Note: Descriptions are shown in the official language in which they were submitted.
CA 02361791 2001-11-09
PRE-CUT FIBROUS INSULATION FOR CUSTOM FITTING
WALL CAVITIES OF DIFFERENT WIDTHS
This application is a continuation-in-part of Application Serial No.
09/522,976, filed
March 10, 2000, which is a division of Application Serial No. 09/167,783,
filed October 7, 1998,
now Patent No. 6,083,594.
BACKGROUND OF THE INVENTION
The present invention relates to a fibrous insulation blanket pre-cut for
custom fitting
the fibrous insulation blanket into cavities of different widths formed by the
framework of a
building, such as both standard and non-standard width wall, floor, ceiling or
roof cavities
formed in part by successive frame members; and, in particular, to a pre-cut
fibrous insulation
blanket that can be handled as a unit when insulating a cavity of a certain
predetermined width
or easily separated or tom apart (by hand) along one or more series of cuts
and separable
connectors formed in the fibrous insulation blanket to form narrower blankets
when insulating
a cavity having a lesser width.
Building structures, such as residential houses, industrial buildings, office
buildings,
mobile homes, prefabricated buildings and similar structures typically include
walls (both
interior and exterior), ceilings, floors and roofs which are insulated for
both thermal and
acoustical purposes, especially the exterior walls, the ceilings below open
attic spaces, and the
roofs of such structures. The walls, ceilings, floors and roofs of these
structures include
framing members, e.g. studs, rafters, floor and ceiling joists, beams and
similar support
members, which are normally spaced-apart standard distances established by the
building
industry. Sheathing, paneling, lathing or similar construction materials are
secured to these
framing members. to form the walls, ceilings, floors and roofs of the
structures. While the
contractor seeks to maintain the spacing of such framing members in these
structures at these
standard distances for ease of construction and the insulation of the
elongated cavities formed
in these walls, ceilings, floors, and roofs, frequently, the walls, ceilings,
floors and/or roofs of
these structures include elongated cavities defined, at least in part, by
successive or adjacent
-1-
CA 02361791 2001-11-09
framing members which are spaced apart a nonstandard distance less than the
standard
spacing between framing members. Studies have shown that in a typical
residential house, it
is common for 50°l° or more of the framing members in the
exterior walls of these structures to
be spaced apart at nonstandard distances less than the standard spacing for
such framing
members.
When insulating these elongated cavities of various nonstandard widths, less
than a
standard width, it has been the practice to take an insulation batt preformed
to fit the standard
cavity width and reduce the width of the insulation batt by cutting off and
removing a strip of
insulation material from one or both longitudinal edges of the insulation
batt. U.S. patent no.
5,331,787; issued July 26, 1994; to Kaarst; illustrates this approach. In the
invention of this
patent, the insulation bans or panels have widths at least equal to a
predetermined maximum
distance between adjacent support members defining the cavities that the batts
or panels are
to insulate. The batts or panels are provided with facings that are folded
over along the
longitudinal edges of the batts or panels so that strips of insulation
material can be cut away
from one or both longitudinal edges of the batts or panels to fit the bans or
panels between
support members spaced apart less than the predetermined maximum spacing. This
method
of trimming the insulation batts at the job site by cutting the batts to fit
between the more
closely spaced support members is time consuming, raises a significant risk or
safety issue,
relies heavily on the worker's skill to accurately trim the batt or panel.
U.S. patent no. 4,866,905; issued September 19, 1989; to Bihy et al; discloses
another
approach to the problem. In the invention disclosed in this patent, a
continuous strip of fibrous
insulation with transverse marking lines is provided. The worker cuts the
strip of fibrous
insulation at the job site to a width somewhat greater than the spacing
between the framing
members, i.e. rafters, defining the space to be insulated. Of course this
method of forming
insulation batts or panels at the job site is also time consuming and relies
heavily on the skill of
the worker cutting the insulation strip to achieve a good result.
A different approach to the problem is shown in U.S. patent no. 2,335,968;
issued Dec.
7, 1943; to Sawtell. In the invention of this patent, the lateral edges of the
insulation blanket
are turned down to enable the insulation batt to be placed between framing
members, i.e.
rafters, spaced closer together. than the width of the insulation batt. This
approach does not
require any cutting or trimming at the job site, but it can only be used where
the spacing
between the framing members is slightly less than the width of insulation
blanket. In addition,
the extra insulation material used to insulate cavities having less than a
standard cavity width
would add significantly to material costs.
_2_
CA 02361791 2001-11-09
Thus it can be seen that there has been a need to provide fibrous insulation
blankets
or batts which can be used to either insulate cavities of a predetermined
width, such as but not
limited to standard width framework cavities, ,or be quickly and easily
reduced in width to fit
cavities of lesser widths, such as less than standard width cavities, without
a need to cut the
fibrous insulation blankets at the job site with knives or similar cutting
tools which is both time
consuming and can result in cuts or other injuries to the workers.
SUMMARY OF THE INVENTION
The pre-cut fibrous insulation blanket of the present invention provides a
solution to the
above discussed problems. The pre-cut fibrous insulation blanket of the
present invention is
pre-cut for custom fitting the insulation blanket into building cavities of
different widths formed
by the framework of a building. The width of the pre-cut fibrous insulation
blanket is normally
equal to or substantially equal to the width of a standard cavity to be
insulated by the pre-cut
fibrous insulation blanket, e.g. about fourteen and one half to about fifteen
inches or about
twenty two and one half to about twenty three inches in width for a typical
wall cavity.
However, the pre-cut fibrous insulation blanket may also be initially formed
at a selected width,
e.g. about thirteen to about thirteen and one half inches, less than a
standard cavity width.
Do to the compressibility and resilience of the pre-cut fibrous insulation
blankets of the
present invention (generally pre-cut glass fiber insulation blankets), the pre-
cut fibrous .
insulation blankets can be fitted into cavities having a width up to about one
and one half
inches less than the width of the pre-cut fibrous insulation blankets without
removing any
sections of the blankets, e.g. a pre-cut fibrous insulation blanket having a
width between about
fourteen and one half to about fifteen inches can be installed within a cavity
having a width of
about thirteen inches or greater. For cavities of lesser widths, greater than
about one and one
half inches less in width than the pre-cut fibrous insulation blankets, the
pre-cut fibrous
insulation blankets may have one or more sections removed from the blankets so
that the
remaining portions of the pre-cut fibrous insulation blankets will better fit
into the cavities being
insulated.
The pre-cut fibrous insulation blanket of the present invention has at least
one
(preferably, two or more) series of cuts extending between a first major
surface to a second
-3-
CA 02361791 2001-11-09
major surface of the pre-cut fibrous insulation blanket with successive cuts
of each series of
cuts being separated by a series of separable connectors located intermediate
the major
surfaces of the pre-cut fibrous insulation blanket. Each series of cuts and
separable
connectors extend for the length of the pre-cut fibrous insulation blanket
with each series of
separable connectors holding together adjacent sections of the pre-cut fibrous
insulation
blanket for handling and being separable by hand whereby the pre-cut fibrous
insulation
blanket can be handled as a unit for insulating a cavity having a
predetermined width, such as
but not limited to a standard cavity width, or easily separated by hand into
two or more
sections at each series of separable connectors for insulating a cavity of
lesser width, such as
a cavity having less than a standard width.
The first or second major surface of the pre-cut fibrous insulation blanket
may have a
facing bonded thereto which, preferably, has one or more perforated lines or
overlapping tabs
(tabs which are adhesively bonded together) for permitting the facing to be
separated at each
series of cuts and separable connectors in the pre-cut fibrous insulation
blanket to facilitate
separating or tearing apart the faced pre-cut insulation blanket by hand, if
required.
Preferably, the perforations of the perforated lines) in the facing are closed
by the bonding
agent bonding the facing to the pre-cut fibrous insulation blanket. The
filling of the
perforations in the facing with the bonding agent helps to reinforce or
increase the integrity of
the facing at the pertorations to prevent an unwanted separation of the facing
at the
perforations and enables the facing to function as a vapor barrier in spite of
the perforations.
Thus, the pre-cut fibrous insulation blanket with the facing can still be
quickly and easily
modified to fit a cavity of a particular width without sacrificing the vapor
barrier properties of the
facing sheet.
Preferably, the facing sheet has tabs for securing the faced pre-cut fibrous
insulation
blanket to framing members, e.g. with staples or an adhesive. These tabs may
be located
along each lateral edge of the pre-cut fibrous insulation blanket and facing
sheet and pairs of
tabs may be located adjacent each series of cuts and separable connectors in
the pre-cut
fibrous insulation blanket with the perforated lines in the facing sheet or an
adhesive layer
separably joining the tabs of each pair of tabs.
With the faced or unfaced pre-cut fibrous insulation blanket of the present
invention,
the pre-cut fibrous insulation blanket can be quickly and easily sized to fit
wall, floor, ceiling,
roof and other building cavities formed by the framework of a building without
the need to use
cutting tools at the job site to cut the insulation. Thus, the use of the pre-
cut fibrous insulation
blanket of the present invention to insulate the wall, floor, ceiling and roof
cavities of buildings,
CA 02361791 2001-11-09
especially wall cavities, not only reduces safety concerns, but greatly speeds
up the installation
process. Since insulation installers are frequently paid by the piece, the
present invention
enables them to operate more profitably.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic elevation of the framework in an outside wall of a
building with
pre-cut fibrous insulation blankets of the present invention installed in
standard width and less
than standard width wall cavities defined by the frame members.
FIG. 2 is a schematic view of a major surtace of an unfaced pre-cut fibrous
insulation
blanket of the present invention with three series of cuts and separable
connectors in the
fibrous insulation blanket.
FIG. 3 is a schematic longitudinal section along one of the series of cuts and
separable
connectors of the unfaced pre-cut fibrous insulation blanket of FIG. 2, taken
substantially
along lines 3-3 of FIG 2.
FIG. 4 is a schematic transverse section of the unfaced pre-cut fibrous
insulation
blanket of FIG. 2, taken substantially along lines 4-4 of FIG. 2.
FIG. 5 is a schematic view, on a larger scale than FIG. 4, of a separable
connector of
FIG. 4.
FIG. 6 and 7 are schematic views, on a larger scale than FIG. 4, of different
embodiments of the separable connector of FIG. 4.
FIG. 8 is a schematic transverse cross section of a faced pre-cut fibrous
insulation
blanket of the present invention with integral tabs in the facing sheet,
formed by Z-pleats,
located adjacent each series of cuts and separable connectors in the pre-cut
fibrous insulation
blanket.
FIG. 9 is a partial schematic transverse cross section, on a larger scale than
FIG. 8, of
the faced pre-cut fibrous insulation blanket of FIG. 8.
FIG. 10 is a partial schematic transverse cross section of the pre-cut fibrous
insulation
blanket of FIGS. 8 and 9 showing the faced pre-cut fibrous insulation blanket
in the process of
being separated along a series of cuts and separable connectors.
FIG. 11 is a partial schematic transverse cross section of a faced pre-cut
fibrous
insulation blanket of the present invention with integral tabs in the facing
sheet, formed by
double Z-pleats, located adjacent one of the series of cuts and separable
connectors in the
-5-
CA 02361791 2001-11-09
pre-cut fibrous insulation blanket.
FIG. 12 is a partial schematic transverse cross section of a faced pre-cut
fibrous
insulation blanket of the present invention with tabs, formed by double Z-
pleats in a separate
sheet of facing material, located adjacent one of the series of cuts and
separable connectors
in the pre-cut fibrous insulation blanket.
FIG. 13 is a partial schematic transverse cross section through a faced, pre-
cut fibrous
insulation blanket of the present invention with integral tabs in the facing
sheet, formed by a Z-
pleat, adjacent one of the series of cuts and separable connectors in the pre-
cut fibrous
insulation blanket.
FIG. 14 is a schematic transverse cross section of a faced pre-cut fibrous
insulation
blanket of the present invention with integral tabs in the facing sheet,
formed by overlapping
lateral edge portions of a series of sheets forming the facing, located
adjacent each series of
cuts and separable connectors in the pre-cut fibrous insulation blanket.
FIG. 15 is a partial schematic transverse cross section, on a larger scale
than FIG. 14,
of the faced pre-cut fibrous insulation blanket of FIG. 14.
FIG. 16 is a schematic plan view of a production line for making a faced or
unfaced
pre-cut fibrous insulation blanket of the present invention.
FIG. 17 is a schematic side elevation view of a production line for making a
faced or
unfaced pre-cut fibrous insulation blanket of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a portion of a typical outside wall of a residential house with a
pre-cut,
three section, fibrous insulation blanket 20 of the present invention
installed in both standard
width and non-standard width wall cavities of the outside wall. The widths of
the wall cavities
are defined by the framing members 22 (e.g. 2X4, 2X6 or 2X10 wall studs) which
are spaced
apart a standard distance (e.g. spaced apart on sixteen or twenty four inch
centers) for
standard width cavities 24 and less than the standard distance for non-
standard width cavities
26.
While the unfaced and faced pre-cut fibrous insulation blankets of the present
invention may be made of other fibrous materials, preferably the unlaced and
faced pre-cut
fibrous insulation blankets of the present invention are made of glass fibers
and typically have
a density between about 0.4 pounds/ft3 and about 1.5 pounds/ft3. In addition,
the unfaced and
-6-
CA 02361791 2001-11-09
faced pre-cut fibrous insulation blankets of the present invention are
preferably resilient so
that, after being compressed to insert the pre-cut fibrous insulation blanket
or sections) of the
pre-cut fibrous insulation blanket into a cavity having a width somewhat less
than the width of
the pre-cut fibrous insulation blanket or the sections) of the pre-cut fibrous
insulation blanket
being inserted into the cavity, the pre-cut fibrous insulation blanket or one
or more sections of
the pre-cut fibrous insulation blanket inserted into the cavity will expand to
the width of the
cavity and press against the sides of the cavity to hold or help hold the pre-
cut fibrous
insulation blanket or sections) of the pre-cut fibrous insulation blanket in
place.
Typically, for most applications, such as walls in residential houses, the
resilient,
unfaced and faced pre-cut fibrous insulation blankets of the present invention
are delivered to
the installer in the form of batts about forty six to about forty eight inches
long or about ninety
three inches long or in the form of rolls of various lengths greater than
ninety three inches in
length. Typically, the widths of the unfaced and faced pre-cut fibrous
insulation blankets of the
present invention are substantially equal to or equal to the standard cavity
width to be
insulated with the pre-cut fibrous insulation blankets, e.g. about fourteen
and one half to about
fifteen inches wide for a cavity where the standard center to center spacing
of the wall, floor,
ceiling or roof framing members is sixteen inches (the cavity has a width of
about fourteen and
one half inches) and about twenty two and one half to about twenty three
inches wide for a
cavity where the standard center to center spacing of the wall, floor, ceiling
or roof framing
members is twenty four inches (the cavity has a width of about twenty two and
one half
inches). However for certain applications, the pre-cut fibrous insulation
blanket may have a
different initial width, such as but not limited to about thirteen to about
thirteen and one half
inches.
The following examples illustrate how the faced or unfaced pre-cut fibrous
insulation
blanket of the present invention may be formed into sections. For a faced or
unfaced pre-cut
fibrous insulation blanket having a width of about fifteen inches which is
divided into three
sections, the sections may be about three and one-half, about five, and about
six and one-half
inches wide. For a faced or unfaced pre-cut fibrous insulation blanket having
a width of about
fifteen inches which is divided into four sections, the sections may be about
three and one-half,
about four and one-half, about five and one-half, and about one and one-half
inches wide or
about two and one half, about four, about four and about four and one half
inches wide. For a
faced or unfaced pre-cut fibrous insulation blanket about thirteen inches in
width which is
divided into three sections, the sections may be about three, about four and
one half and
about five and one half inches wide.
-7-
CA 02361791 2001-11-09
The thicknesses of the unfaced and faced pre-cut fibrous insulation blankets
of the
present invention are determined by the amount of thermal resistance or sound
control desired
and the depth of the cavities being insulated. Typically, the pre-cut fibrous
insulation blanket is
about three to about ten inches or greater in width and approximates the depth
of the cavity
being insulated. For example, in a wall cavity defined in part by nominally
2X4 or 2X6 inch
studs or framing members, a pre-cut fibrous insulation blanket will have a
thickness of about
three and one-half inches or about five and one-quarter inches, respectively.
FIGS. 2 to 4 show an unfaced embodiment 20 of the pre-cut fibrous insulation
blanket
of the present invention. The pre-cut fibrous insulation blanket has a length
"L", a width "W"
and a thickness "T'. A first major surface 30 and a second major surface 32 of
the pre-cut
fibrous insulation blanket 20 are each defined by the width "V11" and length
"L" of the insulation
blanket. There are one or more series of cuts 34 and separable connectors 36,
preferably two
or three series of cuts and separable connectors (three series of cuts and
separable
connectors 38, 40 and 42 are shown) which extend for the length of the pre-cut
fibrous
insulation blanket 20. Each series of cuts 34 and separable connectors 36
divide the pre-cut
fibrous insulation blanket 20 into blanket sections with the pre-cut fibrous
insulation blanket
being divided lengthwise into two or more blanket sections and, preferably,
three or four
blanket sections (four blanket sections 44, 46, 48 and 50 are shown) extending
the length of
the pre-cut fibrous insulation blanket.
Each of the cuts 34 in each series of cuts and separable connectors 38, 40 and
42
extends from the first major surface 30 to the second major surface 32 of the
pre-cut fibrous
insulation blanket 20 and is separated from preceding and succeeding cuts 34
in its series of
cuts and separable connectors by separable connectors 36. Each of the
separable
connectors 36 in each series of cuts and separable connectors 38, 40 and 42
may extend
from the first major surface 30 to the second major surface 32 of the pre-cut
fibrous insulation
blanket and is separated from preceding and succeeding separable connectors 36
in its series
of cuts and separable connectors by cuts 34. While each of the connectors 36
may extend
from the first major surface 30 to the second major surface 32 of the pre-cut
fibrous insulation
blanket 20 as schematically shown in FIG. 5, the separable connectors may have
a height
greater than one half but less than the thickness "T' of the pre-cut fibrous
insulation blanket
20. FIG. 6 shows a separable connector 36 which has a height greater than one
half but less
than the thickness "T' of the fibrous insulation blanket 20 with the separable
connector 36
terminating short of the first major surface 30 of the pre-cut fibrous
insulation blanket (e.g.
about 118 to about 1/2 of an inch short of the first major surface). FIG. 7
shows a separable
_g_
CA 02361791 2001-11-09
connector 36 which has a height greater than one half but less than the
thickness "T' of the
fibrous insulation blanket 20 with the separable connector 36 terminating
short of both the first
major surface 30 and the second major surface 32 of the pre-cut fibrous
insulation blanket
(e.g. about 1/8 to about 1/2 of an inch short of the first and second major
surfaces). The
height of the separable connectors 36 can vary with the density of the pre-cut
fibrous insulation
blanket 20 with the connectors being greater in height for less dense
insulation blankets.
The fibers of the, preferably, compressible and resilient fibrous insulation
blankets
typically used in the pre-cut fibrous insulation blanket 20, e.g. glass fiber
insulation blankets,
are randomly oriented with respect to each other, but, due to the manner in
which the fibers
are collected to form a blanket, the fibers tend to lie predominately in
layers or planes
generally parallel to the major surfaces of the blanket. Thus, adjacent a
major surface of a
blanket, the blanket may tend to separate more easily along these layers than
in a direction
perpendicular to the layers when being pulled apart along a series of cuts and
separable
connectors. By having the separable connectors 36 terminating short of one or
both of the
major surfaces 30 and 32 of the pre-cut fibrous insulation blanket 20, there
may be less
tendency for the pre-cut fibrous insulation blanket to delaminate adjacent a
major surface of
the blanket when the blanket is separated at a series of cuts and separable
connectors.
The relative lengths of the cuts 34 and separable connectors 36 are selected
to ensure
that the pre-cut fibrous insulation blanket 20 can be easily separated by hand
at any of the
series of cuts and separable connectors 38, 40 and 42 in the pre-cut fibrous
insulation blanket.
Generally, the cuts 34 are, each about 1 1/4 to about 5 inches long and the
separable
connectors 36 are each about 1/8 to about 1/2 of an inch long. For example, a
typical series
of cuts and separable connectors may have cuts about 1 1/4 inches long and
separable
connectors about 3/16 of an inch long. The width of the cuts 34 forming the
separable
connectors 36 in both the faced and unlaced embodiments of the pre-cut fibrous
insulation
blanket of the present invention is typically about four thousands of an inch
wide when cut by a
water jet. The resilience of the blanket causes the cuts 34 in the pre-cut
fibrous insulation
blanket 20 to close after the cuts are made in the blanket.
With the separable connectors 36 of each series of cuts and separable
connectors 38, 40
and 42 joining the adjacent blanket sections 44, 46, 48 and 50 of the pre-cut
fibrous insulation
blanket 20 together, the pre-cut fibrous insulation blanket 20 can be handled
as a unit for
insulating a cavity 24 having a predetermined width, such as but not limited
to a thirteen inch
width or a fourteen and one half or twenty two and one half standard cavity
width, or easily
separated or tom apart by hand at one or more of the series of cuts and
separable connectors
-9-
CA 02361791 2001-11-09
38, 40 and/or 42 formed by the cuts 34 and separable connectors 36 (separated
without the
need to use of a knife or other cutting tool) into one or more sections 44,
46, 48 and/or 50 for
insulating a cavity 26 having a lesser width, such as less than a standard
cavity width.
FIGS. 8 to 15 show four different embodiments 120 to 420 of the faced pre-cut
fibrous
insulation blanket of the present invention. Preferably, the facings or facing
sheets of the
faced pre-cut fibrous insulation blankets 120 to 420 are made of kraft paper,
a foil-scrim-kraft
paper laminate, or a polymeric film, such as but not limited to polyethylene,
and are bonded to
a major surface of the pre-cut fibrous insulation blanket by a bonding agent.
Preferably, the
bonding agent for kraft paper or foil-scrim-kraft paper facings is an asphalt
or other bituminous
material that can be coated onto or otherwise applied to one side of the
facing sheet just prior
to applying the facing sheet to the pre-cut fibrous insulation blanket and the
bonding agent for
the polymeric film facing is a commercially available pressure sensitive
adhesive that can be
coated onto or otherwise applied to one side of the facing sheet just prior to
applying the
facing sheet to the pre-cut fibrous insulation blanket.
FIGS. 8 to 10 show a faced embodiment 120 of the pre-cut fibrous insulation
blanket
of the present invention. As shown, the faced pre-cut fibrous insulation
blanket 120 of FIGS. 8
to 10 has a first major surface 130 and a second major surface 132. There are
one or more
series of cuts 134 and separable connectors 136, preferably two or three
series of cuts
separable connectors (three series of cuts and separable connectors 138, 140
and 142 are
shown) in the faced pre-cut fibrous insulation blanket which extend for the
length of the faced
pre-cut fibrous insulation blanket 120. Each series of cuts 134 and separable
connectors 136
divide the faced pre-cut fibrous insulation blanket 120 into blanket sections
with the faced pre-
cut insulation blanket being divided lengthwise into two or more blanket
sections and,
preferably, three or four blanket sections (four blanket sections 144, 146,
148 and 150 are
shown) extending the length of the faced pre-cut fibrous insulation blanket.
Each of the cuts 134 in each series of cuts and separable connectors 138, 140
and
142 extends from the first major surface 130 to the second major surface 132
of the faced pre-
cut fibrous insulation blanket 120 and is separated from preceding and
succeeding cuts 134 in
its series of cuts and separable connectors by separable connectors 136. Each
of the
separable connectors 136 in each series of cuts and separable connectors 138,
140 and 142
may extend from the first major surface 130 to the second major surface 132 of
the faced pre-
cut fibrous insulation blanket and is separated from preceding and succeeding
separable
connectors 136 in its series of cuts and separable connectors by cuts 134.
While each of the
connectors 136 may extend from the first major surface 130 to the second major
surface 132
-10-
CA 02361791 2001-11-09
of the faced pre-cut fibrous insulation blanket 120 as schematically shown in
FIGS. 8 and 9,
the separable connectors 136 may have a height greater than one half but less
than the
thickness 'T' of the faced pre-cut fibrous insulation blanket 120. For
example, the separable
connectors 136 can be like the separable connectors of FIG. 6 which shows a
separable
connector which has a height greater than one half but less than the thickness
'T of the faced
pre-cut fibrous insulation blanket with the separable connector terminating
short of the first .
major surface of the faced pre-cut fibrous insulation blanket (e.g. about 1/8
to about 1/2 of an
inch short of the first major surface) or the separable connectors 136 can be
like the separable
connectors of FIG. 7 which shows a separable connector which has a height
greater than one
half but less than the thickness 'T' of the faced pre-cut fibrous insulation
blanket with the
separable connector terminating short of both the first major surtace and the
second major
surface of the faced pre-cut fibrous insulation blanket (e.g. about 1/8 to
about 1/2 of an inch
short of the first and second major surfaces). The height of the separable
connectors 136 can
vary with the density of the faced pre-cut fibrous insulation blanket 120 with
the connectors
being greater in height for less dense insulation blankets.
The facing or facing sheet 152 typically overlies either the entire first
major surface 130
or second major surface 132 of the pre-cut fibrous insulation blanket 120 and
is secured by a
bonding agent 154 to the major surface of the pre-cut fibrous insulation
blanket which it
overlies. As shown in FIG. 8, the facing sheet 152 has lateral tabs 156 and
pairs of tabs 158,
160 and 162 adjacent each of the series of cuts and separable connectors 138,
140 and 142
in the faced pre-cut fibrous insulation blanket 120 for stapling or otherwise
securing the faced
pre-cut fibrous insulation blanket or sections) of the faced pre-cut fibrous
insulation blanket to
frame members. The lateral tabs 156, which preferably are formed by Z-shaped
pleats in the
facing 152, extend for the length of the faced pre-cut fibrous insulation
blanket 120 and the
pairs of tabs 158, 160 and 162 are longitudinally aligned with and extend for
the lengths of the
series of cuts and separable connectors 138, 140 and 142 of the faced pre-cut
fibrous
insulation blanket 120. Each pair of tabs 158, 160 and 162 is formed by a Z-
shaped pleat in
the facing sheet 152 with the tabs of each pair of tabs 158, 160 and 162 being
separably
connected to each other by perforated lines 164, 166 and 168, respectively so
that the facing
can be separated at each series of cuts and separable connectors. With this
structure, the
faced pre-cut fibrous insulation blanket 120 with the facing 152, can be
handled as a unit for
insulating a cavity having a predetermined width, such as but not limited to a
thirteen inch
width or a fourteen and one half or twenty two and one half inch standard
cavity width, or
easily separated or torn apart by hand into blanket sections 144, 146, 148
and/or 150 by
-11-
CA 02361791 2001-11-09
separating or tearing apart the faced pre-cut fibrous insulation blanket 120
at the series of cuts
and separable connectors 138 in the blanket and the perforated line 164 of the
facing sheet
152, the series of cuts and separable connectors 140 in the blanket and the
perforated line
166 of the facing sheet 152, or the series of cuts and separable connectors
142 in the blanket
and the perforated line 168 of the facing sheet 152 (separated without the
need to use of a
knife or other cutting tool) for insulating a cavity having a lesser width,
e.g. less than a
standard cavity width.
The spaced apart perforations of the perforated lines 164, 166 and 158 may be
of
various shapes, including but not limited to, round, oval, elongated, slit
shaped, etc. and the
spacing between perforations and the length of the perforations may vary as
long as the facing
is easily separated by hand along the line formed by the perforations.
Preferably, the
perforations of perforated lines 164, 166 and 158 in the embodiment of FIGS. 8
to 10, are
filled, e.g. with the bonding agent 154 that bonds the facing sheet 152 to one
of the major
surfaces of the faced pre-cut fibrous insulation blanket or a similar
material, to close the
perforations so that the faang sheet 152 functions as a vapor barrier.
The use of pairs of tabs 158, 160 and 162 formed by Z-shaped pleats in the
facing 152
wherein the tabs of each pair of tabs are separably bonded together by the
bonding agent 154
bonding the facing 152 to a major surtace of the faced pre-cut fibrous
insulation blanket
provides several advantages: the overlapping and bonding together of the tabs
across their
widths in each pair of tabs with the perforations at the juncture of the tabs
improves the vapor
barrier properties of the perforated facing; there is less tendency for the
facing 152 to split
during installation because the bonding agent 154 joining the tabs of each
pair of tabs together
can yield when the faced pre-cut fibrous insulation blanket is flexed; the
folds at the
perforations in the Z-shaped pleats facilitate the tearing of the facing 152
at the perforations
and help prevent the tears from propagating out of the tabs; and, as shown in
FIG. 10, as the
blanket sections adjacent a pair of tabs are separated, the tabs which
initially lie on a major
surface of the blanket are pulled away from the major surface of the blanket
to extend
generally perpendicular to the major surface of the blanket for better
grasping by a worker as
the tabs peel away from each other and finally separate from each other along
the perforated
lines.
The integral tabs adjacent each series of cuts and separable connectors plus
lateral
tabs, such as the lateral tabs shown in FIG. 8, can be used to secure the
faced pre-cut fibrous
insulation blanket 120 or blanket sections of the faced pre-cut fibrous
insulation blanket 120 to
framing members, by stapling or other conventional means, either as a unit or
as one or more
_12_
CA 02361791 2001-11-09
sections when one or more blanket sections are separated from the remainder of
the faced
pre-cut fibrous insulation blanket. Preferably, the tabs are about one half to
about one and
one half inches in width. When securing the faced pre-cut fibrous insulation
blanket 120 or
one or more blanket sections of the faced pre-cut fibrous insulation blanket
to framing
members, the tabs adjacent the series of cuts and separable connectors and
lateral tabs used
to secure the blanket are at least partially unfolded and extended outward
from the faced pre-
cut fibrous insulation blanket or blanket sections of the faced pre-cut
fibrous insulation blanket
prior to stapling or otherwise securing the tabs to the framing members.
FIG. 11 is a partial transverse cross section of a second embodiment 220 of
the faced
pre-cut fibrous insulation blanket of the present invention through one of the
series 238 of cuts
234 and separable connectors 236 of the insulation blanket and a portion of
the facing 252
adjacent the series 238 of cuts and separable connectors which overlays and is
bonded to a
first major surtace 230 of the faced pre-cut fibrous insulation blanket.
Except for the pairs of
tabs formed in the facing 252, the faced pre-cut fibrous insulation blanket
220 of FIG. 11 is the
same as the faced pre-cut insulation blanket 120 of FIGS. 8 and 9. As shown,
the facing 252
is provided with a pair of integral, tabs 258 adjacent and extending for the
length of the series
. 238 of cuts and separable connectors of the faced pre-cut fibrous insulation
blanket. The pair
of tabs 258 are formed by a double Z-shaped pleat in the facing 252 with the
tabs 258 being
joined together along a perforated line 264 in the facing that is aligned with
the series 238 of
cuts and separable connectors so that the tabs 258 can be separated from each
other at the
series 238 of cuts and separable connectors when the blanket sections 244 and
246 are
separated from each other. Each tab 258 is formed by twice folding the facing
sheet 252 back
upon itself into a Z-shaped pleat, and identical pairs of integral tabs are
located adjacent and
extend for the length of the each additional series of cuts and separable
connectors of the
faced pre-cut fibrous insulation blanket 220, joining blanket sections of the
faced pre-cut
fibrous insulation blanket. With this structure, the faced pre-cut fibrous
insulation blanket 220
with the facing 252, can be handled as a unit for insulating a cavity having a
predetermined
cavity width, such as but not limited to a thirteen inch or a standard cavity
width or easily
separated or tom apart by hand into one or more blanket sections by separating
or tearing
apart the faced pre-cut fibrous insulation blanket 220 at any one or more of
the series of cuts
and separable connectors and the perforated lines of the facing sheet 252 ~
adjacent the
particular series of cuts and separable connectors (separated without the need
to use of a
knife or other cutting tool) for insulating a cavity having a lesser cavity
width, e.g. less than a
standard cavity width.
-13-
CA 02361791 2001-11-09
The spaced apart perforations of the perforated lines may be of various
shapes,
including but not limited to, round, oval, elongated, slit shaped, etc., and
the spacing befinreen
perforations and the length of the perforations may vary as long as the facing
is easily
separated by hand along the lines) formed by the perforations. Preferably, the
perforations of
perforated lines in the facing 252 of the faced pre-cut fibrous insulation
blanket 220 are filled,
e.g. with the bonding agent 254 that bonds the facing sheet 252 to a major
surface of the pre-
cut fibrous insulation blanket or a similar material, to close the
pertorations so that the facing
sheet 252 functions as a vapor barrier.
The integral tabs adjacent each series of cuts and separable connectors plus
lateral
tabs, such as the lateral tabs shown in FIG. 8, can be used to secure the
faced pre-cut fibrous
insulation blanket 220 or blanket sections of the faced pre-cut fibrous
insulation blanket 220 to
framing members, by stapling or other conventional means, either as a unit or
as one or more
sections when one or more blanket sections are separated from the remainder of
the faced
pre-cut fibrous insulation blanket. Preferably, the tabs are about one half to
about one and
one half inches in width. When securing the faced pre-cut fibrous insulation
blanket 220 or
one or more blanket sections of the faced pre-cut fibrous insulation blanket
to framing
members, the tabs adjacent the series of cuts and separable connectors and
lateral tabs used
to secure the blanket are at least partially unfolded and extended outward
from the faced pre-
cut fibrous insulation blanket or blanket sections of the faced pre-cut
fibrous insulation blanket
prior to stapling or otherwise securing the tabs to the framing members.
FIG. 12 is a partial transverse cross section of a third embodiment 320 of the
faced
pre-cut fibrous insulation blanket of the present invention through one of the
series 338 of cuts
334 and separable connectors 336 of the insulation blanket and a portion of
the facing 352
adjacent the series 338 of cuts and separable connectors which overlays and is
bonded to a
first major surface 330 of the faced pre-cut fibrous insulation blanket.
Except for the structure
of the tabs and facing sheet adjacent each series of cuts and separable
connectors, the faced
pre-cut fibrous insulation blanket 320 of FIG. 12 is the same as the faced pre-
cut insulation
blanket 220 of FIGS. 11. As shown, the facing 352 is provided with a cut or
perforated line
370. The perforated line 370 is aligned with and extends for the length of the
series 338 of
cuts and separable connectors so that the facing 352 can be separated at the
series of cuts
and separable connectors, if desired. A separate sheet of facing material 372
is bonded by a
bonding agent 374 to the faang 352 on either side of the perforated line 370
and extends for
the length of the perforated line. The sheet 372 has a pair of tabs 358
adjacent and extending
for the length of the series 338 of cuts and separable connectors of the pre-
cut fibrous
-14-
CA 02361791 2001-11-09
insulation blanket. The pair of tabs 358 are formed by a double Z-shaped pleat
in the facing
material 372 with the tabs 358 being joined together along a perforated line
364 that is aligned
with the series 338 of cuts and separable connectors so that the tabs can be
separated from
each other at the series 338 of cuts and separable connectors when the blanket
sections 344
and 346 are separated from each other. Each tab 358 is formed by twice folding
the sheet
372 of facing material back upon itself into a Z-shaped pleat, and identical
pairs of integral
tabs are located adjacent and extend for the length of the each additional
series of cuts and
separable connectors of the faced pre-cut fibrous insulation blanket 320,
joining blanket
sections of the faced pre-cut fibrous insulation blanket. With this structure,
the faced pre-cut
. fibrous insulation blanket 320 with the facing 352, can be handled as a unit
for insulating a
cavity having a predetermined cavity width, such as but not limited to a
thirteen inch width or a
fourteen and one half or twenty two and one half inch standard cavity width,
or easily
separated or tom apart by hand into one or more blanket sections by separating
or tearing
apart the faced pre-cut fibrous insulation blanket 320 at any one or more of
the series of cuts
and separable connectors and the perforated lines of the facing sheet 352 and
tabs adjacent
the particular series of cuts and separable connectors (separated without the
need to use of a
knife or other cutting tool) for insulating a cavity having lesser width, e.g.
less than a standard
cavity width.
The spaced apart perforations of the perforated lines may be of various
shapes,
including but not limited to, round, oval, elongated, slit shaped, etc., and
the spacing between
perforations and the length of the perforations may vary as long as the facing
is easily
separated by hand along the lines) formed by the perforations. Preferably, the
perforations of
perforated lines in the facing 352 and between the tabs adjacent each series
of cuts and
separable connectors of the faced pre-cut fibrous insulation blanket 320 are
filled, e.g. with the
bonding agents 354 and 374 that bond the facing sheet 352 to a major surface
of the pre-cut
fibrous insulation blanket and the sheet of facing material 372 to the facing
sheet 352 or a
similar material, to close the perforations so that the facing sheet 352
functions as a vapor
barrier.
The tabs adjacent each series of cuts and separable connectors plus lateral
tabs, such
as the lateral tabs 160 shown in FIG. 8, can be used to secure the faced pre-
cut fibrous
insulation blanket 320 or blanket sections of the faced pre-cut fibrous
insulation blanket 320 to
framing members, by stapling or other conventional means, either as a unit or
as one or more
blanket sections when one or more blanket sections are separated from the
remainder of the
faced pre-cut fibrous insulation blanket. Preferably, the tabs are about one
half to about one
-15-
CA 02361791 2001-11-09
and one half inches in width. When securing the faced pre-cut fibrous
insulation blanket 320
or one or more blanket sections of the faced pre-cut fibrous insulation
blanket to framing
members, the tabs adjacent the series of cuts and separable connectors and
lateral tabs used
to secure the blanket are at least partially unfolded and extended outward
from the faced pre-
y cut fibrous insulation blanket or blanket sections of the faced pre-cut
fibrous insulation blanket
prior to stapling or otherwise securing the tabs to the framing members.
FIG. 13 shows an embodiment of the faced pre-cut fibrous insulation blanket
120
wherein the separable connectors 136 do not extend to one of the major
surfaces 132 of the
pre-cut fibrous insulation blanket and the facing 152 is bonded to the other
major surface 130
of the pre-cut fibrous insulation blanket. With the separable connectors 136
partially cut at the
second major surface of the pre-cut fibrous insulation blanket 120, the
blanket sections may
be easier to separate from each other, by beginning the separation or tear
from the surface
132, without any delamination of the blanket.
FIGS. 14 and 15 show a faced embodiment 420 of the pre-cut fibrous insulation
blanket of the present invention. As shown, the faced pre-cut fibrous
insulation blanket 420 of
FIGS. 14 and 15 has a first major surface 430 and a second major surface 432.
There are
one or more series of cuts 434 and separable connectors 436, preferably two or
three series
of cuts separable connectors (three series of cuts and separable connectors
438, 440 and 442
are shown) in the faced pre-cut fibrous insulation blanket which extend for
the length of the
faced pre-cut fibrous insulation blanket 420. Each series of cuts 434 and
separable
connectors 436 divide the faced pre-cut fibrous insulation blanket 420 into
blanket sections
with the faced pre-cut insulation blanket being divided lengthwise into two or
more blanket
sections and, preferably, three or four blanket sections (four blanket
sections 444, 446, 448
and 450 are shown) extending the length of the faced pre-cut fibrous
insulation blanket.
Each of the cuts 434 in each series of cuts and separable connectors 438, 440
and
442 extends from the first major surface 430 to the second major surface 432
of the faced pre-
cut fibrous insulation blanket 420 and is separated from preceding and
succeeding cuts 434 in
its series of cuts and separable connectors by separable connectors 436. Each
of the
separable connectors 436 in each series of cuts and separable connectors 438,
440 and 442
may extend from the first major surface 430 to the second major surface 432 of
the faced pre-
cut fibrous insulation blanket and is separated from preceding and succeeding
separable
connectors 436 in its series of cuts and separable connectors by cuts 434.
While each of the
connectors 436 may extend from the first major surface 430 to the second major
surface 432
of the faced pre-cut fibrous insulation blanket 420 as schematically shown in
FIGS. 14 and 15,
-16-
CA 02361791 2001-11-09
the separable connectors 436 may have a height greater than one half but less
than the
thickness 'T' of the faced pre-cut fibrous insulation blanket 420. For
example, the separable
connectors 436 can be like the separable connectors of FIG. 6 which shows a
separable
connector which has a height greater than one half but less than the thickness
"T' of the faced
pre-cut fibrous insulation blanket with the separable connector terminating
short of the first
major surface of the faced pre-cut fibrous insulation blanket (e.g. about 1/8
to about 1/2 of an
inch short of the first major surface) or the separable connectors 436 can be
like the separable
connectors of FIG. 7 which shows a separable connector which has a height
greater than one
half but less than the thickness 'T' of the faced pre-cut fibrous insulation
blanket with the
separable connector terminating short of both the first major surface and the
second major
surface of the faced pre-cut fibrous insulation blanket (e.g. about 1/8 to
about 1/2 of an inch
short of the first and second major surfaces). The height of the separable
connectors 436 can
vary with the density of the faced pre-cut fibrous insulation blanket 420 with
the connectors
being greater in height for less dense insulation blankets.
The facing 452 of the pre-cut fibrous insulation blanket 420 is made of a
plurality or
series of sheets 854 which overlap successive sheets forming the facing 452.
The facing or
facing sheet 452, formed by the series of overlapping sheets 454, typically
overlies the entire
second major surface 432 of the faced pre-cut fibrous insulation blanket 420
and is bonded to
the second major surface of the faced pre-cut fibrous insulation blanket 420
by a bonding
agent 456. As shown in FIG. 14, the facing sheet 452 has lateral tabs 458 and
pairs of tabs
460 and 461, 462 and 463, and 464 and 465, adjacent each series of the cuts
and separable
connectors 438, 440 and 442 in the faced pre-cut fibrous insulation blanket
420 for stapling or
otherwise securing the faced pre-cut fibrous insulation blanket or sections)
of the faced pre-
cut fibrous insulation blanket to frame members. The lateral tabs 458 extend
for the length of
the faced pre-cut fibrous insulation blanket 420. The pairs of tabs 460 and
461, 462 and 463,
and 464 and 465 are aligned or substantially aligned longitudinally with and
extend for the
lengths of each series of cuts and separable connectors 438, 440 and 442 of
the faced pre-cut
fibrous insulation blanket 420. Each pair of tabs 460 and 461, 462 and 463,
and 464 and 465
is formed by a lateral edge portion of a preceding sheet 454 overlapping a
lateral edge portion .
of a succeeding sheet 454 at each of the series of cuts and separable
connectors 438, 440
and 442 in the faced pre-cut fibrous insulation blanket 420 with both lateral
portions of the
sheets extending laterally beyond the series of cuts and separable connectors
in opposite
directions as shown in FIGS. 14 and 15. The tabs 460 and 461, 462 and 463, and
464 and
465 of each pair of tabs are separably bonded together by the bonding agent
456 or a similar
-17-
CA 02361791 2001-11-09
adhesive so that the facing can be separated at each of the cuts and separable
connectors.
With this structure, the faced pre-cut fibrous insulation blanket 420 with the
facing 452, can be
handled as a unit for insulating a cavity having a predetermined width, such
as but not limited
to a thirteen inch width or a standard cavity width of fourteen and one half
or twenty two and
one half inches, or easily separated or tom apart by hand into blanket
sections 444, 446, 448
and/or 450 by separating or tearing apart the faced pre-cut fibrous insulation
blanket 420 at
the series of cuts and separable connectors 438 in the blanket and the tabs
460 and 461 of
the facing sheet 452, the series of cuts and separable connectors 440 in the
blanket and the
pair of tabs 462 and 463 of the facing sheet 452, or the series of cuts and
separable
connectors 442 in the blanket and the pair of tabs 464 and 465 of the facing
sheet 452
(separated without the need to use of a knife or other cutting tool) for
insulating a cavity having
a lesser width, e.g. less than a standard cavity width.
Preferably, the lateral edge portions of the sheets 454 forming the facing
sheet 252 are
bonded together e.g. with the bonding agent 456 that bonds the facing sheet
452 to the first
major surface 430 of the pre-cut fibrous insulation blanket or a similar
material, so that the
facing sheet 452 functions as a vapor ban-ier. The pairs of tabs 460 and 461,
462 and 463,
and 464 and 465 adjacent each series of cuts and separable connectors 438, 440
and 442 in
the faced pre-cut fibrous insulation blanket 420 plus lateral tabs, such as
the lateral tabs 458
shown in FIG. 14, can be used to secure the sections 444, 446, 448 and 450 of
the faced pre-
cut fibrous insulation blanket 420 to framing members, by stapling or other
conventional
means, either as a unit or as one or more sections when one or more sections
444, 446, 448
and 450 are separated from the remainder of the faced pre-cut fibrous
insulation blanket.
Preferably, each tab is about one half of an inch to about one and one half
inches wide. When
securing the faced pre-cut fibrous insulation blanket 420 or one or more
sections 444, 446,
448 and 450 of the faced pre-cut fibrous insulation blanket to framing
members, the pairs tabs
460 and 461, 462 and 463, and 464 and 465, and lateral tabs 458 used to secure
the blanket
are extended outward from the faced pre-cut fibrous insulation blanket 420 or
sections 444,
446, 448 and/or 450 of the faced pre-cut fibrous insulation blanket prior to
stapling or
otherwise securing the tabs to the framing members.
FIGS. 16 and 17 schematically show a preferred method of making the unfaced
pre-
cut fibrous insulation blanket 20 or the faced pre-cut fibrous insulation
blanket 120, 220, 320
and 420 of the present invention. According to the preferred method of the
present invention a
fibrous insulation blanket, typically about eight feet wide, and cut
longitudinally into a series of
six or more blankets 20 (e.g. individual blankets about thirteen, fifteen or
twenty three inches
-18-
CA 02361791 2001-11-09
wide, only one of which is shown for the purposes of illustration), is fed
through a water jet
cutting station 500, a rotary saw cutting station 502, and a facing station
504. From the facing
station, the pre-cut fibrous insulation blankets 20, 120, 220, 320 or 420 are
fed to a windup
station (not shown) where the pre-cut fibrous insulation blankets are wound up
for packaging
and shipment or are fed through a conventional chopper and into a conventional
batt packing
station (not shown) where the hafts are stacked and packaged for shipment.
The water jet cutting station 500 utilizes a series of conventional,
commercially
available water jets 510, such as 6X5-55 water jets sold by Flow International
Corp. The water
jets 510 of the water jet station 500 are spaced apart from each other across
the width of the
water jet station 500 and are activated or fired periodically to send jets of
water through each
fibrous insulation blanket 20 and form one or more spaced apart longitudinally
extending
perforated lines of alternating cuts 34 and separable connectors 36 in each
fibrous insulation
blanket 20, such as the perforated lines 38, 40 and 42 shown in FIG. 16.
Each fibrous blanket 20 with the perforated lines, e.g. lines 38, 40 and 42,
then passes
through the rotary saw cutting station 502 which has an upper series of rotary
saws 512 and a
lower series of rotary saws 514 that are spaced apart from each other across
the width of the
station and aligned with the upstream water jets 510 in the water jet cutting
station 500.
Where no partial cuts are formed in the separable connectors 36 of the
perforated lines in the
pre-cut fibrous insulation blanket 20, as shown in FIG. 5, the rotary saws of
the rotary saw
cutting station 502 are not brought into contact with the fibrous insulation
blanket 20. Where
partial cuts are formed in the separable connectors 36 adjacent one major
surface of each
fibrous insulation blanket 20, either the upper or the lower series of saws
512 or 514 are
brought into contact with each fibrous insulation blanket and form cuts having
a predetermined
depth in the separable connectors 36. Where partial cuts are formed in the
separable
connectors adjacent both major surtaces of each fibrous insulation blanket 20,
both the upper
and lower series of saws 512 and 514 are brought into contact with the fibrous
insulation
blanket and form cuts having predetermined depths at bath ends of the
separable connectors
36.
When the fibrous insulation blankets 20 are to be faced, each pre-cut fibrous
insulation
blanket 20 is fed through the facing station 504 where a facing sheet, such as
one of the
facing sheets 152, 252, 352 and 452 shown in FIGS. 8 to 15, is applied and
bonded to the
underside of the pre-cut fibrous insulation blanket 20. When the facing sheet
152, 252 or 352
is applied to the fibrous insulation blanket 20, the facing sheet has one or
more pairs of tabs,
joined by longitudinally extending perforated lines, and lateral tabs which
extend for the length
-19-
CA 02361791 2001-11-09
of the facing sheet. The facing 152, 252 or 352, which may have its tabs pre-
formed, the
perforations in its perforated lines filled, and be coated with a bonding
agent on the major
surface to be applied to the pre-cut fibrous insulation blanket, is fed from a
supply roll 516.
Where the bonding~agent is an asphalt or another bituminous material, the
facing 152, 252 or
352 is passed through a heater station 518 to heat the bonding agent. The
facing sheet is
then applied to underside or lower major surface of the pre-cut fibrous
insulation blanket 20,
while the bonding agent is still hot, with the pairs of tabs joined by the
perforated lines in the
facing sheet longitudinally aligned with the lines of cuts and separable
connectors, e.g. lines
38, 40 and 42, in the pre-cut fibrous insulation blanket 20 and the facing
sheet is bonded to the
blanket to form the pre-cut fibrous insulation blanket 120, 220 or 320. Where
a pressure
sensitive adhesive is used to bond the facing sheet 152, 252 or 352 to the pre-
cut fibrous
insulation blanket 20, the preformed facing sheet with pressure sensitive
adhesive on one
major surface is fed from the supply roll 516 and the major surface of the
facing sheet with the
bonding agent thereon is then brought into contact with, pressed against and
bonded to the
underside or lower major surface of the pre-cut fibrous insulation blanket 20
with the pairs of
tabs joined by the perforated lines in the facing sheet longitudinally aligned
with the lines of
cuts and separable connectors, e.g. lines 38, 40 and 42, in the pre-cut
fibrous insulation
blanket 20.
When the facing 452 is applied to each fibrous insulation blanket 20, the
facing has
one or more longitudinally extending pairs of overlapping tabs which are
adhesively bonded
together, plus lateral tabs extending for the length of the facing sheet. The
facing 452, which
may have its tabs pre-formed, and be coated with a bonding agent on the major
surface to be
applied to the pre-cut fibrous insulation blanket, is fed from the supply roll
516. Where the
bonding agent is an asphalt or another bituminous material, the facing 452 is
passed through
a heater station 518 to heat the bonding agent. The facing sheet is then
applied to underside
or lower major surface of the pre-cut fibrous insulation blanket 20, while the
bonding agent is
still hot, with the pairs of tabs in the facing sheet longitudinally aligned
with the lines of cuts
and separable connectors, e.g. lines 38, 40 and 42, in the pre-cut fibrous
insulation blanket 20
and the facing sheet is bonded to the blanket to form the pre-cut fibrous
insulation blanket
420. Where a pressure sensitive adhesive is used to bond the facing sheet 452
to the pre-cut
fibrous insulation blanket 20, the preformed facing sheet with pressure
sensitive adhesive on
one major surface is fed from the supply roll 516 and the major surface of the
facing sheet with
the bonding agent thereon is then brought into contact with, pressed against
and bonded to
the underside or lower major surface of the pre-cut fibrous insulation blanket
20 with the pairs
-20-
CA 02361791 2001-11-09
of tabs in the facing sheet longitudinally aligned with the lines of cuts and
separable
connectors, e.g. lines 38, 40 and 42, in the pre-cut fibrous insulation
blanket 20.
While the in the method described above, the facing sheets 152 to 452 are pre-
formed
and pre-coated with a bonding agent and fed from a supply roll 516, the facing
sheets 120 to
420 may also be formed on line and thereafter applied directly to the pre-cut
fibrous insulation
blanket 20. With the facing sheets 152 to 452, the faced pre-cut fibrous
insulation blanket
formed can be handled as a unit or easily tom apart at one or more of the
perforated lines in
the blanket and the perforated lines joining the tabs in the facing by hand
(without the need to
use of a knife or other cutting tool) for insulating a cavity of lesser width
than the faced pre-cut
fibrous insulation blanket. The pre-cut faced fibrous insulation blanket 120,
220, 320 or 420 is
then formed into a roll in the windup station or cut transversely into
selected lengths to form
batts (not shown), e.g. forty eight or ninety three inch length batts, which
are stacked and
packaged.
As an example of the versatility of the pre-cut fibrous insulation blankets 20
to 420, the
preferred different widths of the sections, when three sections are formed in
a fifteen inch wide
embodiment of the invention, enable the pre-cut fibrous insulation blankets 20
to 420 to be
quickly and easily formed into widths of about three and one-half inches (e.g.
section 44), five
inches (e.g. section 46), six and one-half inches (e.g. section 48), eight and
one-half inches
e.g. sections 34 and 46) and eleven and one-half inches (e.g. sections 46 and
48). Where the
pre-cut fibrous insulation blanket is separated into four sections, the
installer has even more
options. Thus, the pre-cut fibrous insulation blankets 20 to 420 can not only
be used to
insulate cavities having standard widths, but the width of the pre-cut fibrous
insulation blanket
can also be quickly and easily modified to fit cavities of various non-
standard widths. The use
of a resilient fibrous insulation blanket 20 to 420, such as a resilient glass
fiber insulation
blanket, further enhances the ability of the pre-cut fibrous insulation
blanket to conform to
various cavity widths.
In describing the invention, certain embodiments have been used to illustrate
the
invention and the practices thereof. However, the invention is not limited to
these specific
embodiments as other embodiments and modifications within the spirit of the
invention will
. readily occur to those skilled in the art on reading this specification.
Thus, the invention is not
intended to be limited to the specific embodiments disclosed, but is to be
limited only by the
claims appended hereto.
-21-
