CA2552517A1 - Insulation product having nonwoven facing and method of making same - Google Patents

Insulation product having nonwoven facing and method of making same Download PDF

Info

Publication number
CA2552517A1
CA2552517A1 CA002552517A CA2552517A CA2552517A1 CA 2552517 A1 CA2552517 A1 CA 2552517A1 CA 002552517 A CA002552517 A CA 002552517A CA 2552517 A CA2552517 A CA 2552517A CA 2552517 A1 CA2552517 A1 CA 2552517A1
Authority
CA
Canada
Prior art keywords
mat
fibers
randomly oriented
nonwoven sheet
insulation product
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CA002552517A
Other languages
French (fr)
Other versions
CA2552517C (en
Inventor
David I. Suda
Michael J. Lembo
Andreas H. Unruh
Joyce A. Chunko
Richard J. Ray, Jr.
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Certainteed LLC
Original Assignee
Certainteed Corporation
David I. Suda
Michael J. Lembo
Andreas H. Unruh
Joyce A. Chunko
Richard J. Ray, Jr.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US10/753,741 external-priority patent/US7625828B2/en
Application filed by Certainteed Corporation, David I. Suda, Michael J. Lembo, Andreas H. Unruh, Joyce A. Chunko, Richard J. Ray, Jr. filed Critical Certainteed Corporation
Publication of CA2552517A1 publication Critical patent/CA2552517A1/en
Application granted granted Critical
Publication of CA2552517C publication Critical patent/CA2552517C/en
Expired - Fee Related legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B11/00—Layered products comprising a layer of bituminous or tarry substances
    • B32B11/04—Layered products comprising a layer of bituminous or tarry substances comprising such bituminous or tarry substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B11/06—Layered products comprising a layer of bituminous or tarry substances comprising such bituminous or tarry substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/02—Layered products essentially comprising sheet glass, or glass, slag, or like fibres in the form of fibres or filaments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/02—Layered products essentially comprising sheet glass, or glass, slag, or like fibres in the form of fibres or filaments
    • B32B17/04—Layered products essentially comprising sheet glass, or glass, slag, or like fibres in the form of fibres or filaments bonded with or embedded in a plastic substance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0036—Heat treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D04H1/4218—Glass fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/593—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives to layered webs
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B1/7654—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only comprising an insulating layer, disposed between two longitudinal supporting elements, e.g. to insulate ceilings
    • E04B1/7658—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only comprising an insulating layer, disposed between two longitudinal supporting elements, e.g. to insulate ceilings comprising fiber insulation, e.g. as panels or loose filled fibres
    • E04B1/7662—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only comprising an insulating layer, disposed between two longitudinal supporting elements, e.g. to insulate ceilings comprising fiber insulation, e.g. as panels or loose filled fibres comprising fiber blankets or batts
    • E04B1/7666—Connection of blankets or batts to the longitudinal supporting elements
    • E04B1/767—Blankets or batts with connecting flanges
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L59/00—Thermal insulation in general
    • F16L59/02—Shape or form of insulating materials, with or without coverings integral with the insulating materials
    • F16L59/026—Mattresses, mats, blankets or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B2038/0052—Other operations not otherwise provided for
    • B32B2038/0076—Curing, vulcanising, cross-linking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/10—Fibres of continuous length
    • B32B2305/20—Fibres of continuous length in the form of a non-woven mat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/02—Temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/04—Time
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B2001/7687—Crumble resistant fibrous blankets or panels using adhesives or meltable fibres
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
    • Y10T428/1352—Polymer or resin containing [i.e., natural or synthetic]
    • Y10T428/1362—Textile, fabric, cloth, or pile containing [e.g., web, net, woven, knitted, mesh, nonwoven, matted, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y10T442/2041—Two or more non-extruded coatings or impregnations
    • Y10T442/2123—At least one coating or impregnation contains particulate material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/659—Including an additional nonwoven fabric
    • Y10T442/664—Including a wood fiber containing layer
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/659—Including an additional nonwoven fabric
    • Y10T442/67—Multiple nonwoven fabric layers composed of the same inorganic strand or fiber material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/693—Including a paper layer

Abstract

An insulation product (100, 101) is provided comprising a low density mat (1 0, 10a, l0b, 111) containing randomly oriented inorganic fibers bonded by a hea t cured binder. The fibers comprise fibers (20) with a melting temperature abo ve the curing temperature of the binder. The fibers comprise fibers (21) with a melting temperature below the curing temperature. The mat (10, 10a, 10b, 111 ) has first and second major surfaces (11, 12) and a pair of side portions (14 , 15). A nonwoven sheet (13, 13a, 13b) is bonded to the first major surface (11). The nonwoven sheet (13, 13 a, 13b) comprises randomly oriented glass fibers and is bonded to the first major surface (11) by the heat cured binde r.

Claims (18)

1. An insulation product comprising:
a low density mat (10, 10a, 10b, 111) containing randomly oriented inorganic fibers bonded by a heat cured binder, said mat having first and second major surfaces (11, 12) and a pair of side portions (14, 15); further comprising, a nonwoven sheet (13, 13a, 13b) comprising randomly oriented glass fibers covering said mat, wherein said nonwoven sheet is bonded to said first major surface (11) by said heat cured binder.
2. The insulation product of claim 1 wherein said nonwoven sheet (13, 13a, 13b) is porous to water vapor and air evacuated when said insulation product is compressed.
3. The insulation product of claim 1, wherein said mat (10, 10a, 10b, 111) has a density of less than about 1.5 pounds per cubic foot and a thickness of greater than about 3.5 inches.
4. The insulation product of claim 1, wherein said nonwoven sheet (13, 13a, 13b) is bonded to at least one of said side portions (14, 15).
5. The insulation product of Claim 1, wherein said binder has a curing temperature between about 300 and about 600°F; and said nonwoven sheet (13, 13a, 13b) comprises randomly oriented fibers (20) having a melting temperature above said curing temperature, wherein said fibers (20) are bonded to said first major surface (11) by said heat cured binder.
6. The insulation product of Claim 1, wherein said nonwoven sheet (13a, 13b) comprises first randomly oriented fibers (20) and second randomly oriented fibers (21), said first randomly oriented fibers (20) having a melting point above a temperature used in curing said mat (10, 10a, 111) and said second randomly oriented fibers (21) having a melting point below said temperature used in curing said mat (10, 10a, 111), said nonwoven sheet (13a, 13b) is bonded to said first major surface (11) at least in part by a melt bond between said second randomly oriented fibers (21) and said mat (10, 10a, 111).
7. A method of making an insulation product, comprising:

(a) forming an uncured or partially cured mat (111c) containing randomly oriented inorganic fibers and a heat curable binder agent, said mat (111c) having a pair of side portions (14, 15) and first and second major surfaces (11, 12) thereon;
(b) applying a nonwoven sheet (13, 13a, 13b) to said first major surface (11), said nonwoven sheet (13, 13a, 13b) comprising randomly oriented glass fibers; and (c) heating said uncured or partially cured mat (111c) and said nonwoven sheet (13, 13a, 13b), wherein said binder agent of said mat (111c) is cured to form a low density mat (10, 10a, 10b, 111), and wherein said binder agent bonds said nonwoven sheet (13, 13a, 13b) to said first major surface (11).
8. The method of claim 7 wherein said nonwoven sheet (13, 13a, 13b) is porous to water vapor and air evacuated when said insulation product is compressed.
9. The method of claim 7 wherein said forming step (a) comprises:
providing said randomly oriented inorganic fibers with a plurality of fiberizers (200);
treating said randomly oriented inorganic fibers with said heat curable binder agent;
and collecting said randomly oriented inorganic fibers treated with said heat curable binder agent on a forming belt (202), said method being characterized by applying an increased amount of heat curable binder agent to said randomly oriented inorganic fibers disposed proximate to said first major surface (11).
10. The method of claim 7 wherein said forming step (a) comprises:
providing said randomly oriented inorganic fibers with a plurality of fiberizers (200);
treating said randomly oriented inorganic fibers with said heat curable binder agent;
and collecting said randomly oriented inorganic fibers treated with said heat curable binder agent on a forming belt (202), said method further comprising the step of applying a heat curable binder agent directly to said nonwoven sheet (13, 13a, 13b) before or during step (b).
11. The method of claim 7, wherein said low density mat (10, 10a, 10b, 111) has a density of less than about 2 pounds per cubic foot and a thickness of greater than about 2 inches.
12. A method of making an insulation product, comprising:
(a) forming an uncured or partially cured mat (111c) containing randomly oriented glass fibers and a heat curable binder agent, said mat (111c) having a pair of side portions (14, 15) and first and second major surfaces (11, 12);
(b) applying a nonwoven sheet (13, 13a, 13b) to said first major surface (11), said nonwoven sheet (13) comprising randomly oriented fibers; and (c) heating said uncured or partially cured low density mat (111c) and nonwoven sheet (13, 13a, 13b) structure in a curing oven at a temperature between about 300-600°F, wherein said randomly oriented fibers of said nonwoven sheet (13, 13a, 13b) comprise fibers (20) having a melting point above about said oven temperature, wherein a low density mat (10, 10a, 10b, 111) is formed and said nonwoven sheet (13, 13a, 13b) is bonded to said first major surface (11) by said heat curable binder agent.
13. The method of claim 12 wherein said randomly oriented fibers of said nonwoven sheet (13, 13a, 13b) comprise glass fiber and wherein said nonwoven sheet (13, 13a, 13b) is porous to water vapor and air evacuated when said insulation product is compressed.
14. The method of claim 12, wherein said mat (111c) is heated to a temperature between about 400-560°F for a period of at least 20 seconds.
15. The method of claim 12, wherein said mat (111c) is heated to a temperature between about 450-525°F for a period of at least 20 seconds.
16. A method of making an insulation product, comprising:

(a) forming an uncured or partially cured mat (111c) containing randomly oriented glass fibers and a heat curable binder agent, said mat (111c) having a pair of side portions (14, 15) and first and second major surfaces (11, 12);
(b) applying a nonwoven sheet (13a, 13b) to said first major surface, said nonwoven sheet (13a, 13b) comprising first randomly oriented fibers (20) and second randomly oriented fibers (21), said first randomly oriented fibers (20) having a melting point above a temperature used in curing said mat (111c) and said second randomly oriented fibers (21) having a melting point below said temperature used in curing said mat (111c); and (c) heating said uncured or partially cured low density mat (111c) and nonwoven sheet (13a, 13b) structure in a curing oven at a temperature above said melting point of said second fibers (21) and below said melting point of said first fibers (20), wherein a low density mat (10, 10a, 10b, 111) is formed and said nonwoven sheet (13a, 13b) is bonded to said first major surface at least in part by a melt bond between said second fibers (21) and said randomly oriented glass fibers in said low density mat (10, 10a, 10b, 111).
17. A method of making an insulation product, comprising:
(a) forming an uncured or partially cured mat (111c) containing randomly oriented glass fibers and a heat curable binder agent, said mat (111c) having a pair of side portions (14, 15) and first and second major surfaces (11, 12);
(b) heating said uncured or partially cured mat (111c) in a curing oven to form a low density mat (10, 10a, 10b, 111); and (c) after step (b) and while said low density mat (10, 10a, 10b, 111) is at an elevated temperature, applying a nonwoven sheet (13a, 13b) to said first major surface, said nonwoven sheet (13a, 13b) comprising first randomly oriented fibers (20) and second randomly oriented fibers (21), said first randomly oriented fibers (20) having a melting point above said elevated temperature and said second randomly oriented fibers (21) having a melting point below said elevated temperature, wherein said nonwoven sheet (13a, 13b) is bonded to said first major surface (11)at least in part by a melt bond between said second fibers (21) and said randomly oriented glass fibers in said low density mat (10, 10a, 10b, 111).
18
CA2552517A 2004-01-08 2005-01-06 Insulation product having nonwoven facing and method of making same Expired - Fee Related CA2552517C (en)

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
US10/753,603 2004-01-08
US10/753,741 US7625828B2 (en) 2004-01-08 2004-01-08 Insulation product having nonwoven facing
US10/753,741 2004-01-08
US10/753,603 US7544267B2 (en) 2004-01-08 2004-01-08 Method of making insulation product having nonwoven facing
PCT/US2005/000204 WO2005067587A2 (en) 2004-01-08 2005-01-06 Insulation product having nonwoven facing and method of making same

Publications (2)

Publication Number Publication Date
CA2552517A1 true CA2552517A1 (en) 2005-07-28
CA2552517C CA2552517C (en) 2010-08-17

Family

ID=34743168

Family Applications (1)

Application Number Title Priority Date Filing Date
CA2552517A Expired - Fee Related CA2552517C (en) 2004-01-08 2005-01-06 Insulation product having nonwoven facing and method of making same

Country Status (3)

Country Link
US (1) US7544267B2 (en)
CA (1) CA2552517C (en)
WO (1) WO2005067587A2 (en)

Families Citing this family (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7476427B2 (en) * 2004-03-11 2009-01-13 Certainteed Corporation Faced fiberglass board with improved surface toughness
CA2493239A1 (en) * 2004-07-26 2006-01-26 Tremco Barrier Solutions, Inc. Aboveground waterproofing boards, systems, and methods
FR2878864B1 (en) * 2004-12-07 2007-01-26 Saint Gobain Isover Sa PROCESS FOR PRODUCING A COLORED MINERAL WOOL PRODUCT COMPRISING A SAME COLOR COATING
US9528261B2 (en) 2013-01-09 2016-12-27 Vita Nonwovens, Llc Synthetic fiber insulation with facing
US20170051502A1 (en) * 2014-02-04 2017-02-23 Owens Corning Intellectual Capital, Llc Roof insulation systems
US9783981B2 (en) * 2015-04-28 2017-10-10 Owens Corning Intellectual Capital, Llc Insulation with installation guide and apparatus and method for installing same
FR3049278B1 (en) * 2016-03-24 2018-04-13 Saint-Gobain Isover METHOD FOR MANUFACTURING SELF-ADHESIVE MINERAL WOOL MATTRESS
US10494809B2 (en) 2016-07-07 2019-12-03 Knauf Insulation, Inc. Insulative material and method for installation
US11813833B2 (en) 2019-12-09 2023-11-14 Owens Corning Intellectual Capital, Llc Fiberglass insulation product
EP4073162A4 (en) * 2019-12-09 2023-12-06 Owens Corning Intellectual Capital, LLC Fiberglass insulation product

Family Cites Families (48)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2341130A (en) 1939-05-12 1944-02-08 E B & A C Whiting Company Method of making fibrous bats
US2543101A (en) 1944-07-20 1951-02-27 American Viscose Corp Composite fibrous products and method of making them
US3642554A (en) 1970-02-16 1972-02-15 Certain Teed Prod Corp Closed mat forming system
US3955031A (en) 1973-01-18 1976-05-04 Owens-Corning Fiberglas Corporation Flame resistant building material
US3958385A (en) 1973-12-03 1976-05-25 Metal Buildings Insulation, Inc. Insulation blanket and method and apparatus for making same
US4101700A (en) 1976-03-12 1978-07-18 Johns-Manville Corporation Thermally insulating duct liner
US4201247A (en) 1977-06-29 1980-05-06 Owens-Corning Fiberglas Corporation Fibrous product and method and apparatus for producing same
US4263007A (en) 1978-06-05 1981-04-21 Saint-Gobain Industries Apparatus for heat treatment of fibrous mats
US4316865A (en) 1978-06-05 1982-02-23 Saint-Gobain Industries Method for heat treatment of fibrous mats
US4310585A (en) * 1979-06-15 1982-01-12 Owens-Corning Fiberglas Corporation Fibrous product formed of layers of compressed fibers
US4342610A (en) 1980-10-20 1982-08-03 Manville Service Corporation Method for intermittently slitting and folding fibrous insulation
US4756945A (en) 1985-01-18 1988-07-12 Backer Rod Manufacturing And Supply Company Heat expandable fireproof and flame retardant construction product
US4661392A (en) 1985-09-25 1987-04-28 Kapstad Odd B Sound dampening panel and method of fabrication
US4709523A (en) 1986-08-18 1987-12-01 Owens-Corning Fiberglas Corporation Insulation batt with press-on facing flanges
US4972644A (en) 1988-09-16 1990-11-27 Manville Corporation Metal building insulation
US5236754A (en) 1989-12-08 1993-08-17 Owens-Corning Fiberglas Technology, Inc. Reoriented insulation assembly and method
DE3941273A1 (en) 1989-12-14 1991-06-20 Rockwool Mineralwolle METHOD FOR THE HEAT AND / OR SOUND INSULATION OF BUILDINGS
US5032431A (en) * 1990-02-06 1991-07-16 Georgia-Pacific Resins, Inc. Glass fiber insulation binder
DE9004744U1 (en) 1990-04-04 1990-08-30 Krickl Lueftungsbau Gmbh, 8264 Waldkraiburg, De
US5246514A (en) * 1990-04-30 1993-09-21 Energy Blanket Of Texas, Inc. Fiberglass blanket and backing sheet laminator system with sonic vibration and vacuum removal of broken fiberglass particles
US5217766A (en) * 1990-09-06 1993-06-08 United Technologies Corporation Stabilized complex composite preforms
US5169700A (en) * 1991-02-22 1992-12-08 Manville Corporation Faced fiber glass insulation
DK26792D0 (en) 1992-02-28 1992-02-28 Rockwool Int METHOD FOR MANUFACTURING MINERAL FIBER PRODUCTS
FI95154C (en) 1992-03-09 1995-12-27 Roctex Oy Ab A method of making a matless product comprising mineral fibers and a binder
US5545279A (en) 1992-12-30 1996-08-13 Hall; Herbert L. Method of making an insulation assembly
ES2105283T3 (en) 1993-06-03 1997-10-16 Owens Corning Fiberglass Corp INSULATING BLOCK WITH LOW FRICTION FACE.
US5840413A (en) * 1993-07-13 1998-11-24 Johns Manville International, Inc. Fire retardant nonwoven mat and method of making
US5783268A (en) * 1993-08-11 1998-07-21 Knauf Fiber Glass Gmbh High air velocity duct board having minimal turbulence
US5486401A (en) 1994-05-09 1996-01-23 Owens-Corning Fiberglas Technology, Inc. Insulation assembly and method of making
US5766395A (en) * 1995-08-28 1998-06-16 Johns Manville International, Inc. Method of making self-supporting composite structures
US5685938A (en) * 1995-08-31 1997-11-11 Certainteed Corporation Process for encapsulating glass fiber insulation
US5848509A (en) * 1995-08-31 1998-12-15 Certainteed Corporation Encapsulated insulation assembly
US5804254A (en) * 1996-09-07 1998-09-08 Rohm And Haas Company Method for flexibilizing cured urea formaldehyde resin-bound glass fiber nonwovens
US5916672A (en) * 1997-04-25 1999-06-29 Brunswick Corporation Thermoplastic multi-layer composite structure
US5900206A (en) 1997-11-24 1999-05-04 Owens Corning Fiberglas Technology, Inc. Method of making a fibrous pack
US6171654B1 (en) * 1997-11-28 2001-01-09 Seydel Research, Inc. Method for bonding glass fibers with cross-linkable polyester resins
EP0990727A1 (en) * 1998-10-02 2000-04-05 Johns Manville International Inc. Polycarboxy/polyol fiberglass binder
US6670011B2 (en) 1998-10-07 2003-12-30 Johns Manville International, Inc. Pre-cut fibrous insulation blanket
US6207245B1 (en) 1998-10-23 2001-03-27 Scott Industries, Inc. Fiberglass insulation blanket with release liner assembly and method
US6357504B1 (en) * 1999-07-29 2002-03-19 Owens Corning Fiberglas Technology, Inc. Technology for attaching facing system to insulation product
US6415573B1 (en) * 1999-09-15 2002-07-09 Certainteed Corporation Metal building insulation assembly
US20070060005A1 (en) * 2001-09-06 2007-03-15 Certainteed Corporation Insulation product from rotary and textile inorganic fibers with improved binder component and method of making same
US20040176003A1 (en) * 2001-09-06 2004-09-09 Alain Yang Insulation product from rotary and textile inorganic fibers and thermoplastic fibers
US6811649B2 (en) * 2002-06-08 2004-11-02 Upf Corporation Line faced marine insulation, and method of production
US7070674B2 (en) * 2002-12-20 2006-07-04 Caterpillar Method of manufacturing a multi-layered piezoelectric actuator
US20040219847A1 (en) * 2003-04-30 2004-11-04 Miller Wayne P. Method for flexibilizing glass fiber nonwoven bound with cured urea formaldehyde resin
US20050098255A1 (en) * 2003-11-06 2005-05-12 Lembo Michael J. Insulation product having nonwoven facing and process for making same
US7354478B2 (en) * 2004-02-20 2008-04-08 Certainteed Corporation Insulation product having bicomponent fiber facing layer and method of manufacturing the same

Also Published As

Publication number Publication date
WO2005067587A3 (en) 2007-03-08
WO2005067587A2 (en) 2005-07-28
US7544267B2 (en) 2009-06-09
CA2552517C (en) 2010-08-17
US20050166543A1 (en) 2005-08-04

Similar Documents

Publication Publication Date Title
CA2552517A1 (en) Insulation product having nonwoven facing and method of making same
US6815380B2 (en) High performance kraft facing for fiberglass insulation
EP1341649A1 (en) Method for controlling thermohysteresis during thermoforming of three-dimensional fibrous compoun constructs and the products thereof
RU2220841C2 (en) Method for steam pressing of fiber board having at least one finishing surface
JP2002192507A (en) Manufacturing method for fibrous plate
WO2001092002A3 (en) Method for consolidation for random carbon fiber orientation and for forming a carbon fiber preform
RU2001103649A (en) METHOD FOR STEAM PRESSING OF A WOOD AND FIBROUS PLATE HAVING AT LEAST A ONE FINISHED SURFACE
CA2440946A1 (en) Low density oriented strand boards
JP3527730B2 (en) Vacuum insulation material and method of manufacturing core material
JP2001001319A (en) Manufacture of thermoplastic vegetable fiber sheet
JP4057947B2 (en) Method for producing consolidated wood
JP3163352B2 (en) Compressed wood and method for producing the same
JPH09155814A (en) Compressed wooden material and production thereof
JP3131605B2 (en) Method for manufacturing compressed wood
JP3153124B2 (en) Method for manufacturing compressed wood
CN117818153A (en) Mica ceramic fiber aerogel composite structure and preparation method thereof
JPH09155819A (en) High-density ligneous material and its manufacture
JPH08224706A (en) Compressed wooden material and manufacture thereof
JPH0110198Y2 (en)
JP2526079B2 (en) Manufacturing method of molded ceiling material for automobiles
JPS5826114Y2 (en) Cushioning material for laminate manufacturing
JPH09155813A (en) Compressed wood material and production thereof
JP3623335B2 (en) Particle board manufacturing method
JPH05278164A (en) Production of inorganic fiber molded object
JP2001009813A (en) Manufacture of wood molding

Legal Events

Date Code Title Description
EEER Examination request
MKLA Lapsed

Effective date: 20160106