Insulation material including extensible mesh material from fibrous material

• US 20060008616A1
• Filed: 12/28/2004
• Published: 01/12/2006
• Est. Priority Date: 07/12/2004
• Status: Abandoned Application

• Current Assignee: Owens- Corning Fiberglas Technology Incorporated (Owens Corning)
• Original Assignee: Owens- Corning Fiberglas Technology Incorporated (Owens Corning)
• Inventors: Rockwell, Anthony L., Dean, Patrick
• Application Number:
  US11/024,081
• Publication Number:
  US 20060008616A1
• Time in Patent Office: Days
• US Class Current: 428/117
• CPC Class Codes: B26F 1/20 with tools carried by a rotating drum or similar support B26F1/22 takes precedence
• CPC Class Codes: B26F 1/22 to form non-rectilinear cuts, e.g. for tabs
• CPC Class Codes: B29C 2793/0081 before shaping
• CPC Class Codes: B31D 3/0292 involving auxiliary operations, e.g. expanding, moistening, glue-applying, joining, controlling
• CPC Class Codes: Y10T 428/24149 Honeycomb-like
• CPC Class Codes: Y10T 428/24157 Filled honeycomb cells [e.g., solid substance in cavities, etc.]
• CPC Class Codes: Y10T 442/2016 Impregnation is confined to a plane disposed between both major fabric surfaces which are essentially free of impregnating material
• CPC Class Codes: Y10T 442/2213 Coating or impregnation is specified as weather proof, water vapor resistant, or moisture resistant
• CPC Class Codes: Y10T 442/2762 Coated or impregnated natural fiber fabric [e.g., cotton, wool, silk, linen, etc.]
• CPC Class Codes: Y10T 442/2861 Coated or impregnated synthetic organic fiber fabric
• CPC Class Codes: Y10T 442/2926 Coated or impregnated inorganic fiber fabric
• CPC Class Codes: Y10T 442/2975 Coated or impregnated ceramic fiber fabric
• CPC Class Codes: Y10T 442/2984 Coated or impregnated carbon or carbonaceous fiber fabric
• CPC Class Codes: Y10T 442/2992 Coated or impregnated glass fiber fabric
• CPC Class Codes: Y10T 442/659 Including an additional nonwoven fabric
• CPC Class Codes: Y10T 442/696 Including strand or fiber material which is stated to have specific attributes [e.g., heat or fire resistance, chemical or solvent resistance, high absorption for aqueous compositions, water solubility, heat shrinkability, etc.]

Abstract

A web or panel of insulation is provided that includes an extensible web of fibrous material that is configured to provide a series of openings in the expanded web. The openings within the web are filled with insulation to provide a batt or panel of thermal or acoustical insulation. More specifically, the present invention relates to insulation filled extended fibrous webs that are suitable for use as thermal or acoustical insulation in a building structure, as a partition or panel or as thermal or acoustical insulation in a motor vehicle.

Claims

1. An insulation panel, comprising:

a fibrous body having first and second opposed surfaces and first and second opposed edges and a plurality of cuts made in said body and extending from said first opposed surface to said second opposed surface, said fibrous web being extensible to create interstices in said body; and

an insulation material in said interstices.

2. The insulation panel of claim 1, wherein the fibrous body is extensible primarily by bending the fibers around a plurality of flexible hinges.

3. The insulation panel of claim 2, wherein the plurality of cuts comprises a pattern of intersecting cuts which form said flexible hinges.

4. The insulation panel of claim 1, wherein said fibrous body is formed of fibers selected from the group consisting essentially of polyolefin fibers, polyamide fibers, polyester fibers, polypropylene fibers, polyvinyl chloride fibers, polyethylene fibers, nylon fibers, rayon fibers, polyethylene terephthalate fibers, polyvinyl acetate fibers, polybutylene terephthalate fibers, melamine fibers, acrylic fibers, visil fibers, aramid fibers, glass fibers, metal fibers, basalt fibers, mineral fibers, carbon fibers, graphite fibers, cotton fibers, kenaf fibers, sisal fibers, and mixtures thereof.

5. The insulation panel of claim 1, wherein said insulation material is formed of fibers selected from the group consisting essentially of polyolefin fibers, polyamide fibers, polyester fibers, polypropylene fibers, polyvinyl chloride fibers, polyethylene fibers, nylon fibers, rayon fibers, polyethylene terephthalate fibers, polyvinyl acetate fibers, polybutylene terephthalate fibers, melamine fibers, acrylic fibers, visil fibers, aramid fibers, glass fibers, metal fibers, basalt fibers, mineral fibers, carbon fibers, graphite fibers, cotton fibers, kenaf fibers, sisal fibers and mixtures thereof.

6. The insulation panel of claim 5, wherein the fibers are selected from the group consisting essentially of staple fibers, chopped fibers, bonded glasswool fibers, unbonded glasswool fibers and mixtures thereof.

7. The insulation panel of claim 5, wherein the fibers are selected from the group consisting essentially of single component and multi-component fibers.

8. The insulation panel of claim 1, further comprising:

a first facer on said first surface, wherein said first facer is formed of a vapor permeable material.

9. The insulation panel of claim 8, further comprising:

a second facer on said second surface, wherein said second facer is formed of a vapor barrier material.

10. A method of forming an insulative panel, comprising the steps of:

providing a fibrous body having first and second opposed surfaces and first and second opposed edges;

forming a plurality of cuts in said body, said cuts extending from said first opposed surface to said second opposed surface;

extending said fibrous body to create interstitial openings; and

filling said interstitial openings with an insulation material.

11. The method of forming an insulative panel of claim 10, wherein the step of forming a plurality of cuts comprises cutting an intersecting pattern to form a plurality of flexible hinges.

12. The method of forming an insulative panel of claim 11, wherein the pattern is selected from the group consisting of slits, holes and combinations thereof.

13. The method of forming an insulative panel of claim 10, wherein the step of filling said interstitial openings comprises the step of inserting fibers selected from the group consisting essentially of polyolefin fibers, polyamide fibers, polyester fibers, polypropylene fibers, polyvinyl chloride fibers, polyethylene fibers, nylon fibers, rayon fibers, polyethylene terephthalate fibers, polyvinyl acetate fibers, polybutylene terephthalate fibers, melamine fibers, acrylic fibers, visil fibers, aramid fibers, glass fibers, metal fibers, basalt fibers, mineral fibers, carbon fibers, graphite fibers, cotton fibers, kenaf fibers, sisal fibers, staple fibers, chopped fibers, bonded glasswool fibers, unbonded glasswool fibers, single component, multi-component fibers and mixtures thereof.

14. The method of forming an insulative panel of claim 10, further comprising the step of:

applying an adhesive to the insulation material.

15. The method of forming an insulative panel of claim 10, further comprising the step of:

applying a facer to the first surface of said insulative panel, wherein said facer is selected from the group consisting of vapor permeable material and vapor barrier material.

16. The method of forming an insulative panel of claim 10, further comprising the steps of:

applying a vapor permeable facer to the first surface; and

applying a vapor barrier facer to the second surface.

17. An insulation panel, comprising:

a fibrous body having first and second opposed surfaces and first and second opposed edges and a plurality of cuts in said body extending from said first opposed surface to said second opposed surface, said fibrous body being extended to create interstices in said body;

an insulation material in said interstices;

a first facer on said first opposed surface; and

a second facer on said second opposed surface.

18. The insulation panel of claim 17, further comprising:

facer flanges on at least one of said opposed edges.

19. The insulation panel of claim 17, wherein said fibrous body is formed of fibers selected from the group consisting essentially of polyolefin fibers, polyamide fibers, polyester fibers, polypropylene fibers, polyvinyl chloride fibers, polyethylene fibers, nylon fibers, rayon fibers, polyethylene terephthalate fibers, polyvinyl acetate fibers, polybutylene terephthalate fibers, melamine fibers, acrylic fibers, visil fibers, aramid fibers, glass fibers, metal fibers, basalt fibers, mineral fibers, carbon fibers, graphite fibers, cotton fibers, kenaf fibers, sisal fibers and mixtures thereof.

20. The insulation panel of claim 17, wherein said insulation material is formed of fibers selected from the group consisting essentially of polyolefin fibers, polyamide fibers, polyester fibers, polypropylene fibers, polyvinyl chloride fibers, polyethylene fibers, nylon fibers, rayon fibers, polyethylene terephthalate fibers, polyvinyl acetate fibers, polybutylene terephthalate fibers, melamine fibers, acrylic fibers, visil fibers, aramid fibers, glass fibers, metal fibers, basalt fibers, mineral fibers, carbon fibers, graphite fibers, cotton fibers, kenaf fibers, sisal fibers and mixtures thereof.