Creased facing material for insulation product applications

Abstract

An insulation product is provided comprising an insulation mat having first and second major surfaces and a pair of side portions. A facing layer is bonded to at least one of the major surfaces of the mat. The facing layer has a fiber orientation such that the facing layer has a ratio of machine direction tensile strength to cross machine direction tensile strength which permits the facing layer to be separated by hand along a substantially straight line selected in the machine direction. The facing layer can also have a crease in the machine direction that allows the facing layer to be separated by hand along the machine direction. The insulation mat may also be separable in the machine direction, and the separable portions of the insulation mat may substantially align with the crease in the facing layer to allow the facing and insulation to be separated together.

1 . An insulation product, comprising: 
 an insulation mat having first and second major surfaces, and a pair of side portions oriented substantially parallel with a machine direction of the insulation product; and    a facing layer bonded to at least a portion of one of the major surfaces of the mat, said facing layer comprising a material having a fiber orientation such that the facing layer has a machine direction tensile strength that is unequal to a cross machine direction tensile strength, said facing layer further having a fault plane oriented substantially in the machine direction which permits said facing layer to be separated by hand along a substantially straight line selected in said machine direction.    
   
   
       2 . The insulation product of  claim 1 , wherein said mat contains mineral fibers, polymeric fibers, rotary glass fibers, textile glass fibers, stonewool fibers, or a combination thereof.  
   
   
       3 . The insulation product of  claim 1 , wherein said facing layer comprises a cellulosic material bonded to said insulation mat with a vapor retardant adhesive.  
   
   
       4 . The insulation product of  claim 3 , wherein said cellulosic material comprises kraft paper.  
   
   
       5 . The insulation product of  claim 4 , wherein the kraft paper is from about 15 pounds per 2880 square feet to about 60 pounds per 2880 square feet.  
   
   
       6 . The insulation product of  claim 4 , wherein the kraft paper is from about 27 pounds per 2880 square feet to about 37 pounds per 2880 square feet.  
   
   
       7 . The insulation product of  claim 1 , wherein the fiber orientation of the facing layer is configured such that the facing layer has a ratio of machine direction tensile strength to cross machine direction tensile strength of at least about 4:1 to facilitate said separation.  
   
   
       8 . The insulation product of  claim 1 , wherein said insulation mat includes a plurality of separable segments, said segments contacting each other along at least one plane oriented substantially in the machine direction.  
   
   
       9 . The insulation product of  claim 8 , wherein said separable segments are coupled to each other using an adhesive, a perforation in said insulation mat along said at least one plane, or a partial cut through said mat along said at least one plane.  
   
   
       10 . The insulation product of  claim 8 , wherein said fault plane is substantially aligned with the at least one plane.  
   
   
       11 . The insulation product of  claim 1 , said facing layer further having at least a second fault plane oriented substantially in the machine direction.  
   
   
       12 . The insulation product of  claim 11 , wherein said insulation mat includes at least three segments, and adjacent segments contact each other along planes substantially aligned with said first and second fault planes.  
   
   
       13 . The insulation product of  claim 1 , said facing layer further having at least a second fault plane oriented substantially non-parallel to the machine direction.  
   
   
       14 . The insulation product of  claim 1 , wherein said fault plane comprises a crease that is substantially free of perforations in the facing layer.  
   
   
       15 . An insulation product comprising: 
 an insulation mat having first and second major surfaces and a pair of side portions; and    a facing layer bonded to said insulation mat, said facing layer including a central portion coextensive with said at least one major surface and at least one tab portion adjacent said central portion and extending beyond said at least one major surface;    wherein said facing layer comprises a material having a fiber orientation such that the facing layer has a machine direction tensile strength that is unequal to a cross machine direction tensile strength, said facing layer further having a weakened section oriented substantially parallel to a machine direction of said insulation product, said weakened section comprising a fault line in the material in the machine direction rendering said facing separable by hand along said weakened section; and    wherein said insulation mat includes a plurality of separable segments, said segments being coupled to each other along at least one plane oriented in said machine direction, the at least one plane being substantially aligned with the weakened section.    
   
   
       16 . The insulation product of  claim 15 , wherein the weakened section comprises an area of broken or otherwise disrupted fibers of the facing layer.  
   
   
       17 . The insulation product of  claim 15 , wherein said weakened section comprises a crease that is substantially free of perforations.  
   
   
       18 . The insulation product of  claim 15 , wherein the weakened section comprises a plurality of perforations in the facing layer.  
   
   
       19 . The insulation product of  claim 15 , wherein the facing layer comprises kraft paper.  
   
   
       20 . The insulation product of  claim 19 , wherein the kraft paper is from about 15 pounds per 2880 square feet to about 60 pounds per 2880 square feet.  
   
   
       21 . The insulation product of  claim 19 , wherein the kraft paper is from about 27 pounds per 2880 square feet to about 37 pounds per 2880 square feet.  
   
   
       22 . The insulation product of  claim 15 , wherein said facing layer further comprises at least a second weakened section oriented substantially non-parallel to said machine direction.  
   
   
       23 . The insulation product of  claim 15 , wherein said facing layer further comprises at least a second weakened section oriented substantially parallel to said first weakened section.  
   
   
       24 . A facing layer for an insulation product, comprising: 
 a material having a fiber orientation such that the facing layer has a ratio of machine direction tensile strength to cross machine direction tensile strength which permits the facing layer to be separated by hand along a substantially straight line selected in the machine direction, said material further comprising a crease oriented substantially in the machine direction.    
   
   
       25 . The facing layer of  claim 24 , wherein the fiber orientation of the facing layer is configured such that the facing layer has a ratio of machine direction tensile strength to cross machine direction tensile strength of between about 4:1 to 20:1 to facilitate said separation.  
   
   
       26 . The facing layer of  claim 24 , wherein the crease is substantially free of perforations.  
   
   
       27 . The facing layer of  claim 24 , wherein the crease further comprises a plurality of perforations, the facing layer further comprising an adhesive layer disposed on a surface thereof that substantially fills the perforations.