DUCT WRAP INSULATION
20230150233 · 2023-05-18
Inventors
Cpc classification
B32B2307/746
PERFORMING OPERATIONS; TRANSPORTING
B32B27/12
PERFORMING OPERATIONS; TRANSPORTING
B32B5/265
PERFORMING OPERATIONS; TRANSPORTING
B32B5/262
PERFORMING OPERATIONS; TRANSPORTING
B32B2255/02
PERFORMING OPERATIONS; TRANSPORTING
B32B2307/718
PERFORMING OPERATIONS; TRANSPORTING
B32B7/02
PERFORMING OPERATIONS; TRANSPORTING
B32B7/14
PERFORMING OPERATIONS; TRANSPORTING
B32B5/02
PERFORMING OPERATIONS; TRANSPORTING
B32B2260/021
PERFORMING OPERATIONS; TRANSPORTING
B32B5/266
PERFORMING OPERATIONS; TRANSPORTING
B32B29/02
PERFORMING OPERATIONS; TRANSPORTING
B32B2262/02
PERFORMING OPERATIONS; TRANSPORTING
International classification
B32B5/26
PERFORMING OPERATIONS; TRANSPORTING
B32B29/02
PERFORMING OPERATIONS; TRANSPORTING
Abstract
An insulation product includes a first layer of a fibrous insulating material, a second layer of a facing material attached to a first surface of the first layer, and a third layer of a slip sheet material and/or a lubricant attached to a second surface of the first layer. The first surface and the second surface are on opposite sides of the first layer and are parallel to one another. For certain applications, the insulation product may include a layer of a slip sheet material and/or lubricant attached to the first surface of the first layer instead of the second layer of a facing material.
Claims
1. An insulation product comprising: a first layer of a fibrous insulating material; a second layer attached to a first surface of the first layer; and a third layer attached to a second surface of the first layer, wherein the first surface and the second surface are on opposite sides of the first layer and are parallel to one another.
2. The insulation product of claim 1, wherein the fibrous insulating material comprises at least one of glass fibers and organic fibers.
3. The insulation product of claim 1, wherein the fibrous insulating material is binderless.
4. The insulating product of claim 1, wherein the second layer comprises a paper facing.
5. The insulation product of claim 1, wherein the third layer comprises a fibrous veil.
6. The insulation product of claim 5, wherein the fibrous veil comprises glass fibers and is nonwoven.
7. The insulation product of claim 1, wherein the third layer comprises at least one slip sheet material selected from the group consisting of a plastic film, a skin coat of binder, a wax paper, and a woven fabric.
8. The insulation product of claim 1, wherein a thickness of the first layer is equal to or greater than a combined thickness of the second layer and the third layer.
9. The insulation product of claim 1, wherein the third layer has a basis weight of 0.1 g/m.sup.2 to 75.0 g/m.sup.2.
10. The insulation product of claim 1, wherein the insulation product has a coefficient of friction of 0.35 to 0.40.
11. The insulation product of claim 1, wherein the insulation product releases dust particles equal to or less than 0.02 grams during installation.
12. The insulation product of claim 1, wherein the insulation product loses less than 0.09 grams of fiber due to fiber transfer when unrolling the insulation product from a rolled state.
13. An insulation product comprising: a first layer of a fibrous insulating material; and a second layer attached to a first surface of the first layer, the second layer being formed from at least one of a slip sheet material and a lubricant.
14. The insulation product of claim 13, wherein the fibrous insulating material comprises at least one of glass fibers and organic fibers.
15. The insulation product of claim 13, wherein the fibrous insulating material is binderless.
16. The insulation product of claim 13, further comprising: a third layer attached to a second surface of the first layer, wherein the first surface and the second surface are on opposite sides of the first layer and are parallel to one another, and wherein the third layer is formed from at least one of a slip sheet material and a lubricant.
17. The insulation product of claim 16, wherein the second layer is a fiberglass veil and the third layer is one of a fiberglass veil and a silicone lubricating oil.
18. The insulation product of claim 13, wherein the insulation product has a coefficient of friction of 0.35 to 0.40.
19. The insulation product of claim 13, wherein the insulation product releases dust particles equal to or less than 0.02 grams during installation.
20. The insulation product of claim 13, wherein the insulation product loses less than 0.09 grams of fiber when unrolling the insulation product from a rolled state.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] These and other features of the present disclosure will become better understood with regard to the following description and accompanying drawings in which:
[0015]
[0016]
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[0027]
DETAILED DESCRIPTION
[0028] The general inventive concepts will be understood more fully from the detailed description given below and from the accompanying drawings of the various aspects and implementations of the disclosure. This disclosure should not be taken to limit the general inventive concepts to the specific aspects or implementations, which are being provided for explanation and understanding only.
[0029] Referring now to the drawings, which are for purposes of illustrating several exemplary embodiments of the general inventive concepts, and not for limiting the same,
[0030] As shown in
[0031] It should be appreciated that the first layer 20 may be formed of other fibers, such as, for example, mineral fibers of rock, slag, or basalt, as well as organic fibers, such as, for example, polymer fibers (e.g., polypropylene, polyester, and polysulfide).
[0032] The fiberglass layer 20 may be formed by fiberizing molten material and depositing the fibers on a collecting conveyor. A binder material may also be used to bond the fibers together where they contact each other, forming a lattice or network. In some embodiments, the binder material may be a thermosetting resin that cures as the fiberglass layer 20 moves through an oven. One type of binder material commonly used with fiberglass insulation is a urea phenol-formaldehyde binder. Additionally, or alternatively, the fiberglass layer 20 may be binderless. “Binderless” means the absence of binder materials or the presence of only small amounts of such binder materials. In the case of a binderless insulating layer 20, the fibers may be mechanically entangled together.
[0033] The fiberglass layer 20 may have a density within the range of 0.75 pounds per cubic foot (pcf) to 1.5 pcf, although other densities may be used.
[0034] The facer 30 may be attached to a first surface (i.e., first major face) of the fiberglass layer 20 in any suitable manner, such as by an adhesive layer, drops, or strips. For example, a hot melt adhesive may be applied in liquid form to a surface of the fiberglass layer 20 (e.g., the first surface) and/or a side of the facer 30 that contacts the fiberglass layer 20. In some embodiments, the adhesive may be applied to the facer 30 while manufacturing, for example, the duct wrap 100. Additionally, or alternatively, the adhesive may be pre-applied to the facer 30 (i.e., prior to the manufacturing the duct wrap 100.)
[0035] The facer 30 may then be pressed into forceful contact with the first surface of the fiberglass layer 20, for example, by the action of one or more pressing rolls, for attaching the facer 30 to the first surface of the fiberglass layer 20. It should be appreciated that one or more of the pressing rolls may be heated for purposes of creating a bond between the facer 30 and the fiberglass layer 20.
[0036] The duct wrap 100 of
[0037] The third layer 110 may be attached and/or bonded to the second surface of the fiberglass layer 20 in any suitable manner, such as by an adhesive layer or strip, heat lamination, and/or chemical bonding. In some embodiments, an adhesive in an amount of 10 g/m.sup.2 to 100 g/m.sup.2, including from 15 g/m.sup.2 to 50 g/m.sup.2, and also including from 25 g/m.sup.2 to 35 g/m.sup.2 may be used to attach and/or bond the third layer 110 to the second surface of the fiberglass layer 20.
[0038] In some embodiments, the third layer 110 may be bonded to the fiberglass layer 20 in a manner similar to how the facer 30 is attached to the fiberglass layer 20 (e.g., by applying a resin to the third layer 110). Additionally, or alternatively, the third layer 110 may be bonded to the fiberglass layer 20 using the binder material that bonds the fibers of the fiberglass layer 20 together. For example, before the binder mixture bonding the fibers is cured via an oven, the third layer 110 may be placed onto a surface of the fiberglass layer 20 and/or onto an uncured binder mixture of the fiberglass layer 20 and then heated via the oven. The heat from the oven may enable some of the binders bonding the fibers to connect or otherwise join the fiberglass layer 20 to the third layer 110.
[0039] In some embodiments, the binder may be a no-added formaldehyde binder or a formaldehyde-free binder. However, it should be appreciated that other binders (e.g., a phenolic binder) may be used for joining the fiberglass layer 20, and/or for adhering one or more additional layers to the fiberglass layer 20.
[0040] In some embodiments, the third layer 110 may be formed from one or more sheet materials (e.g., slip sheet materials). Types of slip sheet materials may include, for example, fiberglass veils, wax papers, skin coats of binders (e.g., an excess quantity of binder materials applied to the second surface and further processed to form the third layer 110), woven fabrics, and/or plastic films.
[0041] Similar to the duct wrap 100 of
[0042] In some embodiments, the lubricant 130 may be a silicone lubricating oil, although other oils may be used (e.g., a mineral oil, which may be derived from a crude oil, and/or a synthetic oil, which may be derived from a synthetic hydrocarbon). Additionally, or alternatively, the lubricant 130 may be a dry solid lubricant (e.g., a graphite, talc, and/or cornstarch).
[0043] In some embodiments, for example, where the third layer 110 is formed from a slip sheet material, the slip sheet material may have a basis weight between 0.1 g/m.sup.2 and 75 g/m.sup.2. Additionally, or alternatively, in embodiments where the third layer 110 is a fiberglass veil 120 (
[0044] In some embodiments, the fiberglass veil 120 may have a basis weight between 0.56 g/m.sup.2 and 32.0 g/m.sup.2 (e.g., 25 g/m.sup.2 or 27 g/m.sup.2). Additionally, or alternatively, the fiberglass veil 120 may have a thickness between 0.14 mm and 0.18 mm (e.g., 0.16 mm). It should be appreciated that the fiberglass veil 120 thickness should have little to no effect on the flexibility of the duct wrap product. The duct wrap product (inclusive of the third layer 110) must maintain its flexibility, for example, to allow the duct wrap 100 to be manipulated between narrow duct spaces.
[0045] In some embodiments, the fiberglass veil 120 may have a binder content between 9% and 20% (e.g., 10% to 15%), and a porosity between 350 l/m.sup.2/s and 5,750 l/m.sup.2/s (e.g., 5,250 l/m.sup.2/s). In some embodiments, a longitudinal tensile strength (Tensile MD) of the fiberglass veil 120 may be between 9 lbf/2 inches and 20 lbf/2 inches (e.g., 18 lbf/2 inches). Additionally, or alternatively, a transverse tensile strength (Tensile CMD) of the fiberglass veil 120 may be between 5 lbf/2 inches and 15 lbf/2 inches (e.g., 11 lbf/2 inches).
[0046] It should be appreciated that including the third layer 110, and in particular, the fiberglass veil 120 (e.g., as illustrated by the chart of
[0047]
[0048] As shown in
[0049] In some embodiments, the fiberglass veil 120 (e.g., as illustrated by the graphs of
[0050]
[0051] As shown in
[0052]
[0053] As shown in
[0054] Because installation of duct wrap products usually requires the duct wrap product to slide over metal ducts, the friction between the duct wrap product and the metal ducts is a significant component of the force needed to move the product into place. The friction component becomes more significant when installation requires squeezing the product through narrow gaps created by adjacent building components. Reducing the friction between the duct wrap product and the metal duct can reduce the physical strain on installers and decrease the likelihood of damage to the duct wrap product.
[0055] To measure COF, a duct wrap specimen (e.g., measuring about 3″×3″×10″) is slid through a narrow gap of about 1 inch, and the following formula:
is applied, where F.sub.friction is the frictional force and F.sub.⊥ is the normal force required to compress the specimen to the desired gap width.
[0056] The following procedure was then followed to determine the duct wrap specimen's COF: (a) measuring the normal force, F.sub.⊥, required to compress a specimen to a desired thickness using a load cell; and (b) measuring the force, F.sub.friction required to pull a specimen at a constant speed through a narrow gap having an upper and lower surface made of metal (e.g., stainless steel), and a thickness corresponding to the desired thickness in Step (a). In Step (b), the instrument's maximum crosshead speed of 20 inches per minute was used to better mimic the typical speeds at which a duct wrap product is slid across duct work. In Step (c), the COF was calculated according to the above COF Equation.
[0057]
Dust Generation and Fiber Transfer
[0058] It should be appreciated that, in some embodiments, the fiberglass veil 120 (e.g., as illustrated by the graphs of
[0059]
[0060] As shown in
[0061]
[0062] As shown in
[0063] In some embodiments, the A-3 product releases dust particles equal to or less than 0.02 grams, during installation. In some embodiments, and to account for differences in the product sample area, the A-3 product releases dust particles equal to or less than 0.02 grams/4 ft.sup.2=0.005 g/ft.sup.2, during installation.
[0064] It should be appreciated that dust may be emitted by most light density fiberglass products during installation and is a well-known complaint of duct wrap installers. To test the propensity of fiberglass to emit dust, a slotted tube vacuum method was employed. In this method, a vacuum is applied to the specimens (e.g., 15″×24″ specimens (
[0065]
[0066]
[0067] As shown in
[0068] It should be appreciated that fiber transfer (also referred to as “sticking”) occurs when insulation from the duct wrap product (i.e., the insulating layer 20) transfers to the foil facer when the duct wrap product is being unrolled for installation. This can occur when the binder holding the fibers together is under-cured, or exposed to environmental conditions (like high temperatures and humidity) that would cause it to become tacky. Fiber transfer is a significant source of wasted material and labor for insulation contractors, as installers are forced to either discard severely affected products or use valuable installation time to carefully clean off mild to moderately affected products.
[0069] Unlike traditional duct wrap products, the A-3 product significantly, if not completely, blocks fiber transfer to the adjacent foil surface as it is unrolled for installation. To quantify the efficacy difference shown in
[0070] Step (k) includes reweighing the specimen from step (b); and Step (1) includes calculating the amount of fiber transfer by subtracting the weight in step (b) from the weight in step (k).
[0071] With continued reference to the drawings, in some embodiments, a combined thickness of the second layer 30 and the third layer 110 may be less than a thickness of the fiberglass layer 20 (See
[0072] Additionally, or alternatively, and for example, if a combination of slip sheet materials is used for forming the third layer 110, a thickness of the third layer 110 with combined slip sheet materials may be equal to or greater than a thickness of the second layer 30.
[0073] With continued reference to the drawings, and now with reference to
[0074] As shown in
[0075] As shown in
[0076] With continued reference to the drawings,
[0077] It is to be understood that the detailed description is intended to be illustrative, and not limiting to the embodiments described. Other embodiments will be apparent to those of skill in the art upon reading and understanding the above description. Moreover, in some instances, elements described with one embodiment may be readily adapted for use with other embodiments. Therefore, any products, methods, and/or systems described herein are not limited to the specific details, the representative embodiments, and/or the illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the general aspects of the present disclosure. The term “about” as used herein means approximately, in the region of, roughly, or around. When the term “about” is used in conjunction with a numerical range, it modifies that range by extending the boundaries above and below the numerical values set forth. In general, the term “about” is used herein to modify a numerical value above and below the stated value by 10%.
[0078] Additionally, the components and materials described hereinafter as making up the various embodiments are intended to be illustrative and not restrictive. It should be appreciated that many suitable components and materials that would perform the same or a similar function as the materials described herein are intended to be embraced within the scope of embodiments of the present disclosure.