Patent ID: 7754122

Claim:
A method of making a polymeric fiber liner insulation with a flame spread/smoke developed index of ≦ 25/50, comprising: forming a resilient insulation blanket core of polymeric fibers; the blanket having a length, a width and a thickness; the blanket having first and second major surfaces defined by the length and width of the blanket; the polymeric fibers being between 60% and 90% by weight standard thermoplastic polymeric staple fibers and between 10% and 40% by weight polymeric lofting and bonding fibers that have a lower softening point temperature than a remainder of the polymeric fibers of the blanket; the polymeric lofting and bonding fibers being intermingled with the remainder of the polymeric fibers of the blanket; the polymeric fibers having an average denier between 3 and 15; the polymeric fibers having an average length between 0.5 and 4.0 inches; heating the blanket to the softening point temperature of the polymeric lofting and bonding fibers, to make surfaces of the polymeric lofting and bonding fibers tacky, and subsequently cooling the insulation blanket core below the softening point temperature of the polymeric lofting and bonding fibers whereby the polymeric lofting and bonding fibers bond the polymeric fibers of the insulation blanket core together at points of fiber intersection within the insulation blanket core; the insulation blanket core formed having a density between 1 pcf and 3 pcf and a thickness of about 0.5 inches or greater, and the insulation blanket core formed having a resilience whereby the polymeric fiber liner insulation, after being compressed to one third or less of an initial thickness of the polymeric fiber liner insulation, substantially recovers to the initial thickness when compressive forces are released; and forming a surface layer on the first major surface of the insulation blanket core by heating, melting, and consolidating the polymeric fibers of the insulation blanket core at and adjacent the first major surface of the insulation blanket core into the surface layer and cooling the surface layer; the surface layer being less permeable than the second major surface of the insulation blanket core with a higher noise reduction coefficient than an identical polymeric fiber insulation blanket without the surface layer and having a smooth surface to minimize locations where dust, dirt particles, bacterial, and mold can collect.