation product 10 may support the growth
and proliferation of microbial organisms. Bacterial and/or mold
growth in the insulation product may cause odor and discoloration
of the insulation product and deterioration of the vapor barrier
properties of Kraft paper. To inhibit the growth of unwanted
microorganisms such as bacteria, fungi, and/or mold in the faced
insulation product 10, the facing materials 12, 16 and/or the
fibrous insulation 14 may be treated with one or more
anti-microbial agents and/or biocides. The anti-microbial agents
and/or biocides may be added during manufacture or in a post
manufacture process of the fibrous insulation product. In addition,
flame retardants, pigments, colorants, and/or other conventional
additives may be included in the faced insulation product 10.
[0068] Application of the waterless, thin-film adhesive to the
first and second facing layers 12, 16 reduces the time associated
with drying and bonding (curing) the adhesive, both to the facing
layers 12, 16 and to the fibrous insulation product 10.
Conventional adhesives are water-based and require an enormous
amount of heat energy to flash off the water during the curing of
the adhesive. The waterless, thin-film adhesive requires much less
energy to cure, which may result in a reduction in manufacturing
costs. Additionally, the lack of water in the waterless, thin-film
adhesive helps to reduce or eliminate the detrimental effects to
the insulation typically caused by water-based adhesives, such as,
but not limited, to surface foil corrosion and the stimulation of
trimethylamine (TMA) and its associated odor. In addition, the
waterless, thin-film adhesive exhibits a constant or nearly
constant weight distribution across the facing, unlike conventional
water-based adhesives which commonly have inconsistent weight
across the facing material due to equipment malfunction or the
inherent uneven application of the water-based adhesive. The
reduction of surface foil corrosion permits a better adhesion of
tape and duct board foil, if such tape is utilized.
[0069] In an alternative embodiment shown in FIG. 9, an uncured
pack 40 is formed as described in detail above with respect to FIG.
7. Once the uncured pack 40 is formed and exits the forming chamber
25, facers 12, 16 are applied to a top and bottom major surface of
the uncured pack 40 from rolls 90, 92. It is contemplated that
facer 12 may instead be supplied to the conveyor 45 prior to the
formation of the uncured pack 40 such that the fibers formed from
the spinners 15 are deposited onto the facer 12. The facers 12, 16
and the uncured pack 40 enter the curing oven 60 where heated air
is forced though a fan 75 through the lower oven conveyor 70, the
insulation pack 40 and the facers 12, 16, the upper oven conveyor
65, and out of the curing oven 60 through an exhaust apparatus 80.
As the double-faced fibrous insulation product 10 exits the oven
60, it may be bisected by a bisect saw 94 or other suitable cutting
device and rolled into two rolls by an upper roll-up device 96 and
a lower roll-tip device 98. The product thus formed is an
insulation product having thereon a facer 12 on one major surface
thereof, such as is depicted in FIG. 5.
[0070] FIGS. 10A and 10B show alternate methods of forming the
faced insulation product 10 in a post-curing or off-line process
using a heated platen 100 (FIG. 10A) and a heated roller 102 (FIG.
10B). Here, the facing material 12 is unrolled from roll 90 onto
the cured insulation layer 14. The heated platen 100 or heated
roller 102 at least partially melts the waterless, thin-film
adhesive that has been pre-applied to the facing material as
described above to adhere the facer 12 onto the insulation layer
14.
[0071] FIG. 11 illustrates an alternative post-cure method of
forming the double-faced fibrous insulation product 10 utilizing a
heated caterpillar 110. The heated caterpillar 110 has a heated
upper belt 112 that rotates around a first upper belt roller 114
and a second upper belt roller 116 to compress the fibrous
insulation layer 14 against a heated lower belt 120 that rotates
around a first lower belt roller 122 and a second lower belt roller
124. The upper belt 112 presses facing 12 to an upper surface of
the cured fibrous insulation layer 14 and the lower belt 120
presses facing 16 to a lower surface of the insulation layer 14 for
a time sufficient to heat the waterless, thin-film adhesives to
adhere facing layers 12, 16 to the fibrous layer 14 and form the
fibrous insulation product 10.
[0072] In one exemplary embodiment, the fibrous insulation product
10 is a duct board having facing materials on first and second
major surfaces of an insulation layer, a sealing flange, and
optionally, male and female shiplap edges. The facing materials are
formed of an outer surface layer, such as, but not limited to, a
vapor barrier, and an inner surface layer formed of a nonwoven
fibrous web, veil, or mat. One example of a duct board 128
according to the present invention is depicted in FIGS. 12-14. In
this exemplary embodiment, a first facing layer 130 is a vapor
barrier positioned on a first major surface of the fibrous
insulation layer 14 and is affixed to the first major surface by a
waterless, thin-film adhesive 125. A second facing layer 132 may be
a fibrous web, such as the web described in detail above, which is
affixed to a second major surface of the fibrous insulation layer
14 by a waterless thin-film adhesive 127. The waterless, thin-film
adhesives 125, 127 may be the same or different, but are both
thermoplastic in nature. It is to be appreciated that the vapor
barrier and the fibrous web forming the first and second facing
layers 130, 132 each correspond to one of facer 12 or facer 16
described in detail above.
[0073] Turning to FIGS. 13 and 14, the duct board 128 may be formed
into an air duct 135 by folding the duct board 128 into a generally
rectangular shape such that the second facing layer 132 faces an
interior portion thereof and the first facing layer (e.g., vapor
barrier) is positioned on an exterior surface of the air duct 135.
It is to be appreciated that although a square air duct is shown,
the air duct may be formed into a non-square shape, such as a
rectangular, round, or oval air duct, as would be understood by
those of skill in the art. The second facing layer 132 facilitates
air flow through the duct and reduces or eliminates the occurrence
of flyaway glass fibers from the insulation layer 14. To facilitate
bending of the duct board 128, grooves 144 may be cut or otherwise
formed into the duct board 128 at even intervals where the duct
board 128 is to be folded to permit the duct board 128 to be folded
along the grooves 144 and formed into the air duct 135. The sealing
flange 134 may be adhered or bonded to the adjoining surface of the
first facing layer 132 (e.g., a foil/scrim/Kraft layer) by heat and
pressure due to the pre-applied waterless, thin-film adhesive
125.
[0074] In an alternate embodiment, shown in FIGS. 15-17, the first
facing layer 130 is wider than the insulation layer 14 and projects
beyond the insulation layer 14 along a transverse edge to form a
sealing flange 134 extending from a male shiplap edge 140. The
first facing layer 130 may be applied to the fibrous layer 14 in an
offset manner such that a transverse edge of the first facing layer
130 extends beyond a corresponding transverse edge of the fibrous
insulation layer 14 to form the male shiplap edge 140. An opposing
transverse edge of the insulation layer 14 is thus formed into a
female shiplap edge 142. The duct board 128 may also be formed such
that one or both of the longitudinal edges also form a shiplap edge
(not depicted). As illustrated in FIG. 16, grooves 144 may be cut
into the duct board to facilitate bending of the duct board into an
air duct 135.
[0075] Once the duct board 128 is folded, as shown in FIG. 17, the
male and female shiplap edges 140, 142 are mated and sealing flange
134 covers the interface of the male and female shiplap edges 140,
142. As with the embodiment set forth above, the sealing flange 134
may be adhered or bonded to the adjoining surface of the first
facing layer 132 (e.g., a foil/scrim/Kraft layer) by heat and
pressure due to the pre-applied waterless, thin-film adhesive
125.
[0076] The waterless, thin-film adhesive seals the sealing flange
134 without tape or staples and thus reduces, or even eliminates,
the need for foil tape or staples, which are conventionally used in
the industry. Because foil tape is expensive and time consuming to
apply, the use of the waterless, thin-film adhesive saves both time
and money. Additionally, the sealing flange 134 may be securely and
easily bonded in the field, such as with a hot iron, and may be
repositioned due to the thermoplastic nature of the waterless,
thin-film adhesive.
[0077] The invention of this application has been described above
both generically and with regard to specific embodiments. Although
the invention has been set forth in what is believed to be the
preferred embodiments, a wide variety of alternatives known to
those of skill in the art can be selected within the generic
disclosure. The invention is not otherwise limited, except for the
recitation of the claims set forth below.
* * * * *