Coated fibrous nodules and insulation product

Abstract

Coated fibrous nodules suitable for forming an insulation product are provided, comprising fibrous nodules formed from inorganic fibers, wherein a majority of the fibrous nodules has a maximum dimension of about one-half inch, and wherein the fibrous nodules are coated with a solution comprising water and a water soluble binder. Also provided is an insulation product formed from the coated fibrous nodules.

1 . Coated fibrous nodules suitable for forming an insulation product, comprising fibrous nodules formed from inorganic fibers, wherein a majority of the fibrous nodules has a maximum dimension of about one-half inch, and wherein the fibrous nodules are coated with a solution comprising water and a water soluble binder. 
     
     
         2 . The coated fibrous nodules of  claim 1 , wherein the inorganic fibers comprise glass fibers. 
     
     
         3 . The coated fibrous nodules of  claim 1 , wherein at least about 70 percent of the coated nodules have a maximum dimension of one-half inch. 
     
     
         4 . The coated fibrous nodules of  claim 3 , wherein at least about 80 percent of the coated nodules have a maximum dimension of one-half inch. 
     
     
         5 . The coated fibrous nodules of  claim 4 , wherein at least about 90 percent of the coated nodules have a maximum dimension of one-half inch. 
     
     
         6 . The coated fibrous nodules of  claim 1 , wherein the water soluble binder comprises a partially hydrolyzed polyester oligomer. 
     
     
         7 . The coated fibrous nodules of  claim 1 , wherein the binder is present in the coated nodules in an amount of less than about 6 wt. percent, on a dry solids basis. 
     
     
         8 . The coated fibrous nodules of  claim 1 , wherein the inorganic fibers have an average fiber diameter of 3 microns or less. 
     
     
         9 . The coated fibrous nodules of  claim 1 , wherein the nodules comprise glass fibers bonded together with a cured resin at one or more of the locations where two or more of the fibers cross one another. 
     
     
         10 . An insulation product formed from the coated fibrous nodules of  claim 1 . 
     
     
         11 . The insulation product of  claim 10 , wherein the inorganic fibers comprise glass fibers. 
     
     
         12 . The insulation product of  claim 10 , wherein at least about 70 percent of the coated nodules have a maximum dimension of one-half inch. 
     
     
         13 . The insulation product of  claim 12 , wherein at least about 80 percent of the coated nodules have a maximum dimension of one-half inch. 
     
     
         14 . The insulation product of  claim 13 , wherein at least about 90 percent of the coated nodules have a maximum dimension of one-half inch. 
     
     
         15 . The insulation product of  claim 10 , wherein the water soluble binder comprises a partially hydrolyzed polyester oligomer. 
     
     
         16 . The insulation product of  claim 10 , wherein the binder is present in the insulation product in an amount of less than about 6 wt. percent, on a dry solids basis. 
     
     
         17 . The insulation product of  claim 10 , wherein the inorganic fibers have an average fiber diameter of 3 microns or less. 
     
     
         18 . The insulation product of  claim 10 , wherein when the insulation product is formed in a standard wall cavity, the just-installed moisture content of the insulation product is less than about 1.5 pounds. 
     
     
         19 . The insulation product of  claim 10 , wherein each coated fibrous nodule is in contact with another coated fibrous nodule to form the insulation product. 
     
     
         20 . The insulation product of  claim 10 , wherein the insulation product has an R value from about 12 to about 16 after drying. 
     
     
         21 . The insulation product of  claim 10 , wherein the insulation product has a density of about 3 PCF or less after drying. 
     
     
         22 . The insulation product of  claim 10 , wherein the insulation product is formed on a surface of a wall, floor or ceiling cavity. 
     
     
         23 . The insulation product of  claim 22 , wherein the wall, floor or ceiling cavity is an open cavity. 
     
     
         24 . The insulation product of  claim 10 , wherein the nodules comprise glass fibers bonded together with a cured resin at one or more of the locations where two or more of the fibers cross one another. 
     
     
         25 . The coated fibrous nodules of  claim 1 , further comprising an additive effective for increasing thermal insulation. 
     
     
         26 . The coated fibrous nodules of  claim 25 , wherein the additive effective for increasing thermal insulation comprises an infrared radiation blocking agent. 
     
     
         27 . The coated fibrous nodules of  claim 26 , wherein the infrared radiation blocking agent comprises B 2 O 3 . 
     
     
         28 . The insulation product of  claim 10 , further comprising an additive effective for increasing thermal insulation. 
     
     
         29 . The insulation product of  claim 28 , wherein the additive effective for increasing thermal insulation comprises an infrared radiation blocking agent. 
     
     
         30 . The insulation product of  claim 29 , wherein the infrared radiation blocking agent comprises B 2 O 3 . 
     
     
         31 . The coated fibrous nodules of  claim 1 , further comprising a fire retardant. 
     
     
         32 . The insulation product of  claim 10 , further comprising a fire retardant.