Duct board with low weight water repellant mat

Abstract

A duct board or duct liner product is provided comprising an insulating layer formed from fibrous material bound with a resin binder; an outer facing layer adhered to an outer surface of the insulating layer; and a water repellant mat facing adhered to an interior surface of the insulating layer opposite the outer surface to form a duct board material, the mat facing having a weight of less than 1.1 lb/100 ft 2 (53.6 g/m 2 ) and having at least an INDA 2 water repellence rating using the IST 80.6-92 water repellency test method.

1 . A duct board or duct liner product, comprising: 
 an insulating layer formed from fibrous material bound with a resin binder;    an outer facing layer adhered to an outer surface of the insulating layer; and    a water repellant mat facing adhered to an interior surface of the insulating layer opposite the outer surface to form a duct board material, the mat facing having a weight of less than 1.1 lb/100 ft 2  (53.6 g/m 2 ) and having at least an INDA 2 water repellence rating using the IST 80.6-92 water repellency test method.    
     
     
         2 . The duct board or duct liner of  claim 1 , wherein the weight of said mat facing is less than about 1.0 lb/100 ft 2  (48.73 g/m 2 ).  
     
     
         3 . The duct board or duct liner of  claim 1 , wherein the weight of said mat facing is between about 0.80 lb/100 ft 2  (39.0 g/m 2 ) and 0.97 lb/100 ft 2  (47.5 g/m 2 ).  
     
     
         4 . The duct board or duct liner of  claim 1 , wherein the mat facing is formed from a non-woven fiber material having a water repellent material integral therein.  
     
     
         5 . The duct board or duct liner of  claim 4 , wherein the mat facing comprises non-woven glass fibers bound with a resin.  
     
     
         6 . The duct or duct liner of  claim 1 , wherein the mat facing is adhered to a surface of said insulating layer by an adhesive, said adhesive and insulating layer being substantially free of water repellent additives or agents.  
     
     
         7 . The duct board or duct liner of  claim 1 , wherein the mat facing comprises a non-woven fiberglass and water repellant material comprising a fluorinated polymer, said mat facing having a weight between about 0.80 lb/100 ft 2  (39.0 g/m 2 ) and 0.97 lb/100 ft 2  (47.5 g/m 2 ).  
     
     
         8 . The duct board or duct liner of  claim 1 , wherein the resin binder in at least a portion of said insulating layer is formed from a resin in an aqueous carrier mixed with a hydrophobic agent in emulsion form.  
     
     
         9 . The duct board or duct liner of  claim 8  wherein the hydrophobic agent is present in said binder in a ratio of about 1:200 to 1:5 hydrophobic agent to binder.  
     
     
         10 . The duct board or duct liner of  claim 9 , wherein said hydrophobic agent is selected from the group consisting of emulsions, latexes, silicone, oil, fluorocarbon and waxes.  
     
     
         11 . The duct board or duct liner of  claim 1 , wherein: 
 the mat is adhered to a surface of said insulating layer by an adhesive containing a first hydrophobic agent, and    the resin binder in at least a portion of said insulating layer contains a second hydrophobic agent.    
     
     
         12 . The duct board or duct liner of  claim 11 , wherein the first hydrophobic agent is one of the group consisting of emulsions, latexes, silicone, oil, fluorocarbon and waxes.  
     
     
         13 . The duct board or duct liner of  claim 11 , wherein the resin binder in the portion of said insulating layer is formed from a resin in an aqueous carrier mixed with a hydrophobic agent in emulsion form.  
     
     
         14 . The duct board or duct liner product according to  claim 1 , wherein the duct board material is formed in a tubular shape capable of conducting air, with the mat facing on an interior thereof.  
     
     
         15 . A method for forming a duct board or duct liner product, comprising: 
 (a) adhering an outer facing layer to an outer surface of an insulating layer formed from fibrous material bound with a resin binder; and    (b) adhering a water repellant mat facing to an interior surface of the insulating layer opposite the outer surface to form a duct board material, the mat facing having a weight of less than 1.1 lb/100 ft 2  (53.6 g/m 2 ) and having at least an INDA 2 water repellence rating using the IST 80.6-92 water repellency test method.    
     
     
         16 . The method of  claim 15 , further comprising forming the duct board material into a tubular shape capable of conducting air, with the mat facing on an interior thereof.  
     
     
         17 . The method of  claim 15 , wherein the weight of the mat facing is less than about 1.0 lb/100 ft 2  (48.73 g/m 2 ).  
     
     
         18 . The method of  claim 15 , wherein the weight of the mat facing is between about 0.80 lb/100 ft 2  (39.0 g/m 2 ) and 0.97 lb/100 ft 2  (47.5 g/m 2 ).  
     
     
         19 . The method of  claim 18 , wherein the mat facing is formed from a non-woven fiber material having a water repellent material integral therein.  
     
     
         20 . The method of  claim 19 , wherein the mat facing comprises glass fibers bound with a resin.  
     
     
         21 . The method of  claim 20 , wherein the mat facing is adhered to a surface of said insulating layer by an adhesive, said adhesive and insulating layer being substantially free of water repellent additives or agents.  
     
     
         22 . The method of  claim 15 , wherein the mat facing comprises a non-woven fiberglass and water repellant material comprising a fluorinated polymer, said mat facing having a weight between about 0.80 lb/100 ft 2  (39.0 g/m 2 ) and 0.97 lb/100 ft 2  (47.544.2 g/m 2 ).  
     
     
         23 . A duct board or duct liner product, comprising: 
 an insulating layer formed from fibrous material bound with a resin binder;    an outer facing layer adhered to an outer surface of the insulating layer; and    a non-woven glass fiber mat facing adhered to an interior surface of the insulating layer opposite the outer surface to form a duct board material, said mat facing having a water repellent material integral therein, the mat facing having a weight of between about 0.80 lb/100 ft 2  (39.0 g/m 2 ) and 0.97 lb/100 ft 2  (47.5 g/m 2 ) and having at least an INDA 2 water repellence rating using the IST 80.6-92 water repellency test method,    wherein the mat is adhered to a surface of said insulating layer by an adhesive, said adhesive and insulating layer being substantially free of water repellent additives or agents.    
     
     
         24 . The duct board or duct liner product according to  claim 23 , wherein the duct board material is formed in a tubular shape capable of conducting air, with the mat facing on an interior thereof.  
     
     
         25 . The duct board or duct liner product according to  claim 23 , wherein said water repellent material comprises a fluorinated polymer.