Fiberglass insulation product

Abstract

A fibrous insulation product having a plurality of randomly oriented glass fibers and a binder composition that holds the glass fibers together is disclosed. The fibrous insulation product has an R-value in the range of 10 to 54 and, after curing, has a density, when uncompressed, in the range of 0.30 pcf to 2.7 pcf. Furthermore, the fibrous insulation product includes glass fibers that, prior to the application of the binder composition, have an average fiber diameter in the range of 8 HT to 12 HT and a quantity of binder that is in the range of 2% to 10% by weight of the fibrous insulation product.

1 - 20 . (canceled) 
     
     
         21 . A fibrous insulation product, comprising:
 a plurality of randomly oriented glass fibers; and   a binder composition that holds the glass fibers together;   wherein the glass fibers have an average fiber diameter in the range of 8 HT to 12 HT;   wherein the quantity of binder is less than or equal to 6% by weight of the fibrous insulation product;   wherein the fibrous insulation product, after curing, has an uncompressed density in the range of 0.30 pcf to 2.7 pcf;   wherein the fibrous insulation product has an R-value in the range of 10 to 54;   wherein the fibrous insulation product has a thickness in the range 2 inches to 18 inches and is formed by no more than two plies of the randomly oriented glass fibers; and   wherein the insulation product has a stiffness less than or equal to 75 degrees.   
     
     
         22 . The fibrous insulation product of  claim 21 , wherein the binder composition comprises 50-80 wt. % of maltodextrin, 20-50 wt. % of citric acid, 0.5-10 wt. % of sodium hypophosphite and 1-20 wt. % of a vegetable oil blend, based on the total solids content of the binder composition. 
     
     
         23 . The fibrous insulation product of  claim 21 , wherein the binder composition comprises 50-85 wt. % of a crosslinking agent, 2.5-30 wt. % of a long-chain polyol, and 2-30 wt. % of a short-chain polyol, based on the total solids content of the binder composition; wherein the long-chain polyol, the crosslinking agent, and the short-chain polyol are present in amounts such that the ratio of the number of molar equivalents of carboxylic acid groups, anhydride groups, or salts thereof to the number of molar equivalents of hydroxyl groups is from 1/0.3 to 1/0.66; and wherein a ratio of the long-chain polyol to the short-chain polyol is between about 0.1/0.9 to about 0.9/0.1. 
     
     
         24 . The fibrous insulation product of  claim 21 , wherein the binder composition comprises 60-80 wt. % of polyacrylic acid, 2.5-30 wt. % of polyvinyl alcohol, 8-30 wt. % of sorbitol, and 2-10 wt. % of sodium hypophosphite, based on the total solids content of the binder composition. 
     
     
         25 . The fibrous insulation product of  claim 21 , wherein the binder composition comprises 30-85 wt. % of a crosslinking agent and 2-65 wt. % of a polyol, based on the total solids content of the binder composition; wherein the aqueous binder composition is free or substantially free of polyols having a number average molecular weight of 2,000 Daltons or above; and wherein the binder composition is free or substantially free of polyols comprising less than four hydroxyl groups. 
     
     
         26 . The fibrous insulation product of  claim 25 , wherein the cross-linking agent and the polyol are present in amounts such that the ratio of the number of molar equivalents of carboxylic acid groups, anhydride groups, or salts thereof to the number of molar equivalents of hydroxyl groups is from about 0.6/1 to about 1/0.6. 
     
     
         27 . The fibrous insulation product of  claim 21 , wherein the binder composition consists of a polymeric polycarboxylic acid-based cross-linking agent and a monomeric polyol having at least four hydroxyl groups with a ratio of carboxylic acid groups to hydroxyl groups OH groups between 0.60/1 to 1/0.6. 
     
     
         28 . The fibrous insulation product of  claim 21 , wherein the binder composition comprises 10% to 30% by weight of binder solids. 
     
     
         29 . The fibrous insulation product of  claim 21 , wherein the binder composition is configured to be processed at a ramp moisture level of from 8% to 10%. 
     
     
         30 . The fibrous insulation product of  claim 21 , wherein the binder composition is configured to be processed at a ramp moisture level of less than 7%. 
     
     
         31 . The fibrous insulation product of  claim 21 , wherein the fibrous insulation product, after curing, has an uncompressed density in the range of 0.326 pcf to 1.097 pcf. 
     
     
         32 . The fibrous insulation product of  claim 21 , wherein the insulation product is a batt having an uncompressed thickness in the range of 2 inches to 3.5 inches, wherein the R-value of the batt is greater than or equal to 11, and wherein the density of the batt is less than or equal to 0.44 pcf. 
     
     
         33 . The fibrous insulation product of  claim 21 , wherein the insulation product is a batt having an uncompressed thickness in the range of 2 inches to 3.5 inches, wherein the R-value of the batt is greater than or equal to 13, and wherein the density of the batt is less than or equal to 0.69 pcf. 
     
     
         34 . The fibrous insulation product of  claim 21 , wherein the insulation product is a batt having an uncompressed thickness in the range of 2 inches to 3.5 inches, wherein the R-value of the batt is greater than or equal to 15, and wherein the density of the batt is less than or equal to 1.41 pcf. 
     
     
         35 . The fibrous insulation product of  claim 21 , wherein the insulation product is a batt having an uncompressed thickness in the range of 2 inches to 6.25 inches, wherein the R-value of the batt is greater than or equal to 19, and wherein the density of the batt is less than or equal to 0.41 pcf. 
     
     
         36 . The fibrous insulation product of  claim 21 , wherein the insulation product is a batt having an uncompressed thickness in the range of 2 inches to 5.5 inches, wherein the R-value of the batt is greater than or equal to 20, and wherein the density of the batt is less than or equal to 0.65 pcf. 
     
     
         37 . The fibrous insulation product of  claim 21 , wherein the insulation product is a batt having an uncompressed thickness in the range of 2 inches to 5.5 inches, wherein the R-value of the batt is greater than or equal to 21, and wherein the density of the batt is less than or equal to 0.75 pcf. 
     
     
         38 . The fibrous insulation product of  claim 21 , wherein the insulation product is a batt having an uncompressed thickness in the range of 2 inches to 9.5 inches, wherein the R-value of the batt is greater than or equal to 30, and wherein the density of the batt is less than or equal to 0.45 pcf. 
     
     
         39 . The fibrous insulation product of  claim 21 , wherein the insulation product is a batt having an uncompressed thickness in the range of 2 inches to 14.0 inches, wherein the R-value of the batt is greater than or equal to 49, and wherein the density of the batt is less than or equal to 0.57 pcf. 
     
     
         40 . A building frame comprising:
 a plurality of parallel, spaced apart framing members;   a fiberglass insulation batt received between two of the framing members, the fiberglass insulation batt comprises the fibrous insulation product according to  claim 21 .