Fine fiber insulation products with improved thermal properties
AssigneeOwens Corning Intellectual Capital, LLC
InventorsLarry Grant, Dan Gurr, Teno Boone, Chung-Ying Tsai, Liang Chen, Gert Mueller
Life of this patent
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Abstract
An insulation product is disclosed comprising a plurality of glass fibers; and a cross-linked formaldehyde-free binder composition at least partially coating the glass fibers. The glass fibers have an average fiber diameter in the range of 8 HT (2.03 μm) to 15 HT (3.81 μm). At a density (x) between 0.3 pcf and 1.6 pcf, the insulation product may achieve a thermal conductivity (y) less than or equal to that which satisfies Formula (III): y=0.116x2−0.3002x+0.4219. Formula (III):
Claims15
An insulation product comprising:
- a plurality of glass fibers;
- and
- a cross-linked formaldehyde-free binder composition at least partially coating the glass fibers,
- wherein the glass fibers have an average fiber diameter within a range 8 HT (2.03 μm) to 15 HT (3.81 μm);
- wherein the insulation product has a binder content (LOI) of less than or equal to 8% by weight;
- wherein the insulation product has a density (x) between 0.2 pcf and 1.6 pcf;
- wherein the insulation product achieves a thermal conductivity (k-value), expressed as BTU-in/(hr·ft2·° F.), less than or equal to a value (y) which satisfies Formula (III):
- y=0.116x2−0.3002x+0.4219 Formula (III).
A method of forming an insulation product, the method comprising:
- fiberizing molten glass into a plurality of glass fibers;
- coating the glass fibers with an aqueous, formaldehyde-free binder composition;
- randomly depositing the glass fibers onto a moving conveyor, forming an uncured fiberglass blanket;
- and
- passing the uncured fiberglass blanket through a curing oven to cross-link the binder composition and form the fibrous insulation product,
- wherein the glass fibers have an average fiber diameter in a range of 8 HT (2.03 μm) to 15 HT (3.81 μm);
- wherein the insulation product has a binder content (LOI) of less than or equal to 8% by weight;
- wherein the insulation product has a density (x) between 0.2 pcf and 1.6 pcf;
- wherein the insulation product achieves a thermal conductivity (k-value), expressed as BTU-in/(hr·ft2·° F.), less than a value (y) which satisfies Formula (III):
- y=0.116x2−0.3002x+0.4219 Formula (III).
Dependencies are inferred from the claim text.