Pre-Applied Waterless Adhesive On HVAC Facings With Sealable Flange

Abstract

A fibrous insulation product having at least one facing material adhered thereto is provided. The facing includes a pre-applied waterless, thin-film adhesive that is thermoplastic and heat activated. Accordingly, the facing may be repaired or repositioned in the field with the use of a hot applicator. In at least one embodiment, the fibrous insulation product is a duct board formed of an insulation layer with a vapor barrier adhered to a first major surface and a fibrous web adhered to a second major surface. The vapor barrier is preferably wider than the insulation layer to form a sealing flange. The waterless, thin-film adhesive may be placed on a sealing flange and heat sealed without the use of hand applied foil tape. The waterless, thin-film adhesive reduces odor potential and improves fiberglass recovery. In addition, the waterless, thin-film adhesive requires less energy to cure than a water-based adhesive, thereby reducing cost.

1 . A faced fibrous insulation product comprising:
 a fibrous insulation layer having first and second opposed major surfaces; and   a first facing layer adhered to said first major surface, said first facing layer having thereon a first pre-applied waterless, thin-film adhesive, wherein said first facing layer is adhered to said first major surface of said fibrous insulation layer by heating said fibrous insulation layer and said first facing layer to a temperature at or above the melting point of said first pre-applied waterless, thin-film adhesive.   
   
   
       2 . The faced insulation product of  claim 1 , wherein said first pre-applied waterless, thin-film adhesive is selected from the group consisting of a polyethylene copolymer, polyurethane, ethylene vinyl acetate, amorphous polyolefin, polyethylene, low density polyethylene, cellophane, polyethylene terephthalate, polyvinyl chloride, nylons, polypropylene, polystyrene, polyamides and cellulose acetate. 
   
   
       3 . The faced insulation product of  claim 1 , wherein said first facing layer is a vapor barrier and said first facing layer extends beyond said fibrous insulation layer to form a sealing flange. 
   
   
       4 . The faced insulation product of  claim 3 , wherein said insulation product contains a plurality of grooves to permit folding of said insulation product into one of a duct liner or a duct wrap. 
   
   
       5 . The faced insulation product of  claim 3 , wherein said first pre-applied thin-film adhesive is thermoplastic and said first facing layer and said sealing flange may be repaired or repositioned with the application of heat. 
   
   
       6 . The faced insulation product of  claim 3 , wherein said first pre-applied waterless, thin-film adhesive is substantially evenly applied to said fibrous insulation layer. 
   
   
       7 . The faced insulation product of  claim 1 , further comprising a second facing layer adhered to said second major surface of said fibrous insulation layer, said second facing layer having thereon a second pre-applied waterless, thin-film adhesive. 
   
   
       8 . The faced insulation product of  claim 7 , wherein said first and second facing layers are selected from the group consisting of a vapor barrier, a nonwoven mat, web and veil. 
   
   
       9 . A fibrous duct board comprising:
 a fibrous insulation layer having a first and second opposing major surfaces;   a first facing layer adhered to said first major surface, said first facing layer having thereon a first pre-applied waterless, thin-film adhesive, wherein said first facing layer is wider than said insulation layer such that said first facing layer extends beyond an edge of said fibrous insulation layer to form a sealing flange; and   a second facing layer adhered to said second major surface, said second facing layer having thereon a second pre-applied waterless, thin-film adhesive,   wherein said first and second facing layers are adhered to said fibrous insulation layer by heating said fibrous insulation layer, said first facing layer, and said second facing layer a temperature at or above the melting points of said first and second waterless, thin-film adhesive.   
   
   
       10 . The fibrous duct board of  claim 9 , further comprising male and female shiplap edges, said sealing flange extending from said male shiplap edge. 
   
   
       11 . The fibrous duct board of  claim 9 , wherein said first and second pre-applied waterless, thin-film adhesive are substantially evenly applied to said fibrous insulation layer 
   
   
       12 . The fibrous duct board of  claim 9 , wherein said first and second pre-applied waterless, thin-film adhesive is selected from the group consisting of a polyethylene copolymer, polyurethane, ethylene vinyl acetate, amorphous polyolefin, polyethylene, low density polyethylene, cellophane, polyethylene terephthalate, polyvinyl chloride, nylons, polypropylene, polystyrene, polyamides and cellulose acetate. 
   
   
       13 . The fibrous duct board of  claim 9 , wherein said first and second pre-applied thin-film adhesives are thermoplastic and said first and second facing layers may be repaired or repositioned with the application of heat. 
   
   
       14 . The fibrous duct board of  claim 9 , wherein said first facing layer is a vapor barrier and said second facing layer is selected from the group consisting of a nonwoven fibrous web, veil and mat. 
   
   
       15 . A method of forming a faced fibrous insulation product comprising:
 pre-applying a first waterless, thin-film adhesive to a first facing material to form a first facing layer;   forming a pack of fibers having an uncured binder thereon;   applying said first facing layer to a first major surface of said pack of fibers;   heating said first facing material and said pack of fibers to cure said binder and at least partially melt said first waterless, thin-film adhesive to form a faced insulation product.   
   
   
       16 . The method of  claim 15 , further comprising:
 pre-applying a second waterless, thin-film adhesive to a second facing material to form a second facing layer;   applying said second facing layer to a second major surface of said pack of fibers;   at least partially melting said second waterless, thin-film adhesive to adhere said second facing layer to said pack of fibers,   wherein said first and second waterless, thin-film adhesives may be the same or different.   
   
   
       17 . The method of  claim 16 , wherein said step of applying said first facing layer positions said first facing layer to extend beyond said pack of fibers to form a sealing flange. 
   
   
       18 . The method of  claim 17 , further comprising:
 forming grooves in said faced insulation product;   folding said insulation product along said grooves into a duct liner; and   heating said sealing flange to seal said sealing flange against a first portion of said insulation product to secure the formation of said duct liner.   
   
   
       19 . The method of  claim 16 , wherein said first and second waterless, thin-film adhesives are selected from the group consisting of a polyethylene copolymer, polyurethane, ethylene vinyl acetate, amorphous polyolefin, polyethylene, low density polyethylene, cellophane, polyethylene terephthalate, polyvinyl chloride, nylons, polypropylene, polystyrene, polyamides and cellulose acetate. 
   
   
       20 . The method of  claim 16 , wherein said first and second thin-film adhesives are thermoplastic and said first and second facing layers may be repaired or repositioned with the application of heat.