Faced fiberglass board with improved surface toughness
AssigneeCertainTeed Corporation
InventorsJohn Ruid, Ronald Moulder
Life of this patent
Estimating the term…
Abstract
An insulation product is provided comprising a sheet of randomly oriented fibers bonded by a binder. The sheet has first and second major surfaces and a pair of side portions. A facing layer is bonded to at least one of the major surfaces. A region of the sheet proximate to the facing layer is more puncture resistant than a remainder of the sheet.
Claims35
An insulation product comprising:
- a sheet of randomly oriented fibers bonded by a binder, said sheet having first and second major surfaces and a pair of side portions;
- and
- a facing layer bonded to at least one of said major surfaces,
- wherein a region of said sheet proximate to said facing layer is more puncture resistant than a remainder of said sheet.
A method of manufacturing an insulation product comprising the steps of:
- forming a web of randomly oriented fibers on a forming belt, said fibers being coated with a heat curable binder, said web generally having a first major surface and a second major surface and a pair of side portions,
- wherein said web has a higher percentage by weight of said heat curable binder in a region of said web proximate to at least one of said major surfaces compared with a total percentage by weight of said binder in said web,
- compressing and heating said web to form a sheet of said randomly oriented fibers bonded by said heat curable binder, said sheet having first and second major surfaces and a pair of side portions;
- and
- affixing a facing layer to said at least one of said major surfaces of said sheet,
- wherein a region of said sheet proximate to said facing layer is more puncture resistant than a remainder of said sheet.
A fiberglass board insulation product, comprising:
- a rigid or semi-rigid fiber glass board comprising randomly oriented glass fibers bonded by a heat cured binder, said board having first and second major surfaces and a pair of side portions and having a fiber density greater than about 2.0 pounds per cubic foot;
- and
- a facing layer bonded to at least one of said major surfaces,
- said board having a higher percentage by weight of said heat cured binder in a region of said board proximate to said facing layer compared with a total percentage by weight of said heat cured binder in said board, thereby improving a puncture resistance of said region.
A fiberglass board insulation product, comprising:
- a rigid or semi-rigid fiber glass board comprising randomly oriented glass fibers bonded by a heat cured binder, said board having first and second major surfaces and a pair of side portions,
- said board having a higher percentage by weight of said heat cured binder in a region of said board proximate to at least one of said major surfaces compared with a total percentage by weight of said heat cured binder in said board, thereby improving a durability of said region.
A building structure comprising a plurality of walls, at least a portion of said walls being insulated with an insulation product, said insulation product comprising:
- a sheet of randomly oriented fibers bonded by a binder, said sheet having first and second major surfaces and a pair of side portions;
- and
- a facing layer bonded to at least one of said major surfaces,
- wherein a region of said sheet proximate to said facing layer is more puncture resistant than a remainder of said sheet.
Dependencies are inferred from the claim text.