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WO2001008870A1 - Technologie permettant de fixer un systeme de parement a un produit d'isolation - Google Patents

Technologie permettant de fixer un systeme de parement a un produit d'isolation Download PDF

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Publication number
WO2001008870A1
WO2001008870A1 PCT/US2000/018428 US0018428W WO0108870A1 WO 2001008870 A1 WO2001008870 A1 WO 2001008870A1 US 0018428 W US0018428 W US 0018428W WO 0108870 A1 WO0108870 A1 WO 0108870A1
Authority
WO
WIPO (PCT)
Prior art keywords
facing
layer
batt
insulation
heating
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2000/018428
Other languages
English (en)
Inventor
Bharat D. Patel
Weigang Qi
Neil R. Hettler
Roberta L. Alkire
Dan A. Gurr
Willard W. Price
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Owens Corning
Original Assignee
Owens Corning
Owens Corning Fiberglas Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Owens Corning, Owens Corning Fiberglas Corp filed Critical Owens Corning
Priority to AU59140/00A priority Critical patent/AU5914000A/en
Publication of WO2001008870A1 publication Critical patent/WO2001008870A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
    • B29C63/02—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/04—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the partial melting of at least one layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2793/00—Shaping techniques involving a cutting or machining operation
    • B29C2793/009—Shaping techniques involving a cutting or machining operation after shaping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/45—Joining of substantially the whole surface of the articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0012—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular thermal properties
    • B29K2995/0015—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2009/00—Layered products

Definitions

  • This invention relates to fibrous insulation products, and in particular those insulation products of the type suitable for insulating buildings. More specifically, this invention pertains to insulation products having a facing system for providing a vapor barrier and/or for assisting in handling the insulation products. The invention also relates to technology for attaching the facing system to insulation products
  • Fibrous insulation is typically formed by fiberizing molten material and depositing the fibers on a collecting conveyor.
  • the fibers for insulation products are mineral fibers, such as glass fibers, although some insulation products are made of organic fibers, such as polypropylene and polyester.
  • Most fibrous insulation products contain a binder material to bond the fibers together where they contact each other, forming a lattice or network. The binder gives the insulation product resiliency for recovery after packaging, and provides stiffness and handleability so that the product can be handled and applied as needed in the insulation cavities of buildings. During manufacturing the insulation is cut into lengths to form individual insulation products, and the insulation products are packaged for shipping to customer locations.
  • One typical insulation product is an insulation batt, usually about 8 feet (2.44 meter) long, and generally suitable for use as wall insulation in residential dwellings, or as insulation in the attic and floor insulation cavities in buildings.
  • the width of insulation batts designed for wall cavities is set to typical insulation cavity widths, such as about 14'/_ inches (36.83 centimeters (cm)) or 22'/ 2 inches (57.15 cm) for stud spacings of 16 inches (40.64 cm) and 24 inches (60.96 cm), respectively.
  • Some insulation products have a facing on one of the major surfaces. In many cases the facing acts as a vapor barrier, and in some insulation products, such as binderless products, the facing gives the product integrity for handleability.
  • Faced insulation products are installed with the facing placed flat on the edge of the insulation cavity, typically the interior side or edge of the insulation cavity.
  • Insulation products where the facing is a vapor barrier are commonly used to insulate wall, floor or ceiling cavities that separate a warm interior space from a cold exterior space.
  • the vapor barrier is usually placed to prevent moisture-laden air from the warm interior of the dwelling from entering the insulation. Otherwise, the water vapor in the warm interior air would enter the insulation material and then cool and condense within the insulation. This would result in a damp insulation product, which is incapable of performing at its designed efficiency.
  • the stiffness of typical asphalt-kraft-faced insulation enhances the difficulty of such installations.
  • insulation product requirements that call for insulation that is not vapor impermeable, but rather allows water vapor to pass through.
  • retrofit insulation products designed for adding additional insulation material on top of existing attic insulation should not have a vapor barrier.
  • insulation for wall cavities having a separate full wall vapor barrier, such as a 4.0 mil (100 microns) polyethylene film on the interior or warm side of the wall do not require a vapor barrier on the insulation product itself.
  • the Schelhorn patent (U.S. Patent No. 5,277,955 to Schelhorn et al.) discloses an encapsulated batt with an encapsulation material adhered with an adhesive that can be applied in longitudinal stripes, or in patterns such as dots, or in an adhesive matrix.
  • the Schelhorn et al. patent also discloses that an alternative method of attachment is for the adhesive layer to be an integral part of the encapsulation film, which, when softened, bonds to the fibers in the batt.
  • the Syme patent (U.S. Patent No.
  • Heating cannot be abruptly terminated or quickly varied.
  • the heated cylinder of the Syme patent and the Romes patent is a large reservoir of temperature that cannot change its temperature quickly.
  • target areas to be heated cannot be energized with great precision. Because of the need to come in close proximity to the hot surface of the heated cylinder, areas near the targeted areas are also inadvertently heated, creating a significant penumbra of unwanted temperature elevation.
  • Vapor barriers for insulation products are typically created with a layer of asphalt in conjunction with a kraft paper or foil facing material.
  • the asphalt layer is applied in molten form and it is pressed against the fibrous insulation material before hardening to bond the kraft facing material to the insulation material.
  • This asphalt and kraft paper system has the advantage of being relatively inexpensive.
  • this facing system lacks flexibility because the asphalt/kraft layer is stiff, and working with the stiff asphalt/kraft facing slows down the installation of the insulation products. Also, cutting the facing without tearing the kraft paper is difficult in cool ambient temperatures because the asphalt can be brittle. Further, and the asphalt material is sticky in hot ambient temperatures, resulting in a gumming up of the cutting tool.
  • a faced insulation product (and technology for the attachment thereof) having a facing material that can be easily cut to fit into nonstandard insulation cavities, and having a facing material that is flexible enough that it can accommodate faster installation of the cut insulation product into nonstandard insulation cavities with the facing in a flat condition at the edge of the insulation cavity.
  • the invention is directed, in part, to an insulation product comprising an elongated batt of fibrous insulation material, and a facing adhered to a major surface of the batt, wherein the facing is a coextruded polymer film of barrier and bonding layers, with the bonding layer having a softening point lower than the softening point of the barrier layer, where the bonding layer can include one or more of ethylene N-butyl acrylate, ethylene methyl acrylate ethylene ethyl acrylate, low density polyethylene (LDPE) and ethylene vinyl acetate, and wherein the facing has been heated to a temperature above the softening point of the bonding layer, but below the softening point of the barrier layer, whereby the facing is adhered to the batt by the attachment of the bonding layer to the fibers in the batt due to the softening of the bonding layer.
  • LDPE low density polyethylene
  • the invention is also, in part, directed to an insulation product comprising an elongated batt of fibrous insulation material, and a facing adhered to a major surface of the batt, wherein the facing is a coextruded polymer film of barrier, carrier and bonding layers, with the bonding layer having a softening point lower than the softening point of the barrier layer, and with the carrier layer being positioned between the barrier and bonding layers, wherein the facing has been heated to a temperature above the softening point of the bonding layer, but below the softening point of the barrier layer, whereby the facing is adhered to the batt by the attachment of the bonding layer to the fibers in the batt due to the softening of the bonding layer.
  • the invention is also, in part, directed to a method of making an insulation product comprising positioning a facing in contact with a major face of an elongated batt of fibrous insulation material, wherein the facing is a coextruded polymer film of barrier and bonding layers, with the bonding layer including one or more of ethylene N-butyl acrylate, ethylene methyl acrylate, LDPE and ethylene ethyl acrylate, and with the bonding layer having a softening point lower than the softening point of the barrier layer, and heating the facing to a temperature above the softening point of the bonding layer, but below the softening point (or bond initiation temperature, BIT) of the barrier layer, while maintaining the facing in contact with the batt to soften the bonding layer to an extent sufficient attach the bonding layer to the fibers in the batt and thereby adhere the facing to the batt.
  • the bonding layer including one or more of ethylene N-butyl acrylate, ethylene methyl acrylate,
  • the invention is also, in part, directed to a method for installing an insulation product and a correspondingly insulated studded wall.
  • the method comprises providing an insulation product including an elongated batt of fibrous insulation material and a facing adhered to a major surface of the batt.
  • the facing is a coextruded polymer film of barrier and bonding layers, with the bonding layer having a softening point lower than the softening point of the barrier layer.
  • the facing has been heated to a temperature above the softening point of the bonding layer, but below the softening point of the barrier layer, whereby the facing is adhered to the batt by the attachment of the bonding layer to the fibers in the batt due to the softening of the bonding layer.
  • the facing has no flanges.
  • the method further comprises installing the insulation product in an insulation cavity by pressing the insulation product into place between opposed structural members.
  • the copolymer facing can be installed as a separate continuous sheet across the cavities in the studded wall.
  • the invention is also, in part, a recognition that ultrasonic bonding of films can be achieved without the high pressures and hard opposing surface (relative to the ultrasonic radiation source) of known ultrasonic welding technology.
  • the invention is also, in part, directed to a method (and an apparatus to implement the method) for attaching a facing to a mineral fiber batt, the method comprising: providing the batt; providing the facing; positioning the facing to be in contact with the batt; and ultrasonically energizing the facing sufficient to soften a portion of the facing onto fibers of the batt.
  • the facing is a coextruded polymer film, the first layer of which is a bonding layer that is resonant at a first frequency of ultrasonic radiation.
  • the second layer is preferably not resonant at the first frequency. More preferably, the second layer is a carrier layer.
  • the invention is also, in part, directed to an apparatus for attaching at least two facings to a mineral fiber batt, the apparatus comprising: a first facing source; a first roller arranged to place a first facing from the first facing source into contact with a first side of the batt; a first heating source operable to heat a region through which passes the first facing while in contact with the batt, the heating by the first heating source being sufficient to soften a portion of the first facing onto fibers of the batt; a second facing source; a second roller arranged to place a second facing from the second facing source into contact with a second side of the batt; and a second heating source operable to heat a region through which passes the second facing while in contact with the batt, the heating by the second heating source being sufficient to soften a portion of the second facing onto fibers of the batt.
  • Fig. 1 is a schematic view in perspective of typical nonstandard wall insulation cavities.
  • Fig. 2 is a schematic perspective view of the wall cavities of Fig. 1, partially cut away and insulated with typical prior art insulation products.
  • Fig. 3 is a schematic perspective view of a faced insulation product according to the present invention, with a portion cut away.
  • Fig. 4 is a schematic perspective view of the insulation product of Fig. 3, partially cut away and installed into the wall cavity of Fig. 1.
  • Fig. 5 is a schematic perspective view, similar to Fig. 3, of another embodiment of the insulation product according to the present invention, having no side edge extensions or flanges.
  • Fig. 6 is a schematic perspective view of another embodiment of the insulation product according to the present invention, with a portion cut away, and having encapsulation material on the rear and sides of the insulation product.
  • Fig. 7 is a schematic perspective view of a first apparatus for manufacturing the insulation products according to the invention.
  • Fig. 8 is a schematic perspective view illustrating a faced insulation product of the invention, having been slit longitudinally to provide a partial batt suitable for insulating the nonstandard insulation cavity of Fig. 1.
  • Fig. 9 is a schematic cross-sectional view in elevation illustrating the various layers of a multilayer facing film of the invention.
  • Fig. 10 is a schematic perspective view of a second apparatus for manufacturing the insulation products of the invention.
  • Fig. 1 1 is a schematic perspective view of a third apparatus for manufacturing insulation products according to the invention.
  • Fig. 12 depicts a simplified schematic perspective view of a fourth apparatus for manufacturing an insulation product according to the invention.
  • the insulation material can be any compressible fibrous insulation material, such as rock wool, polypropylene or polyester.
  • a typical wall structure As shown in Fig. 1, a typical wall structure, indicated generally at 10, includes a bottom plate 12 on which rests a plurality of studs 14.
  • the front and the back of the wall cavity are typically made of drywall on the interior side and foam sheathing on the exterior, both not shown.
  • Wall cavity 16 can be considered to be a non- standard wall cavity since it has a width much narrower than that of a typical wall cavity. Insulating wall cavity 16 will require cutting the insulation product to a narrower width. Insulation cavity 18 is also difficult to insulate since there is a vent pipe 22 running vertically within the cavity, making cavity 18 a nonstandard cavity.
  • Insulating cavity 18 will usually require cutting an insulation batt longitudinally into two narrower insulation pieces, not shown in Fig. 1.
  • insulation cavity 18 can be considered to comprise two partial cavities, indicated at 24 and 26, each of which must be insulated.
  • Insulation cavity 20 is also a nonstandard cavity since the insulation material must be positioned around an electrical outlet box 28 and conduit 30. Installation of the insulation material around these obstructions requires cutting the batt to fit it around the obstruction.
  • Other typical obstructions include door jambs, window frames, air ducts, and water pipes, all not shown.
  • a typical flanged prior art insulation product has been cut to a narrow partial insulation product 32 and installed in insulation cavity 16.
  • another prior art insulation product 34 has been installed in nonstandard wall cavity 18, and another similar prior art insulation product 36 has been installed in non standard wall cavity 20.
  • the rear of the insulation cavities 16, 18 and 20 is defined by exterior sheathing 38. It can be seen that in order to install the insulation product 34 into the nonstandard insulation cavity 18, the insulation product was split longitudinally into two partial batts 40 and 42. Further, the facing material 44, which is a kraft paper bonded to the fibrous insulation material by asphalt, has been cut to form the facing for the two partial batts 40 and 42.
  • the facing material of insulation product 34 is attached to the studs 14 by staples 46.
  • the stapling of the flanges of the insulation product 32 can be to the ends of the studs, it is preferred that the flanges be side stapled to the sides of the studs. This procedure leaves the ends or exposed edges of the studs smooth for a potentially better application of the drywall.
  • the side or inset stapling of the flanges requires the asphalt/kraft facing to be bent, creating a valley-shaped depression or crease 48 running the length of the insulation product. This crease 48 is undesirable because the insulation material is prevented from flat, smooth contact with the front edge of the insulation cavity, and additionally the insulation material can be overcompressed, thereby lowering the insulation value of the insulation product.
  • the stiff asphalt/kraft facing 44 cannot always be stapled flat against the side of the stud 14, leaving fishmouth or openings 50 between the facing and the sides of the studs.
  • the insulation of the two partial cavities also presents a problem. It can be seen that the portions of the facing material on the two partial batts 40 and 42 are slightly separated, forming a gap 52 through which water vapor can travel into the insulation material of the batt.
  • the gap 52 is typically caused because cutting the batt and facing material is difficult when the facing material is an asphalt/kraft paper system, as shown in Fig. 2.
  • the opening 50 and the gap 52 are undesirable aspects of the insulation job illustrated in Fig. 2.
  • prior art insulation product 36 into insulation cavity 20 involved cutting out a portion of the fibrous insulation material around the electrical outlet box 28. If the insulation were installed without cutting out for the electrical outlet box, the insulation would be over compressed, and might even affect the drywall. Cutting the insulation to accommodate the outlet box required a portion of the flange to be removed. With a conventional asphalt/kraft facing it is difficult to obtain a good seal if a portion of a flange is missing. The difficulty in obtaining a good seal because of the cutout for the outlet box and other obstructions, and because of other imperfections in the structure, results in the openings 50 between the facing material 44 and the stud walls 14. Because of the stiffness of the asphalt/kraft facing combination, openings similar to openings 50 can occur even with standard insulation cavities having no obstructions in situations where the studs are uneven or out of alignment.
  • the insulation product of the invention is comprised of an elongated batt 62 of fibrous insulation material, and a facing 64 adhered to a major surface, front surface 66 of the batt 62.
  • the fibrous insulation material is preferably fibrous glass having a density within the range of from about 0.3 to about 15.0 pounds per cubic foot (pcf) (about 4.80 to about 240.2 kilograms per cubic meter (kg/m 3 ) , although other densities can be used.
  • pcf pounds per cubic foot
  • other fibers such as mineral fibers of rock, slag or basalt
  • organic fibers such as the polymer fibers polypropylene, polyester and polysulfide, as well as other organic fibers.
  • the fibers may be bonded together with a binder material, such as a urea phenol-formaldehyde commonly used with fiberglass insulation, or the glass fibers can be binderless.
  • Bmderless glass fibers will be capable of much greater movement within the insulation pack structure than fibers in a pack structure with binder.
  • binderless means the absence of binder materials or the presence of only small amounts of such binder materials, amounting to no more than one percent by weight of the insulation product. Addition of suppressants, for example oils, for dust control or other purposes is not considered a binder.
  • An example of an encapsulated binderless product is disclosed in the U.S. Patent No. 5,277,955 to Schelhorn et al., as mentioned above.
  • the facing 64 is a dual layer facing comprising a coextruded polymer film of a barrier layer 70 and a bonding layer 72.
  • the purpose of the ba ⁇ ier layer 70 is to provide a tough but flexible outer surface for the insulation product 60.
  • the barrier layer 70 is a vapor barrier, although in other embodiments of the insulation, where the insulation product does not need to provide vapor protection, the barrier layer can be vapor porous.
  • the prefe ⁇ ed form of the facing 64 is a coextruded polymer film, it is to be understood that in other forms of the invention the facing is made of a dual layer film that is not coextruded, but rather formed in another manner, such as by as adhesive, heat lamination or chemical bonding.
  • the softening temperatures of the barrier layer 70 and bonding layer 72 are different by about 100°F (38°C) with the bonding layer having a softening point lower than the softening point of the barrier layer.
  • the facing 64 is adhered to the batt 62 by heating the facing to a temperature above the softening point of the bonding layer, but below the softening point of the barrier layer.
  • the facing is adhered to the batt 62 by the attachment of the bonding layer 72 to the fibers in the batt due to the softening of the bonding layer.
  • a preferred material for the ba ⁇ ier layer is a high density polyethylene (HDPE) film having a softening point within the range of from about 250°F (121 °C) to about 280°F (138°C), and most preferably about 275°F (135°C). High molecular weight HDPE can also be used, but a greater cost.
  • Another material suitable for the barrier layer is a polypropylene film having a softening point within the range of from about 330°F (166°C) to about 390°F (199°C).
  • Other polymer films, such as polypropylene, polyester and polystyrene could also be used.
  • a preferred material for the bonding layer is a film of one or more of ethylene N- butyl acrylate (Et-BA), ethylene methyl acrylate (EMA), ethylene ethyl acrylate (EEA), low density polyethylene (LDPE) and ethylene vinyl acetate (EVA).
  • Et-BA ethylene N- butyl acrylate
  • EMA ethylene methyl acrylate
  • EAA ethylene ethyl acrylate
  • LDPE low density polyethylene
  • EVA ethylene vinyl acetate
  • the softening points of these materials are within the range of from about 100°F (38°C) to about 200°F (93°C), and most preferably within the range of from about 120°F (49°C) to about 180°F (82°C).
  • these ethylene acrylate materials are synthesized using a metallocene catalyst to lower the softening point.
  • Another material potentially useful for the low melt bonding layer is a low melt or low density polyethylene, preferably synthesized using a metallocene catalyst to lower the softening point.
  • the difference in softening temperatures for the barrier layer and the bonding layer is preferably within the range of from about 50°F (10°C) to about 225°F (107°C), and for an HDPE/ethylene acrylate system (that is, ethylene N-butyl acrylate, ethylene methyl acrylate and ethylene ethyl acrylate), the temperature difference is about 140°F (60°C).
  • an HDPE/ethylene acrylate system that is, ethylene N-butyl acrylate, ethylene methyl acrylate and ethylene ethyl acrylate
  • the temperature difference is about 140°F (60°C).
  • One of the great advantages of the HDPE/ethylene acrylate facing system of the invention is that the facing and insulation product can be cut easily over a broad temperature range.
  • the bonding layer 72 is readily cuttable at even such warm temperatures as about 110°F (43°C), and will not leave a gummy residue on the cutting tool.
  • the facing does not soften at temperatures less than about 110°F (43°C), and is not brittle at temperatures greater than about 30°F (-1°C).
  • Another advantage of the faced insulation product 60 of the invention is that the facing 64 is more flexible than a conventional asphalt/kraft paper facing. As measured by ASTM test D-1388 the flexural rigidity of the facing of the invention is preferably less than 500 gm cm, whereas the flexural rigidity of standard asphalt/Kraft facing is greater than about 2000 gm cm.
  • the elastic (tangent) modulus of the facing 64 of the invention is within the range of from about 25,000 to about 200,000 pounds per square inch (psi) (about .172 to about 1.38 GPa). Typically, the elastic modulus of the facing of the invention is about 100,000 psi (.689 GPa).
  • the facing is a multilayer film 78, as shown in Fig. 9, comprising a barrier layer 80, a bonding layer 82 and a carrier layer 84.
  • the barrier layer 80 and bonding layer 82 can be similar to the HDPE and ethylene acrylate (that is, ethylene N-butyl acrylate, ethylene methyl acrylate and ethylene ethyl acrylate) layers 70 and 72, respectively.
  • the ca ⁇ ier layer can be a linear low density polyethylene (LLDPE) with a softening point of about 230°F (110°C) or a high density polyethylene (HDPE), and the carrier layer can be reinforced by any suitable material.
  • LLDPE linear low density polyethylene
  • HDPE high density polyethylene
  • a carrier layer is particularly advantageous where the difference in softening temperatures between the barrier layer and the bonding layer is great.
  • the carrier layer provides an insulative barrier between the barrier layer and the bonding layer during the coextrusion of the polymer film sufficient to improve the permissible difference in softening temperatures between the barrier layer and the bonding layer, preferably by at least 30°F (-1°C).
  • the carrier layer (that is, the middle layer of the three layers) can be configured to be the actual vapor ba ⁇ ier layer, and the outside layer can be a high friction surface that is not necessarily a vapor ba ⁇ ier, but is a surface designed for good printability.
  • High density polyethylene may be too slippery for good printing.
  • the multilayer facing film includes four individual layers, two HDPE layers, a ca ⁇ ier layer, and a bonding layer.
  • the number of layers can be up to eleven or greater.
  • the facing on a fibrous pack insulation product When exposed to fire, the facing on a fibrous pack insulation product preferably will shrink and pull away from the fibrous pack. By pulling away, the facing retards the spread of the flames.
  • the rate at which the facing shrinks and pulls away should be small below about 150°F (66°C), and should be large above about 180°F (82°C), especially in the range of about 170°F-180°F (77°C-82°C).
  • the embodiments of the invention that emphasize shrinking and pulling away of the facing preferably form the bonding layer of EMA, EEA, E/-BA, Surlyn or low-melt- temperature polyethylene. Where Surlyn ® (a type of ionic copolymer marketed by DuPont) is used as the bonding layer material, a flame spread (FS) has been achieved, which is comparable to conventional foil-faced products.
  • Surlyn ® a type of ionic copolymer marketed by DuPont
  • the shrinkage of the facing does not occur instantly, so another embodiment of the invention adds a fire retardant layer to the multilayer facing.
  • the fire retardant layer retards the spread of flames during the time it takes for the facing to unbond and then shrink. Where such a layer includes, for example, antimony oxide and a halogen, a low FS rating has been achieved.
  • a phosphate-based fire retardant can also be used.
  • a multilayer facing that includes a Surlyn bonding layer and a fire retardant layer should achieve an even lower FS rating.
  • Another embodiment of the invention selects the bonding layer so that flanges formed from it will bond together when overlapped.
  • the flanges are typically stapled to the studs.
  • a stud located between neighboring cavities will typically have the flange from the insulation in one cavity stapled over the top of a flange from the insulation in the other cavity.
  • the coextruded film facing according to the invention can be formulated so that the bonding layers, over time due to the pressure of the overlying gypsum wallboard, will bond together when overlapped as described above.
  • the building code requires that a separate continuous vapor barrier of thick polyethylene film be stapled and bonded with an adhesive over the installed (typically unfaced) insulation products.
  • the separate continuous vapor barrier is preferably made of a copolymer film as discussed herein rather than thick polyethylene film.
  • the insulation products incorporating the coextruded film facing according to the invention eliminate the need for such a discrete barrier because the individual facings bond together, especially if the overlapped flanges are heated, for example, with a heat gun or a heated roll.
  • the bonding layer can be formulated to be slightly tacky when cooled so as to enhance the attachment of the overlapped flanges.
  • an uppermost layer of the coextruded film facing is coated with metal and another layer is, or preferably several layers (to prevent pinholes in different layers from aligning) are, chosen to function as a vapor barrier layer.
  • this product will appear like a conventional foil-scrim-kraft (FSK) facing.
  • FSK foil-scrim-kraft
  • the facing 64 for the insulation product 60, and the facing 78 for the multilayer product both have an overall thickness, before the bonding step, within the range of from about 0.4 to about 4 mils (about 10 to about 100 microns), and preferably within the range of from about .5 to about 1.5 mils (about 12.5 to about 37.5 microns).
  • the two layers of the two-layer facing 64 preferably have equal thicknesses.
  • each of its three layers is roughly one-third of the thickness of the facing. Individual thickness could be different - example .25, .25 and .50 inch (.635, .635 and 1.27 cm).
  • the insulation product 60 of the invention is applied into nonstandard insulation cavities 16, 18 and 20.
  • the insulation product has been divided or cut into partial batts in order to fit around the vent pipe 22.
  • the seam 88 in the facing 64 This seam can be of minimal width, with practically no gap, as shown.
  • the seam 88 is relatively straight.
  • the cutting of the insulation product 60 to accommodate the electrical box 28 can be accomplished without a seam.
  • the seams 88 can be covered with tape to provide an absolute vapor barrier, but this should not usually be necessary with the facing of the invention.
  • the facing 64 can be provided with extension flaps 92 that can be tucked between the insulation product 60 and the studs 14 to provide a better vapor seal at the side edges of the insulation product.
  • the conventional asphalt-kraft facing is too stiff to permit such tucking, as a practical matter.
  • the extension flaps 92 could be used for stapling purposes, and therefore should also be considered stapling flanges.
  • the extension flaps extend about .50 to 1 inch (1.27 to 2.54 cm) beyond the side edges of the batt.
  • the facing is a coextruded dual or tri-layer film having a low softening point bonding layer on side facing the fibrous insulation batt
  • the difference in softening points and coefficients of thermal expansion between the two layers causes a curling of the extension flap toward the insulation material. This curling helps provide a good seal when the extension flap is tucked between the facing and the stud.
  • a particular advantage of the insulation product and method of the invention is the reduction in installation time for the insulation.
  • the elimination of the stapling of flanges for the product of the invention significantly reduces the installation time, with the installation time of the product of the invention being at least 10 percent faster, and possibly up to 50 percent faster than standard asphalt/kraft faced insulation.
  • the time savings come from elimination of the stapling operation and eliminating the use of the stiff kraft paper that is hard to handle and install in the wall.
  • another embodiment of the invention is similar in all respects to the insulation product illustrated in Fig. 3 except that there are no extension flaps.
  • an insulation product 94 has a facing 96, similar to the facing 64, on one major surface of the batt 98.
  • This insulation product is provided with an encapsulation film 100 on the side edges 102 and rear major face 104 of the batt.
  • the encapsulation film can be attached to the fibrous batt in any suitable manner, such as by an adhesive layer or strip.
  • a strip of hot melt adhesive can be applied in liquid form during manufacture of the insulation product.
  • U.S. Patent No. 5,277,955 to Schelhorn et al. discloses an encapsulated batt with an encapsulation material adhered with an adhesive that can be applied in longitudinal stripes, or in patterns such as dots, or in an adhesive matrix.
  • the encapsulation film can be securely bonded to the entire surface of the side edges and the rear major surface, such as by using a multilayer coextruded film similar to the facing 64.
  • a film might be, for example, a dual film of HDPE and polyethylene (PE), with a thickness within the range of at least about 0.5 to about 0.8 mils (about 12.5 to about 20 microns) if not in range of about 0.3 to 1.5 mils (about 7.5 to about 37.5 microns).
  • Fig. 6 includes encapsulation on the side edges and rear major surface of the batt 98, it is to be understood that another embodiment of the invention, not shown, provides encapsulation material on the rear surface only, with the side edges lacking the encapsulation material.
  • the insulation product 94 optionally can be provided with an opening 106 in the side edge of the facing 100 to expose the glass fibers in the batt 98.
  • the glass fibers inherently have high friction component, and therefore the opening 106 provides a friction enhancing aspect of the batt to aid in the friction fit application of the insulation product 94 into insulation cavities.
  • Another friction enhancing element is the addition of friction surface treatment, such as a semi-tacky coating, to the side edge of the facing 100.
  • the encapsulation material can be applied to the insulation batt by any suitable process.
  • Apparatus suitable for directing and guiding the encapsulation material onto the glass fiber pack is disclosed in U.S. Patent No. 5,545,279 to Hall et al., the entirety of which is hereby incorporated by reference.
  • a pack 110 of glass fibers is being carried on a conveyor 112.
  • the manufacture of the glass fiber pack 110 is well known technology, and those skilled in the art will be aware of several conventional methods for producing glass fiber packs.
  • the glass fiber pack is preferably a light density insulation material, having a density within the range of from about 0.3 to about 1.0 pcf (about 4.8 to about 16.01 kg/m 3 ).
  • the glass fiber pack can be bonded with a binder material, such as a urea phenol-formaldehyde binder, as is well known in the art. Alternatively, the glass fiber pack can be binderless.
  • a sheet of the facing material 64 is payed out from roll 114 and directed into contact with the glass fiber pack 110.
  • the facing material 64 is pressed into forceful contact with the pack by the action of journaled pressing rolls 116 and 118, which compress the glass fiber pack by a ratio of up to about 25:1, and preferably about 5:1.
  • the amount of compression needed will be a function of the density.
  • the upper pressing roll 116 is heated so that the temperature of the facing 64 will increase to a point above the softening point of the bonding layer.
  • the heating of the roll 116 can be accomplished in a variety of ways, such as by electrical resistance heating or by the circulation of hot oil.
  • the combination of the softened bonding layer and the extreme pressure applied by the two pressing rolls 116 and 118 causes the bonding layer to firmly bond the barrier layer to the glass fiber pack 110.
  • An alternative method of heating the bonding layer is with an infrared heater 120, as shown. Such a heater would have to be positioned immediately upstream of a pair of pressing rolls, not shown, similar to rolls 116 and 118, so that the softened bonding layer could be pressed into the fibrous batt and be integrally bonded to the batt.
  • ultrasonic, laser and microwave bonding can be used. The alternative of ultrasonic bonding will be discussed in more detail below relative to Fig. 10.
  • a cooling section can be used to cool the softened layer after the bonding process.
  • the remainder of the surface of the fibrous pack 110 can be encapsulated with encapsulation material or film 100 which can be supplied by encapsulation film roll 122.
  • the film 100 can be applied using a folding shoe 124, an example of which is disclosed in the above- identified U.S. Patent No. 5,545,279 to Hall et al.
  • the encapsulation film can be bonded with small amounts of discrete adhesive bands.
  • the adhesive can be applied in a variety of ways, such as by an adhesive nozzle 126, supplied with an appropriate adhesive from a source, not shown.
  • the encapsulation film 100 can be securely bonded to the entire surface of the side edges and the rear major surface with a multilayer coextruded film similar to the facing 64, as disclosed above. Also, it is to be understood that the encapsulation material can be applied just to the rear surface, leaving the side edges unencapsulated.
  • a faced insulation product 60 of the invention has been slit longitudinally to provide partial batts 130 and 132 suitable for insulating nonstandard insulation cavities.
  • the insulation product 60 is faced with the facing 64 of the invention, but there is no encapsulation material.
  • the insulation product is a hindered product, and therefore the partial batts 130 and 132 will maintain their shape and handleability even when cut.
  • Either of the partial batts is suitable for insulating nonstandard insulation cavities, such as the partial cavity 26 shown in Fig. 1, or such as the narrow cavity 16 shown in Fig. 1.
  • Fig. 10 is a schematic perspective view of a second apparatus for manufacturing the insulation products of the invention. Fig. 10 is similar to Fig. 7. The following discussion will concentrate on the differences between Fig.
  • the energy used to melt the facing material, for example, a coextruded polymer, 64 is supplied as ultrasonic energy rather than via conduction heating.
  • ultrasonic energy is similarly more selective than infrared (IR) heating.
  • IR infrared
  • ultrasonic energization can be turned on and off abruptly with little to no phase lag.
  • the apparatus needed to implement conduction heating cannot be cooled or heated quickly.
  • the heated pressing roll 1 16 and the complimentary pressing roll 118 have been replaced by an unheated pressing roll 116A and its complimentary unheated pressing roll 118 A. Together, they form a first nip or pinch.
  • An optional, but preferred, second pinch is provided by unheated pressing rolls 116B and 118B.
  • the first and second nips are separated by a distance sufficient to accommodate at least a first ultrasonic radiation source 128 A, located above the facing material 64.
  • the distance is sufficient to also accommodate a second ultrasonic radiation source 128B, located above the facing material 64.
  • Second source 128B is preferably considered to be a redundant backup to the first source 128A so that if the first source 128A fails or must be serviced, the entire production line does not have to be incapacitated.
  • a pair of ultrasonic radiation sources 128C and 128D could be located below the fibrous pack or batt 110.
  • the lower location of the sources 128C and 128D is less preferred than the upper location of the sources 128A and 128B because the ultrasonic radiation must travel through the fibrous pack 110 to reach the facing material 64.
  • the effects of gravity tend to keep the sources 128 A and 128B cleaner than the sources 128C and 128D.
  • the sources 128C and 128D could be replaced with rollers.
  • the first nip compresses the facing material 64 against the fibrous pack 110 by a ratio of up to 25:1, and preferably about 5:1.
  • the compressed pack 110 and facing material 64 pass before the first ultrasonic radiation source 128A.
  • the source 128 emits enough energy so that a portion of the facing system melts sufficiently to permit a portion of the fibrous batt 110 to be pressed into the softened facing material 64.
  • the facing material is energized in a cross-hatch or web pattern, according to the technology disclosed in commonly assigned and copending U.S. patent application serial no. 09/088,990, filed June 2, 1998, for whom Bharat Patel, Larry J. Grant, Dallas L.
  • the facing material 64 and the fibrous batt 110 leave the first nip (between the rollers 116A and 118A), they begin to decompress. This decompression retards the pressing of the fibrous batt 110 into the softened facing material 110, that is, the decompression promotes debonding. Fortunately, the ultrasonic heating imparts the minimum energy to the facing material 64, so that it re-solidifies quickly before significant debonding can take place.
  • the optional, but preferred, second nip (between the rollers 116B and 118B) is located closely enough to the first nip so that the deleterious effects of the decompression can be minimized before the softened facing material 64 can re-solidify. The compression of the second nip is comparable to the first nip.
  • pinch rollers 116 A, 118A, 116B and 118B include flat pieces or caterpillar conveyer belts that are similar to the conveyors 112.
  • the facing material 64 is preferably a coextruded polymer film, as in the embodiment of Fig. 7.
  • the bonding layer for example, 82 of Fig. 9, should resonate at a first frequency of ultrasonic radiation to which the other layer(s) is not resonant.
  • the melting point(s) of the other layer(s) should be selected so that the other layers are not sympathetically melted via conduction heating due to the increase in temperature of the bonding layer.
  • Fig. 11 is a schematic perspective view of a third apparatus for manufacturing insulation products according to the invention.
  • Fig. 11 has two parts, a left-hand part
  • the left-hand part 1400 is similar to Fig. 10. The following discussion will concentrate on the differences between Fig. 11 and Fig. 10.
  • the left-hand part 1400 of Fig. 11 has two, namely rolls 114A and 114B of facings 64A and 64B, for example, coextruded polymer.
  • the first facing 64A is attached ultrasonically to the top of the fibrous pack 110.
  • the second facing 64B is ultrasonically attached to the bottom of the fibrous pack 1 10.
  • the ultrasonic radiation source 128C is the primary energy source for heating the facing 64B.
  • the ultrasonic radiation source 128D is preferably a redundant backup to the source 128C in the same relationship as source 128B relative to source 128A.
  • the right-hand part 1401 is optional.
  • the coating 64A might be formulated to be a vapor barrier while the coating 64B might be formulated to be permeable to water vapor.
  • the sides could also be.
  • the double faces of Fig. 1 1 could alternatively be attached using the conductive heating system of Fig. 7. In that case, the ultrasonic sources 128A, 128B, 128C and 128D would not be present and the rollers 1 16A and 1 16B would be heated.
  • the optional right-hand part 1401 of Fig. 11 depicts an arrangement for horizontally splitting the doubly- faced insulation product 1424 into a first singly- faced insulation product 1408 and a second singly- faced insulation product 1410.
  • a blade (or saw) 1402 is positioned to horizontally split the doubly- faced product 1424 into the two singly- faced products 1408 and 1410.
  • the first singly-faced product 1404 is guided upward by a first roller 1404.
  • the second singly- faced product 106 is guided downward by a second roller 1406.
  • each of the singly- faced products 1408 and 1410 can be vertically slit to increase the number of singly- faced products or lanes.
  • the singly- faced product 1408 is slit into the lanes 1416 and 1418 (separated by a gap 1422) via a vertically-oriented blade (or saw) 1412.
  • the singly- faced product 1410 is slit into the lanes 1420 and 1422 (separated by a gap 1424) via a vertically-oriented blade (or saw) 1414.
  • the right-hand part 1401 of Fig. 11 has been depicted as forming only two singly- faced products, for simplicity. In the alternative, the right-hand portion 1401 could horizontally split the doubly- faced insulation product 1424 into three or more insulation products via the provision of two or more horizontally-oriented knife blades. However, only the uppermost and lowermost product would have a facing. Also, Fig.
  • the right-hand portion 1401 could slit the singly- faced products 1408 and 1410 into three or more lanes each via two or more vertically-oriented blades.
  • the right-hand part 1401 produces singly-faced products that have, at most, one flap that is analogous to the flap 92 of Fig. 3.
  • the edges produced by the knives 1412 and 1414 have no such flaps.
  • flaps Depending upon the overhang of the facings 64A and 64B relative to the width of the fibrous pack 1 10, there will or will not be flaps on the outer edges of the lanes 1416, 1418, 1420 and 1422. If flaps are present, they can be trimmed by additional knives.
  • Fig. 11 could also be used with the conduction-heating facing-attachment technology of Fig. 7.
  • Fig. 12 depicts a simplified schematic perspective view of a fourth apparatus for manufacturing an insulation product according to the invention.
  • Fig. 12 depicts an apparatus that forms the fibrous pack lanes 1708, 1710 and 1712 from a single fibrous pack 110 before the facings 64A and 64B are applied, either via conduction heating (not shown, but see Fig. 7) or ultrasonic heating (not shown, but see Fig. 10).
  • the fibrous pack 110 is vertically slit into the lanes 1708, 1710 and 1712 via the blades 1714 and 1716. Only three lanes have been depicted in Fig. 12. However, any number can be formed depending upon the circumstances to which the technology is applied.
  • gaps 1732 and 1734 are formed between the lanes 1708, 1710 and 1712. Only the facings 64A and 64B are present in the gaps 1732 and 1734.
  • the facings 64A and 64B are slit via (preferably heated) knives 1718 and 1720 to form the doubly- faced products 1722, 1724 and 1726 separated by the gaps 1738 and 1740.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Laminated Bodies (AREA)

Abstract

L'invention concerne un produit d'isolation comprenant un panneau isolant (110) semi-rigide allongé, en matériau d'isolation fibreux, et un parement (64) collé à une surface principale dudit panneau isolant semi-rigide. Le parement est constitué d'un film barrière (80) polymère coextrudé, et de couches de liaison (82) (de préférence des couches barrière (84)), ces couches de liaison possédant un point de ramollissement inférieur au point de ramollissement de la couche barrière. Ladite couche barrière comprend au moins un éthylène N-butyle acrylate, un éthylène méthyle acrylate, un polyéthylène à faible densité, et un éthylène éthyle acrylate. Lorsque le parement a été chauffé à une température au-dessus du point de ramollissement de la couche de liaison, mais en-dessous du point de ramollissement de la couche barrière, ledit parement adhère au panneau isolant semi-rigide par fixation de la couche de liaison aux fibres dudit panneau isolant semi-rigide, grâce au ramollissement de la couche de liaison. La chaleur peut être obtenue soit par conduction soit par ultrasons. Dans le cas de la chaleur obtenue par ultrasons, la couche de liaison est résonante à une fréquence ultrasonore différente de celle de la couche barrière. Le produit d'isolation possède deux faces (1424), et peut être séparé, afin de former deux produits d'isolation (1408, 1410) à une seule face.
PCT/US2000/018428 1999-07-29 2000-07-05 Technologie permettant de fixer un systeme de parement a un produit d'isolation Ceased WO2001008870A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU59140/00A AU5914000A (en) 1999-07-29 2000-07-05 Technology for attaching facing system to insulation product

Applications Claiming Priority (2)

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US36351599A 1999-07-29 1999-07-29
US09/363,515 1999-07-29

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Cited By (3)

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Publication number Priority date Publication date Assignee Title
WO2002002476A1 (fr) * 2000-06-30 2002-01-10 Owens Corning Isolation a base de fibre de verre coloree
CH702596A1 (de) * 2010-01-28 2011-07-29 Sager Ag Verfahren zur Herstellung von Dämmplatten.
WO2023042280A1 (fr) * 2021-09-14 2023-03-23 住友電気工業株式会社 Électrode, cellule de batterie, empilement de cellules, système de batterie, et procédé de fabrication d'électrode

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US4128678A (en) * 1977-04-12 1978-12-05 Fiberglas Canada Limited Heat insulating material and method of and apparatus for the manufacture thereof
EP0449414A2 (fr) * 1990-02-22 1991-10-02 Siderise (Holdings) Limited Fabrication de produits de fibres minérales en couches
US5059277A (en) * 1986-02-28 1991-10-22 The Procter & Gamble Company Adhesive-free bonding of continuously moving webs to form laminate web
US5240527A (en) * 1992-02-20 1993-08-31 Schuller International, Inc. Method of producing encapsulated fibrous insulation blanket
US5746854A (en) * 1996-07-22 1998-05-05 Guardian Fiberglass, Inc. Method of making mineral fiber insulation batt impregnated with coextruded polymer layering system
WO1999063175A1 (fr) * 1998-06-02 1999-12-09 Owens Corning Systeme de revetement pour produit d'isolation

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Publication number Priority date Publication date Assignee Title
US4128678A (en) * 1977-04-12 1978-12-05 Fiberglas Canada Limited Heat insulating material and method of and apparatus for the manufacture thereof
US5059277A (en) * 1986-02-28 1991-10-22 The Procter & Gamble Company Adhesive-free bonding of continuously moving webs to form laminate web
EP0449414A2 (fr) * 1990-02-22 1991-10-02 Siderise (Holdings) Limited Fabrication de produits de fibres minérales en couches
US5240527A (en) * 1992-02-20 1993-08-31 Schuller International, Inc. Method of producing encapsulated fibrous insulation blanket
US5746854A (en) * 1996-07-22 1998-05-05 Guardian Fiberglass, Inc. Method of making mineral fiber insulation batt impregnated with coextruded polymer layering system
WO1999063175A1 (fr) * 1998-06-02 1999-12-09 Owens Corning Systeme de revetement pour produit d'isolation

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2002002476A1 (fr) * 2000-06-30 2002-01-10 Owens Corning Isolation a base de fibre de verre coloree
US6399694B1 (en) 2000-06-30 2002-06-04 Owens Corning Fiberglas Technology, Inc. Colorable fiberglass insulation
CH702596A1 (de) * 2010-01-28 2011-07-29 Sager Ag Verfahren zur Herstellung von Dämmplatten.
EP2353846A1 (fr) * 2010-01-28 2011-08-10 Sager AG Procédé destiné à la fabrication de plaques isolantes
WO2023042280A1 (fr) * 2021-09-14 2023-03-23 住友電気工業株式会社 Électrode, cellule de batterie, empilement de cellules, système de batterie, et procédé de fabrication d'électrode
JP2023155421A (ja) * 2021-09-14 2023-10-20 住友電気工業株式会社 電極、電池セル、セルスタック、電池システム、及び電極の製造方法

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