Faced fibrous insulation

Abstract

A faced fibrous insulation having a facing on one or more surfaces of a fibrous insulation material is provided. The facing provides improved surface quality, high and controlled adhesion, and is easily manufactured. The facing of the present invention includes a pre-applied adhesive that is heat activated to provide adhesion to the fibrous insulation. The facing may be input into the glass fiber forming section of a fibrous insulation production line. Alternatively, the facing may be applied to the uncured pack prior to curing or applied to the cured fibrous insulation. As another alternative, a vapor barrier layer may be attached on a surface of the insulation opposite the facing.

1 .) A faced fibrous insulation product, comprising: 
 a fibrous insulation layer having first and second opposed major surfaces; and    a first facing adhered to a first major surface of the fibrous insulation layer, the facing including a facing layer having a particulate adhesive sintered thereto having a point and, wherein the facing is adhered to the first major surface of the fibrous insulation layer by heating the facing and the fibrous insulation layer to a temperature above the melting point of said adhesive for a time sufficient to adhere the facing to the fibrous insulation layer.    
     
     
         2 .) The faced fibrous insulation product of  claim 1 , further comprising: 
 a thermally activated binder applied to the fibrous insulation layer, wherein said thermally activated binder is cured by the heat used to adhere the facing to the first major surface.    
     
     
         3 .) The faced fibrous insulation product of  claim 1 , wherein the particulate adhesive is selected from the group consisting of polyethylene, polypropylene, ethylene vinyl acetate, polyamide, epoxy, urea formaldehyde, melamine, urethane, phenolics and combinations thereof.  
     
     
         4 .) The mat faced fibrous insulation product of  claim 1 , wherein the particulate adhesive is a powdered adhesive.  
     
     
         5 .) The faced fibrous insulation product of  claim 4 , wherein the particulate adhesive is a fibrous adhesive.  
     
     
         6 .) The faced fibrous insulation product of  claim 1 , wherein the facing layer is formed of fibers selected from the group consisting of polyethylene, polypropylene, polyesters, rayon, nylon and blends thereof.  
     
     
         7 .) The faced fibrous insulation product of  claim 6 , wherein the facing layer is formed of a blend of polyester and rayon fibers.  
     
     
         8 .) The faced fibrous insulation product of  claim 1 , further comprising: 
 a second facing adhered to the second major surface of the fibrous insulation.    
     
     
         9 .) The faced fibrous insulation product of  claim 1 , wherein the fibrous insulation is glass fibers.  
     
     
         10 .) A method of making a faced fibrous insulation product comprising the steps of: 
 forming a pack of fibers having thereon an uncured binder;    applying a facer to a first surface of said pack of fibers, said facer including a facing layer, a particulate adhesive sintered to said facing layer; and    curing the pack of fibers to form a fibrous insulation product,    wherein the facer is adhered to the pack of fibers during said curing step.    
     
     
         11 .) The method of  claim 10 , further comprising the step of applying a second facer to a second surface of said pack of fibers prior to said curing step.  
     
     
         12 .) The method of  claim 10 , further comprising the step of applying a second facer to a second surface of said the faced fibrous insulation after said curing step.  
     
     
         13 .) The method of  claim 10 , further comprising the step of applying a vapor barrier to a second surface of said the faced fibrous insulation.  
     
     
         14 .) The method of  claim 10 , wherein the particulate adhesive is selected from the group consisting of polyethylene, polypropylene, ethylene vinyl acetate, polyamide, epoxy, urea formaldehyde, melamine, urethane, phenolics and combinations thereof.  
     
     
         15 .) The method of  claim 10 , wherein the particulate adhesive is a powdered adhesive.  
     
     
         16 .) The method of  claim 10 , wherein the particulate adhesive is a fibrous adhesive.  
     
     
         17 .) The method of  claim 10 , wherein the facing layer is formed of fibers selected from the group consisting of polyethylene, polypropylene, polyesters, rayon, nylon and blends thereof.  
     
     
         18 .) A method of making a faced fibrous insulation product comprising the steps of: 
 forming an uncured pack of glass fibers and uncured binder on said mat;    curing said pack by to form an insulation product; and    supplying facer having a facing layer and a particulate adhesive adhered to said facing layer to said insulation product; and    activating said particulate adhesive to adhere the facer to the insulation product.    
     
     
         19 .) The method of  claim 18 , further comprising the step of applying a second facer to the insulation product.  
     
     
         20 .) The method of  claim 18 , further comprising the step of applying a vapor barrier to a second surface of said the faced fibrous insulation after said curing step.  
     
     
         21 .) The method of  claim 18 , further comprising the step of applying a vapor barrier to a second surface of said the faced fibrous insulation.