Packaging to improve shelflife of insulation products

Abstract

Fibrous insulation products have a binder composition that may include a carbohydrate and a crosslinking agent, and potentially other optional ingredients. The shelf life and physical properties of fibrous insulation products, particularly those having bio-based binders, can be improved by packaging that completely envelopes and seals the fibrous product from exposure to atmospheric conditions. Exemplary envelopes disclosed include sealed bags, double stretch wrap and stretch hoods. Properties that can be improved include recovery of loft, restoring force and tensile strength among others.

What is claimed is: 
     
         1 . A method of improving the physical properties of a fibrous insulation product, the method comprising:
 applying a binder to the fibrous product;   curing the binder to form a cured fibrous insulation product having defined physical properties; and   packaging the cured fibrous product in a package that preserves the defined physical properties.   
     
     
         2 . The method of  claim 1  wherein the package for the packaging step is selected from a sealable bag, a double wrapped package and a stretch hood. 
     
     
         3 . The method of  claim 2 , wherein the binder is a bio-based binder. 
     
     
         4 . The method of  claim 1  wherein the defined physical property is at least one property selected from recovery of loft, restoring force, and tensile strength. 
     
     
         5 . The method of  claim 1  wherein the package is made of a polymer selected from low-density polyethylene (LDPE) or a copolymer of LDPE with polyvinylchloride, polypropylene or polyamides. 
     
     
         6 . The method of  claim 1  wherein the package has a permeance not more than about 0.9 g/hr-ft 2 -in Hg. 
     
     
         7 . The method of  claim 6  wherein the package has a permeance not more than about 0.5 g/hr-ft 2 -in Hg. 
     
     
         8 . The method of  claim 7  wherein the package has a permeance between about 0.05 and about 0.5 g/hr-ft 2 -in Hg. 
     
     
         9 . The method of  claim 6  wherein the package has a permeance that varies with the relative humidity, permeance being greater at higher humidity. 
     
     
         10 . The method of  claim 1  wherein the package is made of a material having elasticity in the range of about 400% to about 1000%. 
     
     
         11 . A method of minimizing the recovery degradation of a fibrous insulation product having a cured binder, the method comprising:
 storing the cured fibrous product in a package that has a permeance not more than about 0.9 g/hr-ft 2 -in Hg.   
     
     
         12 . The method of  claim 10  wherein the package has a permeance not more than about 0.5 g/hr-ft 2 -in Hg. 
     
     
         13 . The method of  claim 12  wherein the package has a permeance between about 0.05 and about 0.5 g/hr-ft 2 -in Hg. 
     
     
         14 . The method of  claim 11  wherein the package has elasticity in the range of about 400% to about 1000%. 
     
     
         15 . The method of  claim 11  wherein the package has tensile strength in the range of about 3500 to about 8400 psi. 
     
     
         16 . The method of  claim 11  wherein the package has tear strength in the range of 300 to about 900 grams/mil nominal thickness. 
     
     
         17 . The method of  claim 11  wherein the package is selected from a sealable bag, a double wrapped package and a stretch hood. 
     
     
         19 . The method of  claim 11  wherein the package is a stretch hood. 
     
     
         20 . The method of  claim 11  wherein the package is made of a polymer selected from low-density polyethylene (LDPE) or a copolymer of LDPE with polyvinylchloride, polypropylene or polyamides.