Abstract: A method of making thermal insulation includes, forming a thermal insulation product precursor having randomly distributed inorganic fibers and about 5-500 wt. % heat-expandable hollow microspheres in dry or slurry form and having a polymeric shell and having disposed therein a blowing agent or gas, and calcium acetate or cupric carbonate, or a combination of calcium acetate and cupric carbonate, and heating the precursor to expand the microspheres.

Abstract: A method of making thermal insulation includes, forming a thermal insulation product precursor having randomly distributed inorganic fibers and about 5-500 wt. % heat-expandable hollow microspheres in dry or slurry form and having a polymeric shell and having disposed therein a blowing agent or gas, and calcium acetate or cupric carbonate, or a combination of calcium acetate and cupric carbonate, and heating the precursor to expand the microspheres.

Abstract: Thermal insulation is provided which includes randomly distributed inorganic fibers and about 5-500 wt. % unexpanded hollow microspheres comprising a polymeric shell having disposed therein a blowing agent or gas, said unexpanded hollow microspheres increasing in size when heated. Also provided is an insulated attic, including a plurality of rafters, an attic floor and a thermal insulation comprising randomly distributed glass fibers in at least about 5 wt. % hollow expanded microspheres having a diameter of 20-140 microns, which have been expanded from about 6-40 microns. The hollow expanded microspheres reduce the thermal conductivity of the thermal insulation by at least about 5%, and have shown improvement up to 19.4% decreased thermal conductivity during tests at loadings from 30% to 257%. Additionally, calcium acetate and cupric carbonate additions to glass fiber insulation products showed improvement by at least about a 1% decrease in thermal conductivity.

Abstract: A fibrous insulation has insulation fibers (104) with a fungicide in a dispersed additive affixed to the fibers (104), and a method of making a fibrous insulation by dispersing a fungicide and a dispersed additive on the fibers (104) followed by affixing the dispersed additive on the fibers (104). The method produces thermal, acoustic, duct liner or board insulation either as loose fill insulation or as an insulation mat.

Abstract: An insulation product having an integral air vent channel is disclosed for use in attic and cathedral ceiling applications. The product includes an insulation blanket having at least a pair of raised strips formed on one side thereof. When installed, the blanket is fit up between a pair of roof rafters until the raised strips contact the undersurface of the roof. The strips ensure that a predetermined offset exists between the insulation blanket and the roof, thus forming an unobstructed ventilation path running from the soffit to the roof peak. The raised strips can be foamed polyurethane or other polymer material that is dispensed or laminated onto the insulation blanket after the blanket exits the curing oven. The blanket may be a foamed polymer insulation that is extruded as a blanket at the proper insulation height for installation or may be cut to size from an overthick bun of insulation. The blanket and strips may be formed by a mold that shapes a pour in place foam.

Abstract: An insulation composite for attenuating energy or sound transmission has a body layer of insulating material with a roughly textured face and a uniform thickness solid cover layer permanently embedded in the body layer to a partial depth so that material of the body layer does not protrude through the surface of the cover layer. The body layer can be rigid board or resilient batting such as fiberglass. The cover layer is formed from a curable fluid cast onto the upwardly facing surface of the body layer. The uniform thickness of the cover layer is achieved by spreading the fluid over the surface utilizing a coating bar having a downwardly facing corrugated profile defining ridges in contact with the body layer and grooves between the ridges, such as a wire wound coating bar Some of the fluid is pressed into the body layer by the ridges while other fluid passes through the grooves then settles to uniform thickness over the wet surface of the body layer.

Abstract: The present invention relates to apparatus for improving the thermal performance of fibrous glass insulation in the admix recycling of the insulation, which includes corrugated hose in a recycling portion of the apparatus.

Abstract: A duct board or duct liner comprises: an insulating layer formed from fibrous material bound with a resin binder, an outer facing layer adhered to an outer surface of the insulating layer, and a water repellant mat facing adhered to an interior surface of the insulating layer opposite the outer surface to form a duct board material. The mat facing provides sufficient water repellency to repel a mixture of about 40% isopropanol and about 60% water. The duct board or duct liner material may be formed into a tubular shape capable of conducting air, with the mat facing on the interior of the tubular shape.

Abstract: Thermal insulation is provided which includes randomly distributed inorganic fibers and about 5-500 wt. % unexpanded hollow microspheres comprising a polymeric shell having disposed therein a blowing agent or gas, said unexpanded hollow microspheres increasing in size when heated. Also provided is an insulated attic, including a plurality of rafters, an attic floor and a thermal insulation comprising randomly distributed glass fibers in at least about 5 wt. % hollow expanded microspheres having a diameter of 20-140 microns, which have been expanded from about 6-40 microns. The hollow expanded microspheres reduce the thermal conductivity of the thermal insulation by at least about 5%, and have shown improvement up to 19.4% decreased thermal conductivity during tests at loadings from 30% to 257%. Additionally, calcium acetate and cupric carbonate additions to glass fiber insulation products showed improvement by at least about a 1% decrease in thermal conductivity.

Abstract: A laminated article includes a substrate of a building material; and an adaptive vapor retarder film adhered to the substrate. The film is selected as being at least one from the group consisting of: ethylene vinyl alcohol (EVOH), EVOH coextruded or laminated with at least a second polymer, a blended polymer comprising EVOH, or a combination of these materials.

Abstract: A packaged insulation product comprises an insulation assembly having first and second insulation blanket portions and a folded sheet facing sandwiched between the insulation blanket portions. Each insulation blanket portion has a major face bonded to the sheet of facing. The folded sheet of facing forms a hinge that connects the first and second insulation blanket portions. A wrapper may be used to at least partially enclose the insulation assembly, to form a packaged insulation product.

Abstract: An insulation board product is provided comprising a insulation board layer having a first major surface corresponding to or proximate to a contact or airflow surface and a second major surface opposite the first major surface. A weatherproof barrier layer is applied to the insulation board layer and a bridging contact layer is coupled between the second major surface and the weatherproof barrier layer.

Abstract: A fibrous insulation has insulation fibers (104) with a fungicide in a dispersed additive affixed to the fibers (104), and a method of making a fibrous insulation by dispersing a fungicide and a dispersed additive on the fibers (104) followed by affixing the dispersed additive on the fibers (104). The method produces thermal, acoustic, duct liner or board insulation either as loose fill insulation or as an insulation mat.

Abstract: The present invention relates to a method of manufacturing an laminated article which includes a building material adhered to a water vapor retarder film having a water vapor permeance dependent on the ambient humidity adhered to the insulation, laminated articles, and uses thereof.

Abstract: A product comprises: a mineral fiber insulation board which is resistant to liquid water-penetration and has first and second major surfaces, a facing material, which is resistant to air infiltration and liquid water-penetration, laminated to the first major surface of the insulation board, the facing material being permeable to water vapor, and an interior facing laminated to the second surface of the insulation board with an adhesive, so that the second major surface with the interior facing and adhesive thereon is resistant to liquid water-penetration, thereby to form a unitary building exterior envelope product.

Abstract: A thermal insulation product is provided comprising a loose fill insulation for insulating an interior of a hollow or open space in a structure and at least one phase change material dispersed in the loose fill insulation.

Abstract: The present invention provides coating materials (14), insulation-containing building material products bearing the materials and methods for applying the coatings to the building material products. The coating materials (14) possess one-way “breathability” characteristics with respect to water and aqueous solutions. That is, the coatings are essentially impermeable to liquid water and permeable to water vapor. Vapor from water insulation coated by the material may thus pass through the coating, whereas liquid water is effectively prevented from passing through the coating and entering the insulation.

Abstract: The invention relates to fibrous insulation products that exhibit improved flame resistance, relative to previously known products. The insulation product has a fibrous mineral matrix, into which is incorporated a phosphate-containing compound (e.g., an inorganic phosphate salt) and a refractory mineral filler (e.g., alumina or aluminum sulfate). The product exhibits flame resistance superior to the fibrous mineral matrix alone.

Abstract: A Method for forming a shiplap edge in a duct board comprises the steps of: molding a shiplap edge in a first duct made of mineral fiber or mineral wool, so that the molded shiplap edge has a molded edge thickness, and machining the molded shiplap edge to a desired machined edge thickness that is less than the molded edge thickness.

Abstract: A duct board includes a sheet, facing having a tab and adhesive applied to the tab. The sheet of the duct board has an outer surface and includes a male shiplap edge. The facing is located on the outer surface of the sheet. The tab of the facing extends substantially over the width of the male shiplap edge. The adhesive is applied to an inner surface of the tab.