# US 2014/0193620 A1 · Synthetic fiber insulation with facing

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- Number: US 2014/0193620 A1
- Document ID: US20140193620A1
- Status: Published application
- Kind: A1
- Application number: 13/737,421
- Filed: 2013-01-09
- Published: 2014-07-10
- Earliest claimed: 2013-01-09
- Assignees: Vita Nonwovens, LLC
- Applicants: Vita Nonwovens, LLC
- Inventors: Michael D. Sandoe; Timothy J. Warrington
- Web page: https://patentgrep.com/patent/US20140193620A1

## CPC

- E04B 1/7662: {comprising fiber blankets or batts}
- B32B 5/022: {Non-woven fabric}
- B32B 5/08: the fibres or filaments of a layer being of different substances {, e.g. conjugate fibres, mixture of different fibres}
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 15/14: next to a fibrous or filamentary layer
- B32B 15/20: comprising aluminium or copper {(B32B15/016 and B32B15/017 take precedence)}
- B32B 29/02: next to a fibrous or filamentary layer
- D04H 1/5412: {sheath-core}
- D04H 1/5418: {Mixed fibres, e.g. at least two chemically different fibres or fibre blends}
- B32B 2262/0284: Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT]
- B32B 2262/101: Glass fibres
- B32B 2262/12: Conjugate fibres, e.g. core/sheath or side-by-side
- B32B 2307/304: Insulating
- B32B 2307/3065: Flame resistant or retardant, fire resistant or retardant
- B32B 2307/718: Weight, e.g. weight per square meter
- B32B 2419/00: Buildings or parts thereof
- B32B 2605/00: Vehicles
- B32B 2605/18: Aircraft
- E04B 2001/7687: {Crumble resistant fibrous blankets or panels using adhesives or meltable fibres}
- E04B 2001/7691: {Heat reflecting layers or coatings}
- Y10T 428/24967: Absolute thicknesses specified
- E04B: GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS (border constructions of opening in walls, floors or ceilings E06B1/00; {electromagnetic shielding H05K9/0001})
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- D04H: MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL (weaving D03; knitting D04B; braiding D04C; net-making D04G; sewing D05B; tufting D05C; finishing non-woven fabrics D06); FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING {; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION}(non-woven fabrics having an intermediate or external layer of a different kind, e.g. of woven fabric, B32B)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

An insulation product includes a fibrous layer and a facing layer. The fibrous layer includes synthetic fibers, has first and second opposing major surfaces, and has an average denier of less than about 3.0. The facing layer includes a paper-backed facing adhered to one of the first and second major surfaces of the fibrous layer. The insulation product has: a flame spread index of no greater than 25 and a smoke developed index of no greater than 50 as measured in accordance with ASTM E84; a thickness of between about 0.5 and 2 inches; and a thermal conductivity of less than about 0.3 Btu-in./ft2-hr-° F.

## Claims

### Claim 1

An insulation product, comprising:
a fibrous layer comprising synthetic fibers, the fibrous layer having first and second opposing major surfaces, the fibrous layer having an average denier of less than about 3.0; and
a facing layer comprising a paper-backed facing adhered to one of the first and second major surfaces of the fibrous layer;
wherein the insulation product has a flame spread index of no greater than 25 and a smoke developed index of no greater than 50 as measured in accordance with ASTM E84, wherein the insulation product has a thickness of between about 0.5 and 2 inches, and wherein the insulation product has a thermal conductivity of less than about 0.3 Btu-in./ft2-hr-° F.

### Claim 2 (depends on 1)

The insulation product of claim 1, wherein the fibrous layer comprises PET fibers.

### Claim 3 (depends on 1)

The insulation product of claim 1, wherein the fibrous layer has an average denier of less than about 2.5.

### Claim 4 (depends on 1)

The insulation product of claim 1, wherein the fibrous layer has an average denier of no greater than 2.1.

### Claim 5 (depends on 1)

The insulation product of claim 1, wherein the facing layer includes a paper layer and a metallic layer, wherein the paper layer is adhered to one of the first and second major surfaces of the fibrous layer.

### Claim 6 (depends on 5)

The insulation product of claim 5, wherein the metallic layer is an aluminum foil layer.

### Claim 7 (depends on 5)

The insulation product of claim 5, wherein the facing layer further includes a reinforcing layer disposed between the paper layer and the metallic layer.

### Claim 8 (depends on 1)

The insulation product of claim 1, wherein the facing layer has a thickness of about 0.01 inches.

### Claim 9 (depends on 1)

The insulation product of claim 1, wherein the insulation product has a thermal resistance of between about 2 and 8.5 hr-ft2-° F./Btu.

### Claim 10 (depends on 1)

The insulation product of claim 1, wherein the insulation product has a weight of between about 1 and 4 osf.

### Claim 11 (depends on 1)

The insulation product of claim 1, wherein the insulation product has a density of less than about 2 pcf.

### Claim 12 (depends on 1)

The insulation product of claim 1, wherein the fibrous layer comprises PET fibers, the PET fibers being between about 20% and 70% by weight standard staple fibers, between about 0% and 50% flame retardant staple fibers and between about 20% and 40% by weight bicomponent fibers.

### Claim 13 (depends on 1)

The insulation product of claim 1, wherein the facing layer is adhered to the fibrous layer by a thermoplastic adhesive.

### Claim 14

An insulation product, comprising:
a synthetic fibrous layer comprising PET fibers, the fibrous layer having first and second opposing major surfaces, the fibrous layer having an average denier of less than about 2.5; and
a paper-backed facing layer comprising a paper layer and a metallic layer, the paper layer adhered to one of the first and second major surfaces of the synthetic fibrous layer;
wherein the insulation product has a flame spread index of no greater than 25 and a smoke developed index of no greater than 50 as measured in accordance with ASTM E84, wherein the insulation product has a product thickness of between about 0.5 and 2 inches, and wherein the insulation product has a thermal conductivity of less than about 0.3 Btu-in./ft2-hr-° F.

### Claim 15 (depends on 14)

The insulation product of claim 14, wherein the facing layer further includes a reinforcing layer disposed between the paper layer and the metallic layer.

### Claim 16 (depends on 15)

The insulation product of claim 15, wherein the reinforcing layer comprises fiberglass.

### Claim 17 (depends on 14)

The insulation product of claim 14, wherein the insulation product has a weight of between 1 and 4 osf.

### Claim 18 (depends on 14)

The insulation product of claim 14, wherein the PET fibers are between about 20% and 70% by weight standard staple fibers, between about 0% and 50% flame retardant staple fibers and between about 20% and 40% by weight sheath-core bicomponent fibers.

### Claim 19 (depends on 14)

The insulation product of claim 14, wherein the facing layer is adhered to the fibrous layer by a thermoplastic adhesive.

### Claim 20

An insulation product, comprising:
a synthetic fibrous layer comprising PET fibers, the fibrous layer having first and second opposing major surfaces, the fibrous layer having an average denier of less than about 3.0; and
a paper-backed facing layer comprising a paper layer and a metallic layer, the paper layer adhered to one of the first and second major surfaces of the synthetic fibrous layer by a thermoplastic adhesive;
wherein the insulation product has a flame spread index of no greater than 25 and a smoke developed index of no greater than 50 as measured in accordance with ASTM E84, wherein the insulation product has a product thickness of between about 0.5 and 2 inches, wherein the insulation product has a weight of between about 1 and 4 osf, and wherein the insulation product has a thermal conductivity of less than about 0.3 Btu-in./ft2-hr-° F.