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Method of making mineral fiber insulation batt impregnated with coextruded polymer layering system
| Details |
Inventors: Romes, Gary E.; Church, Joseph T.; Sanford, Steven; Syme, Robert W.;
Assignee: Guardian Fiberglass, Inc. (Albion, MI)
Primary Examiner: Ball; Michael W.
Assistant Examiner: Yao; Sam Chuan
Attorney, Agent or Firm: Myers Liniak & Berenato
A method of manufacturing/making mineral fiber (e.g. fiberglass) thermal insulation batt is disclosed wherein a base mineral fiber layer is impregnated with a two-layer layering system so as to produce a batt which is substantially vapor impermeable with a perm vapor rating less than about one. The first layer of the layering system is of a low melt material while the second layer is of a high melt material, the first layer being sandwiched between the base insulating layer and the second layer, and functioning to bond the layering system to the base. In certain embodiments, the first layer includes quick blooming ethyl vinyl acetate (e.g. from about 10-25% by weight) and a low density (e.g. 22-26 lbs. per cubic foot) polyethylene, and the second layer includes high density (e.g. 28-38 lbs. per cubic foot) polyethylene. The resulting insulation batt is vapor impermeable, less susceptible to cold-crack, easier to manufacture, fire retardant, more durable, and easier to handle. |
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DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS OF THIS INVENTION Referring now more particularly to the accompanying drawings in which like reference numerals indicate like parts throughout the several views.
FIG.
1 is a perspective view of thermal insulating batt 3 according to an embodiment of this invention.
Batt 3 includes mineral fiber (e.
g.
fiberglass) base 5 which is impregnated with vapor impermeable layering system 7.
Layering system 7 includes first layer 9 and second layer 11, with first layer 9 being sandwiched between mineral fiber base or core 5 and second layer 11.
According to the FIG.
1 embodiment, only one side (i.
e.
the top surface) of mineral fiber (e.
g.
fiberglass) base 5 is impregnated with the vapor impermeable layering system 7.
The phrase "vapor impermeable" as used herein refers to a vapor perm rating of less than about 1.
FIG.
4 illustrates an example of layering system 7 according to certain embodiments, including double folded stapling flanges 8 which renders attachment of the batt within vertical wall cavities easier.
According to certain embodiments of this invention, first layer 9 includes a low melt polymer while second layer 11 includes a high melt polymer, these two layers making up coextruded layering system 7.
In other words, the melting point of layer 9 is substantially less than the melting point of layer 11.
The melting point of first layer 9 may be from about 80.
degree.
-130.
degree.
C.
according to certain embodiments of this invention, while the melting point of layer 11 (which is greater than that of layer 9) is at least about 100.
degree.
C.
First layer 9 of layering system 7 includes, according to certain embodiments, a mixture of ethyl vinyl acetate and low density polyethylene.
With regard to the respective contents of these materials in layer 9, the ethyl vinyl acetate makes up from about 10-25% by weight of the layer while the low density polyethylene makes up from about 75-85% of layer 9.
The density of the polyethylene in layer 9 is from about 22-26 lbs
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Manufacturing Materials 
