CA2128974C - Mat faced duct board and method of manufacture thereof - Google Patents
Mat faced duct board and method of manufacture thereof Download PDFInfo
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- CA2128974C CA2128974C CA 2128974 CA2128974A CA2128974C CA 2128974 C CA2128974 C CA 2128974C CA 2128974 CA2128974 CA 2128974 CA 2128974 A CA2128974 A CA 2128974A CA 2128974 C CA2128974 C CA 2128974C
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Abstract
An improved fiber glass air duct board is provided for the manufacture of insulated air ducts. The board features an air surface facing means providing a smoother interior surface that engages the air flowing through the duct. The smoother surface afforded by the facing reduces friction loss of the air flowing through the ducts as well as reduces the accumulation of dust and dirt within the ducts. Further, the facing provides an additional means for treating the interior of the ducts with biocides to reduce the likelihood of microorganisms surviving in the interior walls of the duct. In the preferred method of manufacturing the duct made in accordance with the present invention, the surface facing is applied to the upper surface of the fiber glass before it is transferred into the flighted oven.
Description
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MAT FACED DOCT HOARD AND METHOD OF MANUFACTpRE THEREOF
This invention relates generally to air ducts manufactured from resin-bonded fiber glass. More specifically, the present invention relates to an improved air duct manufactured from resin-bonded fiber glass that includes an improved interior surface or air surface which provides less air resistance during use and improved means for sanitizing the air duct.
Insulated air ducts are well known. Recent developments in insulated air ducts include air ducts fabricated from fiber glass board with a ~metallfc exterior facing. The insulated ducts have .,the appearance of traditional ducts made from aluminum or galvanized steel yet include the insulation benefits provided by the fiber glass board.
However, problems have arisen with the use of fiber glass board in the fabrication ofyinsulated air ducts. Specifically, exposed fiber glass board will often accumulate dirt, dust and microorganisms if not adequately cleaned and it is difficult as well as expensive to clean the inside of an insulated duct.
Further, fiber glass board is relatively rough which can cause ' turbulent flow at the board surface thereby causing increased friction loss and requiring additional energy to pump air through the ducts.
. One previous attempt at solving the aforenoted problems is the application of an acrylic coating on the interior surfaces of the air, duct or on the surfaces of the fiber glass board exposed to the flowing air. It has been found that a layer of acrylic does provide a smoother surface than exposed resin-bonded fiber glass board for improved duct efficiency. Further, it is 5. believed that the application of the acrylic will provide a greater degree of laminar flow immediately adjacent to the board at corners and other non-straight sections of duct than with untreated fiber glass board. However, it is also believed that a significant amount of turbulence still exists during normal operating conditions even with the use of acrylic coatings. It is also possible to include biocides in the liquid acrylic before application to the exposed surface of the board. Biocides help reduce the accumulation of microorganisms in the air ducts.
Despite the aforenoted advances, the application of acrylic to fiber glass boards is not deemed to be entirely satisfactory.
First, a smoother interior surface providing a greater degree of laminar flow adjacent to the anterior surface of the duct board is desired. The acrylic does not provide as smooth an interior surface as desired and therefore dirt, dust and microorganisms still accumulate in the interior surfaces of the ducts. Further, while the acrylic layer does provide the manufacturer with~an opportunity to apply some biocides to the interior of the air ducts, additional biocide treatment is desired. Because manufacturers often instruct end users not to clean the interior of the air ducts for fear of damage to the ducts, additional biocida treatment is desired to reduce the likelihood of the 21~89'~~
accumulation and flourishment of microorganisms in the ducts during use.
Therefore, there is a need in the insulation and construction industries for an improved thermally insulated air duct with an improved interior surface. The interior surface should be smooth to reduce friction loss and to resist the -accumulation of dirt and other debris. Further, the interior surface must be treatable with biocides to reduce the likelihood of accumulation of microorganisms inside the duct.
SUMMARY OF THE INVENTION
The present invention provides a significant contribution to the art of manufacturing insulated air ducts by providing an .;15 improved insulated air duct with a smooth interior surface mat that may be treated with biocides and further that provides for increased laminar flow adjacent to the duct board. The present invention accomplishes this without adding substantially to the cost of manufacture of insulated duct board or requiring changes to the general methods of constructing and installing the insulated dusts.
The improved insulated duct board for constructing insulated afr ducts includes an outside facing means attached to the outside surfaces of the fiber glass duct board. in the preferred embodiment, the outside facing means consists essentially of a foil-scrim-kraft which is adhered to the outer surface of the -fiber glass board by a coating of adhesive. The fiber glass board is preferably fabricated from inorganic glass fibers bonded by a thermal setting resin to provide a tightly bonded fiber glass mat. The inside or air surface of the fiber glass board is again coated with adhesive and an air surface facing means is applied to the adhesive. In the alternative, an air surfacing means is coated with adhesive and applied to the fiber glass board.
In the preferred embodiment, the air surface facing means is a fabric made from a combination of glass fibers, polyester fibers and styrene fibers. The preferred fabric for providing the air surface spacing means is a lightweight, woven or non-woven, fabric having a weight of about~l5 to about 35 pounds 15~ per 2880 square foot ream of fabric. The air surface facing means mx~y be treated with biocide before or during fabrication thereof or after it has been applied to the inner surface of the fiber glass duct board.
In an alternative embodiment, a layer of acrylic is applied to the inside surface of the duct board and the air surface facing means is applied directly to the layer of acrylic or with an adhesive. A biocide material may be mixed into the liquid ' acrylic material before it fs applied to the fiber glass duct t5 board or the acrylic material may be coated with a biocide material after it has been applied to the fiber glass duct board.
212~~"~~
The improved fiber glass duct board is fabricated as follows. First, a plurality of fiber veils is created using known means (i.e. flame attenuation technology, rotary spinner technology, etc.). The fiber veils are deposited on a moving collection chain to form a fiber blanket. Binder has been applied to the fiber veils and fumes resulting trom the application of binder to hot glass fibers are at. least partially controlled by suction fans disposed underneath the collection .
chain.
l0 The fiber blanket is at least partially compressed underneath at least one seal roller to form a fiber glass board before a layer of adhesive is deposited on top of the board via an over spray applicator. The~air surface facing means is applied to the upper surface of the board on top of the layer of adhesive and the board with the air surface facing means adhered to it is cured in an oven. After the board exits the oven, the bottom facing, preferably in the form of a foil-scrim-kraft with adhesive previously applied to it, is adhered to the undersurface of the now-cured board. The duct board is now ready to be sized and cut and packaged.
It is therefore an object of the present invention is to ' provide an improved fiber glass duct board with a smooth interior surface to minimize the collection of dust and dirt inside the fabricated air ducts.
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Another object of the present invention is to provide an improved fiber glass duct that provides reduced friction between the interior surfaces of the duct and the flowing air., Yet another object of the present invention is to provide an improved method of manufacturing fiber glass duct board.
HRIEB DESCRIPTION OF T8E DR7lWINGB
The invention is illustrated more or less diagrammatically in the accompanying drawings, wherein:
Figure 1 is a partial perspective view of a piece of fiber glass duct board made in accordance with the present invention:
Figure 2 is a partial side sectional view of a fiber glass duct board during fabrication, particularly illustrating the compressed fiber glass blanket or board and air surface facing means in a flighted oven:
Figure 3 is a partial side sectional view of a completed fiber glass duct board made in accordance with the present invention: and ' Figure 4 is a schematic illustration of a method of manufacturing fiber glass duct board in accordance with the present invention.
It should be understood that the drawings are not necessarily to scale and that the embodiments are sometimes illustrated as diagrammatic representations and fragmentary views. Details which are not necessary for an understanding of the present invention or which render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.
DET11ILED DEBCRIPTIOld OF THE INVENTION
Like reference numerals will be used to refer to like or similar parts from Figure to Figure in the following description of the drawing.
The dramatic improvement contributed by the present invention is best understood after consideration of the conventional materials used in fabricating insulated air ducts.
Specifically, it will be noted that even high quality resin-bonded fiber glass has a relatively rough surface: The rough surface causes at least two problems. First, the relatively rough surface of resin-bonded fiber glass will accumulate dirt, dust and provide a habitat for microorganisms. Second, the air flow directly adjacent to the surface at straight sections and especially at corners is less likely to be laminar and more 5 likely to be turbulent thereby causing friction loss and increasing the amount of energy needed to pump the air through the system.' An application of acrylic materials to resin-bonded -"l 212 ~ ~1'~ ~.
fiber glass duct boards is an improvement over the exposed resin-bonded fiber glass but still does not provide as smooth a surtace as desired.
As seen in Figure 1, the duct board l0 includes a resin-bonded fiber glass board 11 with an upper surface 12 that carries an interior air surface facing means or air surface mat 13. The exposed surface 13a of the mat 13 is smoother than the exposed surface 12 of the board 11. The undersurface of the board li carries a foil-scrim-kraft 14 which is preferably fire-resistant as well as a vapor retarder.
The mat 13 is preferably attached to the board 11 with a coating of adhesive (not shown in Figure 1) which is applied to ~15 the board 11 during fabrication as will be discussed with respect to Figure 4 below. The fire-resistant foil-scrim-kraft (FSK) 14 is attached to the undersurface of the board il by applying a -coating of adhesive (not shown in Figure l: see Figure 4) to the FSK l4 prior to adhering the FSK l4 to the undersurface of the board li: Of course, as will be discussed below, adhesive may be applied to the undersurface of the board ll for attaching the FSK
14 as opposed to applying the adhesive to the FSK or other alternative outside facing means id.
ZS Figure 2 is an illustration of one step of the preferred method of manufacturing the duct board 10 more completely illustrated in Figure 4. Specifically, the board 11 has been - g ~c , compressed and an air surface facing means or air mat 13 has been applied to the upper surface thereof. The board 11 and facing 13 axe then transported into a flighted oven 15 (see Figure 4). A
top flight'ls is provided with a shoe 17 and a bottom flight 18 is provided with a shoe 19 to create the shiplap ends shown generally at 21, 22. The shiplap-type edges 21, 22 are useful for providing duct boards 11 that may be readily fabricated together with a minimum of cutting. Further, alternative Plights to those shown at 16, 18 and alternative shoes to those shown at 17, 19 may be provided to fabricate boards with v-grooves, angled ends (not shown in the Figures).
Figure 3 is a partial view of a finished duct board 10 made in accordance with the present invention. The upper or inside surface 12 accommodates the face mat 13 and the lower or outer surface 23 carries the foil-scrim-kraft 14. The fiber glass insulation 11 is resin-bonded Piber glass with low thermal conductivity properties and improved sound absorption coefficients.
The,prePerred method of manufacturing the duct board 10 is illustrated in Figure 4. A plurality of fiber glass veils, indicated generally at 31 are created via rotary spinner means, or other suitable means for manufacturing glass fibers. The 'S veils 31 are deposited on the collection chain 32 to create a fiber blanket 33. In the preferred method, negative pressure is applied underneath the collection chain 32 with suction fans (not g shown) to control the amount of fumes created by the application of binder onto the hot glass fibers 31. The fiber blanket 33 is compressed by a seal roll 34 before adhesive 35 is applied to the upper surface 12 (see also Figure 1) thereof by an over spray 36.
After the adhesive 35 is applied to the upper surface 12 of the compressed blanket 33a, the air surface facing means or surface mat 13 is laid down on top of the adhesive thereby adhering the mat 13 to the upper surface 12 of the compressed blanket 33a. -The surface mat 13 is preferably provided in roll form, indicated generally at 37. The compressed fiber blanket 33a and mat 13 are then transported into a flighted oven 15 for heating and further compressing by the top flight 16 and bottom flight 18 (see also Figure 2). The compressed and now-cured blanket 11 is transported underneath edge cut saws 38. The bottom facing or foil-scrim-kraft 14 is provided in roll form indicated generally at 40. Adhesive is applied to one side of the facing 14 by the adhesive applicator 41 and the adhesive-bearing surface 14a is then applied to the undersurface 23 of 'the cured and compressed blanket 11. Top pressure is supplied b;y the roller 39. The cut off knife 43 completes the fabrication and the finished boards 10 are ready t~ bP hffYPlj 4l1 t'h Ctar!lti nr~f orn~ i r~w~nnt /r~~,f-~1,~~.rr,\
According to a preferred embodiment, a layer of acrylic material is deposited on top of the upper surface of the fiber blanket after the compression of the fiber blanket and before the application of the coating of adhesive. The layer of acrylic material being disposed between the air surface means and the fiber glass board. Furthermore, a biocide is applied to the layer of acrylic material.
As noted above, the preferred i:abric for the mat 13 is a blend of glass fibers, polyester fibers and styrene based polymers. Use of air surface facing means 13 made in accordance with the present invention reduces the friction loss correction factors attributable to the friction between the flowing air and - l0a -_., 212~~1'~~
the inner or upper surface 12 of the duct board. The preferred adhesive is a polyvinyl acetate or other resin-based adhesive.
Polyvinyl acetate emulsion can be mixed with a water soluble biocide and water soluble fire retardants. Polyvinyl acetate and other adhesives can be used to coat the interior surfaces of the ducts as well as providing excellent adhesive properties between the surface mat 13 and the interior surface 12 0! the Tiber glass board 11. It is deemed preferable, but not an absolute requirement, to use a water based adhesive. The fire-resistant foil-scrim-kraft (FSK) or outer facing means 14 also acts as a vapor retarder and further increases the thermal performance of the duct.
Returning briefly to Figure 4, the thickness of the fiber blanket or pelt 33 as it leaves the forming chamber 44 can range from about six inches to about twenty inches. The temperature of the (lighted curing oven 15 ranges from about 350'F to about 500'F. The time the duct boards il remain in the oven 15 ranges from about 1 to about 3 minutes. As shown in Figure 4, the flights 16, 18 are moving and the speeds range from about 50 to about 170 feet per minute.
Thus, an improved resin-bonded fiber glass duct board 10 is provided with a smooth interior surface mat 13 which provides a smoother surface for less dust and dirt accumulation as well as less accumulation of microorganisms. Further, the air surface .. .... ,:~.;;~., .:<N:,;~. . ..r. . .... . . ,. .. . ... ._.... . .. ...,..
.. . .... .. , ..... ...
212~!)~~!
mat 13 may also be easily treated with biocides to reduce the likelihood of accumulation of microorganisms.
. Although only one preferred embodiment of the present invention has been illustrated and described, it will at once be apparent to those skilled in the art that variations may be made within the spirit and scope of the invention. Accordingly, it is intended that the scope of the invention be limited solely by the scope of the hereafter appended claims and not by any specific wording fn the foregoing description.
~ 12 ~
MAT FACED DOCT HOARD AND METHOD OF MANUFACTpRE THEREOF
This invention relates generally to air ducts manufactured from resin-bonded fiber glass. More specifically, the present invention relates to an improved air duct manufactured from resin-bonded fiber glass that includes an improved interior surface or air surface which provides less air resistance during use and improved means for sanitizing the air duct.
Insulated air ducts are well known. Recent developments in insulated air ducts include air ducts fabricated from fiber glass board with a ~metallfc exterior facing. The insulated ducts have .,the appearance of traditional ducts made from aluminum or galvanized steel yet include the insulation benefits provided by the fiber glass board.
However, problems have arisen with the use of fiber glass board in the fabrication ofyinsulated air ducts. Specifically, exposed fiber glass board will often accumulate dirt, dust and microorganisms if not adequately cleaned and it is difficult as well as expensive to clean the inside of an insulated duct.
Further, fiber glass board is relatively rough which can cause ' turbulent flow at the board surface thereby causing increased friction loss and requiring additional energy to pump air through the ducts.
. One previous attempt at solving the aforenoted problems is the application of an acrylic coating on the interior surfaces of the air, duct or on the surfaces of the fiber glass board exposed to the flowing air. It has been found that a layer of acrylic does provide a smoother surface than exposed resin-bonded fiber glass board for improved duct efficiency. Further, it is 5. believed that the application of the acrylic will provide a greater degree of laminar flow immediately adjacent to the board at corners and other non-straight sections of duct than with untreated fiber glass board. However, it is also believed that a significant amount of turbulence still exists during normal operating conditions even with the use of acrylic coatings. It is also possible to include biocides in the liquid acrylic before application to the exposed surface of the board. Biocides help reduce the accumulation of microorganisms in the air ducts.
Despite the aforenoted advances, the application of acrylic to fiber glass boards is not deemed to be entirely satisfactory.
First, a smoother interior surface providing a greater degree of laminar flow adjacent to the anterior surface of the duct board is desired. The acrylic does not provide as smooth an interior surface as desired and therefore dirt, dust and microorganisms still accumulate in the interior surfaces of the ducts. Further, while the acrylic layer does provide the manufacturer with~an opportunity to apply some biocides to the interior of the air ducts, additional biocide treatment is desired. Because manufacturers often instruct end users not to clean the interior of the air ducts for fear of damage to the ducts, additional biocida treatment is desired to reduce the likelihood of the 21~89'~~
accumulation and flourishment of microorganisms in the ducts during use.
Therefore, there is a need in the insulation and construction industries for an improved thermally insulated air duct with an improved interior surface. The interior surface should be smooth to reduce friction loss and to resist the -accumulation of dirt and other debris. Further, the interior surface must be treatable with biocides to reduce the likelihood of accumulation of microorganisms inside the duct.
SUMMARY OF THE INVENTION
The present invention provides a significant contribution to the art of manufacturing insulated air ducts by providing an .;15 improved insulated air duct with a smooth interior surface mat that may be treated with biocides and further that provides for increased laminar flow adjacent to the duct board. The present invention accomplishes this without adding substantially to the cost of manufacture of insulated duct board or requiring changes to the general methods of constructing and installing the insulated dusts.
The improved insulated duct board for constructing insulated afr ducts includes an outside facing means attached to the outside surfaces of the fiber glass duct board. in the preferred embodiment, the outside facing means consists essentially of a foil-scrim-kraft which is adhered to the outer surface of the -fiber glass board by a coating of adhesive. The fiber glass board is preferably fabricated from inorganic glass fibers bonded by a thermal setting resin to provide a tightly bonded fiber glass mat. The inside or air surface of the fiber glass board is again coated with adhesive and an air surface facing means is applied to the adhesive. In the alternative, an air surfacing means is coated with adhesive and applied to the fiber glass board.
In the preferred embodiment, the air surface facing means is a fabric made from a combination of glass fibers, polyester fibers and styrene fibers. The preferred fabric for providing the air surface spacing means is a lightweight, woven or non-woven, fabric having a weight of about~l5 to about 35 pounds 15~ per 2880 square foot ream of fabric. The air surface facing means mx~y be treated with biocide before or during fabrication thereof or after it has been applied to the inner surface of the fiber glass duct board.
In an alternative embodiment, a layer of acrylic is applied to the inside surface of the duct board and the air surface facing means is applied directly to the layer of acrylic or with an adhesive. A biocide material may be mixed into the liquid ' acrylic material before it fs applied to the fiber glass duct t5 board or the acrylic material may be coated with a biocide material after it has been applied to the fiber glass duct board.
212~~"~~
The improved fiber glass duct board is fabricated as follows. First, a plurality of fiber veils is created using known means (i.e. flame attenuation technology, rotary spinner technology, etc.). The fiber veils are deposited on a moving collection chain to form a fiber blanket. Binder has been applied to the fiber veils and fumes resulting trom the application of binder to hot glass fibers are at. least partially controlled by suction fans disposed underneath the collection .
chain.
l0 The fiber blanket is at least partially compressed underneath at least one seal roller to form a fiber glass board before a layer of adhesive is deposited on top of the board via an over spray applicator. The~air surface facing means is applied to the upper surface of the board on top of the layer of adhesive and the board with the air surface facing means adhered to it is cured in an oven. After the board exits the oven, the bottom facing, preferably in the form of a foil-scrim-kraft with adhesive previously applied to it, is adhered to the undersurface of the now-cured board. The duct board is now ready to be sized and cut and packaged.
It is therefore an object of the present invention is to ' provide an improved fiber glass duct board with a smooth interior surface to minimize the collection of dust and dirt inside the fabricated air ducts.
' .: _:aa >.',.. ;.: .,; ,.... y: ''.~ ,.. ..- , ..
,, 2129"~~~
Another object of the present invention is to provide an improved fiber glass duct that provides reduced friction between the interior surfaces of the duct and the flowing air., Yet another object of the present invention is to provide an improved method of manufacturing fiber glass duct board.
HRIEB DESCRIPTION OF T8E DR7lWINGB
The invention is illustrated more or less diagrammatically in the accompanying drawings, wherein:
Figure 1 is a partial perspective view of a piece of fiber glass duct board made in accordance with the present invention:
Figure 2 is a partial side sectional view of a fiber glass duct board during fabrication, particularly illustrating the compressed fiber glass blanket or board and air surface facing means in a flighted oven:
Figure 3 is a partial side sectional view of a completed fiber glass duct board made in accordance with the present invention: and ' Figure 4 is a schematic illustration of a method of manufacturing fiber glass duct board in accordance with the present invention.
It should be understood that the drawings are not necessarily to scale and that the embodiments are sometimes illustrated as diagrammatic representations and fragmentary views. Details which are not necessary for an understanding of the present invention or which render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.
DET11ILED DEBCRIPTIOld OF THE INVENTION
Like reference numerals will be used to refer to like or similar parts from Figure to Figure in the following description of the drawing.
The dramatic improvement contributed by the present invention is best understood after consideration of the conventional materials used in fabricating insulated air ducts.
Specifically, it will be noted that even high quality resin-bonded fiber glass has a relatively rough surface: The rough surface causes at least two problems. First, the relatively rough surface of resin-bonded fiber glass will accumulate dirt, dust and provide a habitat for microorganisms. Second, the air flow directly adjacent to the surface at straight sections and especially at corners is less likely to be laminar and more 5 likely to be turbulent thereby causing friction loss and increasing the amount of energy needed to pump the air through the system.' An application of acrylic materials to resin-bonded -"l 212 ~ ~1'~ ~.
fiber glass duct boards is an improvement over the exposed resin-bonded fiber glass but still does not provide as smooth a surtace as desired.
As seen in Figure 1, the duct board l0 includes a resin-bonded fiber glass board 11 with an upper surface 12 that carries an interior air surface facing means or air surface mat 13. The exposed surface 13a of the mat 13 is smoother than the exposed surface 12 of the board 11. The undersurface of the board li carries a foil-scrim-kraft 14 which is preferably fire-resistant as well as a vapor retarder.
The mat 13 is preferably attached to the board 11 with a coating of adhesive (not shown in Figure 1) which is applied to ~15 the board 11 during fabrication as will be discussed with respect to Figure 4 below. The fire-resistant foil-scrim-kraft (FSK) 14 is attached to the undersurface of the board il by applying a -coating of adhesive (not shown in Figure l: see Figure 4) to the FSK l4 prior to adhering the FSK l4 to the undersurface of the board li: Of course, as will be discussed below, adhesive may be applied to the undersurface of the board ll for attaching the FSK
14 as opposed to applying the adhesive to the FSK or other alternative outside facing means id.
ZS Figure 2 is an illustration of one step of the preferred method of manufacturing the duct board 10 more completely illustrated in Figure 4. Specifically, the board 11 has been - g ~c , compressed and an air surface facing means or air mat 13 has been applied to the upper surface thereof. The board 11 and facing 13 axe then transported into a flighted oven 15 (see Figure 4). A
top flight'ls is provided with a shoe 17 and a bottom flight 18 is provided with a shoe 19 to create the shiplap ends shown generally at 21, 22. The shiplap-type edges 21, 22 are useful for providing duct boards 11 that may be readily fabricated together with a minimum of cutting. Further, alternative Plights to those shown at 16, 18 and alternative shoes to those shown at 17, 19 may be provided to fabricate boards with v-grooves, angled ends (not shown in the Figures).
Figure 3 is a partial view of a finished duct board 10 made in accordance with the present invention. The upper or inside surface 12 accommodates the face mat 13 and the lower or outer surface 23 carries the foil-scrim-kraft 14. The fiber glass insulation 11 is resin-bonded Piber glass with low thermal conductivity properties and improved sound absorption coefficients.
The,prePerred method of manufacturing the duct board 10 is illustrated in Figure 4. A plurality of fiber glass veils, indicated generally at 31 are created via rotary spinner means, or other suitable means for manufacturing glass fibers. The 'S veils 31 are deposited on the collection chain 32 to create a fiber blanket 33. In the preferred method, negative pressure is applied underneath the collection chain 32 with suction fans (not g shown) to control the amount of fumes created by the application of binder onto the hot glass fibers 31. The fiber blanket 33 is compressed by a seal roll 34 before adhesive 35 is applied to the upper surface 12 (see also Figure 1) thereof by an over spray 36.
After the adhesive 35 is applied to the upper surface 12 of the compressed blanket 33a, the air surface facing means or surface mat 13 is laid down on top of the adhesive thereby adhering the mat 13 to the upper surface 12 of the compressed blanket 33a. -The surface mat 13 is preferably provided in roll form, indicated generally at 37. The compressed fiber blanket 33a and mat 13 are then transported into a flighted oven 15 for heating and further compressing by the top flight 16 and bottom flight 18 (see also Figure 2). The compressed and now-cured blanket 11 is transported underneath edge cut saws 38. The bottom facing or foil-scrim-kraft 14 is provided in roll form indicated generally at 40. Adhesive is applied to one side of the facing 14 by the adhesive applicator 41 and the adhesive-bearing surface 14a is then applied to the undersurface 23 of 'the cured and compressed blanket 11. Top pressure is supplied b;y the roller 39. The cut off knife 43 completes the fabrication and the finished boards 10 are ready t~ bP hffYPlj 4l1 t'h Ctar!lti nr~f orn~ i r~w~nnt /r~~,f-~1,~~.rr,\
According to a preferred embodiment, a layer of acrylic material is deposited on top of the upper surface of the fiber blanket after the compression of the fiber blanket and before the application of the coating of adhesive. The layer of acrylic material being disposed between the air surface means and the fiber glass board. Furthermore, a biocide is applied to the layer of acrylic material.
As noted above, the preferred i:abric for the mat 13 is a blend of glass fibers, polyester fibers and styrene based polymers. Use of air surface facing means 13 made in accordance with the present invention reduces the friction loss correction factors attributable to the friction between the flowing air and - l0a -_., 212~~1'~~
the inner or upper surface 12 of the duct board. The preferred adhesive is a polyvinyl acetate or other resin-based adhesive.
Polyvinyl acetate emulsion can be mixed with a water soluble biocide and water soluble fire retardants. Polyvinyl acetate and other adhesives can be used to coat the interior surfaces of the ducts as well as providing excellent adhesive properties between the surface mat 13 and the interior surface 12 0! the Tiber glass board 11. It is deemed preferable, but not an absolute requirement, to use a water based adhesive. The fire-resistant foil-scrim-kraft (FSK) or outer facing means 14 also acts as a vapor retarder and further increases the thermal performance of the duct.
Returning briefly to Figure 4, the thickness of the fiber blanket or pelt 33 as it leaves the forming chamber 44 can range from about six inches to about twenty inches. The temperature of the (lighted curing oven 15 ranges from about 350'F to about 500'F. The time the duct boards il remain in the oven 15 ranges from about 1 to about 3 minutes. As shown in Figure 4, the flights 16, 18 are moving and the speeds range from about 50 to about 170 feet per minute.
Thus, an improved resin-bonded fiber glass duct board 10 is provided with a smooth interior surface mat 13 which provides a smoother surface for less dust and dirt accumulation as well as less accumulation of microorganisms. Further, the air surface .. .... ,:~.;;~., .:<N:,;~. . ..r. . .... . . ,. .. . ... ._.... . .. ...,..
.. . .... .. , ..... ...
212~!)~~!
mat 13 may also be easily treated with biocides to reduce the likelihood of accumulation of microorganisms.
. Although only one preferred embodiment of the present invention has been illustrated and described, it will at once be apparent to those skilled in the art that variations may be made within the spirit and scope of the invention. Accordingly, it is intended that the scope of the invention be limited solely by the scope of the hereafter appended claims and not by any specific wording fn the foregoing description.
~ 12 ~
Claims (55)
1. A fiber glass duct board, the duct board comprising:
an outside facing, a fiber glass board attached to the outside facing, and an air surface fiber glass mat facing configured to engage flowing air inside an air duct, the air surface facing being attached to the fiber glass board at an inside surface thereof to form a rigid structure therewith.
an outside facing, a fiber glass board attached to the outside facing, and an air surface fiber glass mat facing configured to engage flowing air inside an air duct, the air surface facing being attached to the fiber glass board at an inside surface thereof to form a rigid structure therewith.
2. The duct board of claim 1, wherein the air surface facing is a non-woven fabric.
3. The duct board of claim 1, wherein the air surface facing is a woven fabric.
4. The duct board of claim 2, wherein the air surface facing is treated with a biocide.
5. The duct board of claim 4, wherein the duct board is further characterized as including a layer of acrylic material disposed between the air surface facing and the fiber glass board.
6. The duct board of claim 5, wherein the acrylic material includes a biocide.
7. The duct board of claim 4, wherein the duct board is further characterized as including a layer of adhesive disposed between the air surface facing and the fiber glass board, the air surface facing being attached to the fiber glass board by the adhesive.
8. The duct board of claim 4, wherein the mat facing is fabricated from fibers selected from the group consisting of glass fibers, polyester fibers, and styrene fibers.
9. The duct board of claim 8, wherein the mat facing has a weight of from 15 to 35 pounds per 2880 square feet ream of said fabric.
10. The duct board of claim 2, wherein the mat facing is fabricated from a mixture of glass fibers and polyester fibers, the glass fibers and polyester fibers being bonded with styrene base fibers.
11. A method of manufacturing a fiber glass duct board, the method comprising:
depositing a plurality of fiber veils on a moving collection chain to create a fiber blanket, compressing the fiber blanket with at least one seal roller, applying a coating of adhesive to an upper surface of the fiber blanket, depositing an air surface facing fiber glass mat onto the coating of adhesive thereby adhering said air surface facing to the upper surface of the fiber blanket, heating the fiber blanket, adhesive and air surface facing in an oven, applying adhesive to an upper surface of a bottom facing, attaching the upper surface of the bottom facing and the adhesive to an undersurface of the fiber blanket, cutting the fiber blanket into pieces of predetermined sizes.
depositing a plurality of fiber veils on a moving collection chain to create a fiber blanket, compressing the fiber blanket with at least one seal roller, applying a coating of adhesive to an upper surface of the fiber blanket, depositing an air surface facing fiber glass mat onto the coating of adhesive thereby adhering said air surface facing to the upper surface of the fiber blanket, heating the fiber blanket, adhesive and air surface facing in an oven, applying adhesive to an upper surface of a bottom facing, attaching the upper surface of the bottom facing and the adhesive to an undersurface of the fiber blanket, cutting the fiber blanket into pieces of predetermined sizes.
12. The method of claim 11, further comprising the step of depositing a layer of acrylic material on top of the upper surface of the fiber blanket after the compression of the fiber blanket and before the application of the coating of adhesive to the upper surface of the fiber blanket.
13. The method of claim 12, further comprising the step of applying biocide to the air surface facing mat.
14. The method of claim 13, further comprising the step of applying biocide to the acrylic layer.
15. A rigid air duct for conducting flowing air, the air duct comprising:
a fiber glass board having an interior surface and an exterior surface, the fiber glass board being deformed to cause the interior surface to define a channel for conducting flowing air, and a fiber glass mat facing adhered to the interior surface of the fiber glass board to provide a smooth air-contacting surface lining the channel to maximize laminar flow of air flowing through the channel.
a fiber glass board having an interior surface and an exterior surface, the fiber glass board being deformed to cause the interior surface to define a channel for conducting flowing air, and a fiber glass mat facing adhered to the interior surface of the fiber glass board to provide a smooth air-contacting surface lining the channel to maximize laminar flow of air flowing through the channel.
16. The air duct of claim 15, further comprising a biocide material applied to the mat facing.
17. The air duct of claim 15, wherein the mat facing has a weight between 15 and 35 pounds per 2880 square feet.
18. The air duct of claim 15, wherein the mat facing includes a woven material.
19. The air duct of claim 15, wherein the mat facing includes a non-woven material.
20. The air duct of claim 15, wherein the fiber glass board further includes a first shiplap edge adjacent to the interior surface and the mat facing is adhered to the shiplap edge.
21. The air duct of claim 20, wherein the fiber glass board further includes a second shiplap edge lying in spaced-apart relation to the first shiplap edge to position the interior surface therebetween and the mat facing is adhered to the first and second shiplap edges.
22. The air duct of claim 15, further comprising an adhesive adhering the mat facing to the interior surface of the fiber glass board.
23. The air duct of claim 22, wherein the adhesive is a water-based adhesive.
24. The air duct of claim 22, wherein the adhesive is a resin-based adhesive.
25. The air duct of claim 24, wherein the resin-based adhesive is a polyvinyl acetate.
26. The air duct of claim 22, wherein the adhesive includes a polyvinyl acetate emulsion and a water soluble biocide.
27. The air duct of claim 26, wherein the adhesive further includes a water soluble fire retardant.
28. The air duct of claim 22, wherein the adhesive includes a polyvinyl acetate emulsion and a water soluble fire retardant.
29. A rigid air duct for conducting flowing air, the air duct comprising:
a fiber glass board having an interior surface and an exterior surface, the fiber glass board being deformed to cause the interior surface to define a channel for conducting flowing air, an acrylic layer applied to the interior surface, and a fiber glass mat facing in the channel, the mat facing being applied directly to the acrylic layer applied to the interior surface of the fiber glass board to provide a smooth air-contacting surface lining the channel to maximize laminar flow of air flowing through the channel.
a fiber glass board having an interior surface and an exterior surface, the fiber glass board being deformed to cause the interior surface to define a channel for conducting flowing air, an acrylic layer applied to the interior surface, and a fiber glass mat facing in the channel, the mat facing being applied directly to the acrylic layer applied to the interior surface of the fiber glass board to provide a smooth air-contacting surface lining the channel to maximize laminar flow of air flowing through the channel.
30. The air duct of claim 29, further comprising a biocide material applied to the mat facing.
31. The air duct of claim 29, wherein the mat facing has a weight between 15 and 35 pounds per 2880 square feet.
32. The air duct of claim 29, wherein the mat facing includes a woven material.
33. The air duct of claim 29, wherein the mat facing includes a non-woven material.
34. The air duct of claim 29, wherein the fiber glass board further includes a first shiplap edge adjacent to the interior surface and the mat facing is applied to the shiplap edge.
35. The air duct of claim 34, wherein the fiber glass board further includes a second shiplap edge lying in spaced-apart relation to the first shiplap edge to position the interior surface therebetween and the mat facing is applied to the first and second shiplap edges.
36. A rigid air duct for conducting flowing air, the air duct comprising:
a fiber glass board having an interior surface and an exterior surface, the fiber glass board being deformed to cause the interior surface to define a channel for conducting flowing air, and a fiber glass mat facing adhered to the interior surface of the fiber glass board to provide a smooth air-contacting surface lining the channel to maximize laminar flow of air flowing through the channel, wherein the fiber glass board further includes a first shiplap edge adjacent to the interior surface and the mat facing is adhered to the shiplap edge.
a fiber glass board having an interior surface and an exterior surface, the fiber glass board being deformed to cause the interior surface to define a channel for conducting flowing air, and a fiber glass mat facing adhered to the interior surface of the fiber glass board to provide a smooth air-contacting surface lining the channel to maximize laminar flow of air flowing through the channel, wherein the fiber glass board further includes a first shiplap edge adjacent to the interior surface and the mat facing is adhered to the shiplap edge.
37. The air duct of claim 36, wherein the fiber glass board further includes a second shiplap edge lying in spaced-apart relation to the first shiplap edge to position the interior surface there between and the mat facing is adhered to the first and second shiplap edges.
38. The air duct of claim 37, further comprising an adhesive adhering the mat facing to the interior surface of the fiber glass board.
39. The air duct of claim 36, further comprising an adhesive adhering the mat facing to the interior surface of the fiber glass board.
40. The method of claim 11, further comprising the step of depositing a layer of acrylic material on top of the upper surface of the fiber blanket in place of the coating of adhesive, the layer of acrylic being disposed between the air surface and the fiber glass blanket.
41. The method of claim 11, further comprising the step of applying biocide to the air surface facing.
42. The duct board of claim 1, wherein the duct board is further characterized as including shiplap edges.
43. The duct board of claim 42, wherein the air surface facing covers one of the shiplap edges.
44. The duct board of claim 7, wherein the adhesive is a resin-based adhesive.
45. The duct board of claim 7, wherein the adhesive is polyvinyl acetate.
46. The duct board of claim 7, wherein the adhesive is water-based.
47. The duct board of claim 46, wherein the adhesive includes a water soluble fire retardant.
48. A method of manufacturing a fiber duct board, the method comprising:
providing a fiber blanket having an upper surface and an undersurface, a fiber glass air surface facing, and a bottom facing, adhering the fiber glass air surface facing to the upper surface of the fiber blanket to form a rigid structure with a smooth air surface, and adhering the bottom facing to the undersurface of the fiber blanket.
providing a fiber blanket having an upper surface and an undersurface, a fiber glass air surface facing, and a bottom facing, adhering the fiber glass air surface facing to the upper surface of the fiber blanket to form a rigid structure with a smooth air surface, and adhering the bottom facing to the undersurface of the fiber blanket.
49. The method of claim 48, wherein the step of providing a fiber blanket includes the step of depositing a plurality of fiber veils on a moving collection chain to provide the fiber blanket.
50. The method of claim 49, further comprising the step of compressing the fiber blanket.
51. The method of claim 48, wherein the step of adhering the fiber glass air surface facing to the upper surface of the fiber blanket includes the steps of applying a coating of adhesive to the upper surface of the fiber blanket and depositing the fiber glass air surface facing onto the coating of adhesive.
52. The method of claim 48, further comprising the step of heating the fiber blanket and the fiber glass air surface facing.
53. The method of claim 52, wherein the temperature of heating ranges from 350ÀF to 500ÀF.
54. The method of claim 48, wherein the step of adhering the bottom facing to the undersurface of the fiber blanket including the step of applying adhesive to an upper surface of the bottom facing and depositing the bottom facing and the adhesive to the underside of the fiber blanket.
55. The method of claim 48, further comprising the step of cutting the fiber blanket into pieces of predetermined size.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US10497593A | 1993-08-11 | 1993-08-11 | |
| US08/104,975 | 1993-08-11 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2128974A1 CA2128974A1 (en) | 1995-02-12 |
| CA2128974C true CA2128974C (en) | 2002-03-12 |
Family
ID=22303435
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2128974 Expired - Fee Related CA2128974C (en) | 1993-08-11 | 1994-07-27 | Mat faced duct board and method of manufacture thereof |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2128974C (en) |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| ES2387158B1 (en) * | 2010-07-28 | 2013-07-31 | Saint-Gobain Cristaleria, S.L | CONFORMATION SYSTEM OF SMALL CURVATURE RADIOS FOR PREFORMED MINERAL WOOL PANELS |
| DE102016007157B4 (en) * | 2016-06-10 | 2019-11-28 | Diehl Aviation Laupheim Gmbh | Guide tube and manufacturing process |
-
1994
- 1994-07-27 CA CA 2128974 patent/CA2128974C/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| CA2128974A1 (en) | 1995-02-12 |
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| EEER | Examination request | ||
| MKLA | Lapsed |