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WO2001009423A1 - Technologie permettant de fixer un systeme de coussin a un produit d'isolation - Google Patents

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

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Publication number
WO2001009423A1
WO2001009423A1 PCT/US2000/018429 US0018429W WO0109423A1 WO 2001009423 A1 WO2001009423 A1 WO 2001009423A1 US 0018429 W US0018429 W US 0018429W WO 0109423 A1 WO0109423 A1 WO 0109423A1
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WO
WIPO (PCT)
Prior art keywords
facing
insulation
layer
roller
batt
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/US2000/018429
Other languages
English (en)
Inventor
Bharat D. Patel
Weigang Qi
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 AU59141/00A priority Critical patent/AU5914100A/en
Publication of WO2001009423A1 publication Critical patent/WO2001009423A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B1/7654—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only comprising an insulating layer, disposed between two longitudinal supporting elements, e.g. to insulate ceilings
    • E04B1/7658—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only comprising an insulating layer, disposed between two longitudinal supporting elements, e.g. to insulate ceilings comprising fiber insulation, e.g. as panels or loose filled fibres
    • E04B1/7662—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only comprising an insulating layer, disposed between two longitudinal supporting elements, e.g. to insulate ceilings comprising fiber insulation, e.g. as panels or loose filled fibres comprising fiber blankets or batts
    • 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
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0036—Heat treatment
    • B32B38/004—Heat treatment by physically contacting the layers, e.g. by the use of heated platens or rollers
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B1/78—Heat insulating elements
    • 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
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/06—Angles

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 meters) 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 14.5 inches (36.38 centimeters (cm)) or 22.5 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 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. 5,733,624 to Syme et al.) discloses a mineral fiber batt impregnated with a coextruded polymer layering system, and the Romes patent
  • 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.
  • 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, directed to an apparatus for varying an amount of circumferential contact between a primary roller and a first layer of material (for example, a coextruded polymer) passing thereover, where the roller will compresses the first layer against a second layer of material.
  • the apparatus comprises: a source of the first layer of material; a first satellite roller around which the first layer of material passes; second satellite roller around which the first layer of material passes; and an arm assembly having a proximal end rotatably mounted about an axis of the primary roller and at least one distal end connected to axes of the first and second satellite rollers.
  • the first layer of material passes between the first and second satellite rollers such that the first and second satellite rollers must rotate in opposite directions.
  • 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.
  • Figs. 10, 11, 12 and 13 depict side views of an apparatus for use with the apparatus of Fig. 7.
  • 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.
  • 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 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 is undesirable because the insulation material is prevented from flat, smooth contact with the front edge of the insulation cavity, and additionally
  • 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.
  • the installation of 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.
  • 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. Binderless 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 barrier 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 preferred 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 barrier 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
  • a preferred material for the bonding layer is a film of one or more of ethylene N- butyl acrylate ( ⁇ t- A), ethylene methyl acrylate (EMA), ethylene ethyl acrylate (EEA), low density polyethylene (LDPE) and ethylene vinyl acetate (EVA).
  • ⁇ t- A ethylene N- butyl acrylate
  • EMA ethylene methyl acrylate
  • ESA 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).
  • 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 carrier 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).
  • Another advantage of using a carrier layer is that it allows separation of the function of the vapor barrier quality of the barrier layer and the outside surface of the facing as follows: the carrier layer (that is, the middle layer of the three layers) can be configured to be the actual vapor barrier layer, and the outside layer can be a high friction surface that is not necessarily a vapor barrier, 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 carrier 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, Et-BA, Surlyn or low-melt- temperature polyethylene.
  • a flame spread (FS) has been achieved, which is comparable to conventional foil-faced products.
  • 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.
  • 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 is the only evidence of the fact that the insulation product 60 is divided into two partial batts.
  • 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 insulation of cavities 16, 18 and 20 with the insulation product 60, having the flexible facing 64, lends itself to a smooth appearance for the insulation product, and the friction fit of the insulation product 60 enables installation without the need for staples or other fasteners.
  • 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.
  • FIG. 5 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).
  • 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.
  • 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. In the alternative, the encapsulation film
  • 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.
  • Figs. 10, 11, 12 and 13 depict side views of an apparatus 1600 for use with the apparatus of Fig. 7.
  • the portion of the circumference of the heated roller 116 that the facing 64 contacts before it meets the fibrous pack 110 is fixed. It is desirable to be able to vary the portion of the circumference over which contact is made. At higher roller speeds, more contact is desired. At lower speeds, less contact is desired.
  • the apparatus 1600 includes a pair 1602 of satellite rollers 1604 and 1606.
  • a T-shaped structure 1608 is used to connect the pair 1602 to the central axis of the roller 116.
  • the pair 1602 are movable in a circular fashion about the central axis of the roller 116.
  • Fig. 10 also depicts a pair 1610 of guide rollers 1612 and 1614.
  • the pair 1610 is attached to a carriage 1616 that can be moved along a track structure 1618 from the right end 1624 to the left end 1626.
  • the facing 64 is dispensed from the clockwise-rotating roll 114 and passes between the guide rollers 1612 and 1614, in contact with the clockwise-rotating guide roller 1612.
  • the facing 64 passes around the clockwise-rotating roller 1604, between the pair 1602, around counterclockwise-rotating roller 1606 and onto the counterclockwise- rotating roller 116 at a point 1622 on its circumference.
  • the T-shaped structure 1608 resembles the hour hand on a clock that is displaying a time between 3 and 4 o'clock. This produces contact between the facing 64 and the roller 116 from the point 1622 on the circumference of the roller 116 until the point 1620 where the facing 64 contacts the fibrous pack 110. This wraps the facing 64 around about five-eighths of the circumference. This is described as a large amount of prewrap. Depending upon the diameters of the satellite rollers 1604 and 1606, the maximum amount of pre- wrap could be even greater.
  • Fig. 11 depicts the apparatus 1600 when it arranged to have medium amount of prewrap.
  • the T-shaped structure 1608 is in approximately the 1-2 o'clock position.
  • the carriage 1616 of the guide pair 1610 has moved in phase with the movement of the satellite pair 1602.
  • the facing 64 continues to pass around the clockwise-rotating guide roller 1612 without contacting the guide roller 1614. This produces contact between the facing 64 and the roller 116 from the point 1628 on the circumference of the roller 116 until the point 1620 where the facing contacts the fibrous pack 110, that is, contact over about one-half the circumference.
  • the amount of pre- wrap has changed by one-fourth of the circumference of the roller 116.
  • the technology to move the T-shaped structure 1608 about the center of the roller 116 and to move the carriage 1616 is known and will not be discussed in detail.
  • the alternative of the individual mounting bars has the advantage that it permits the position of each roller to be adjusted, rather than merely the position of a roller pair. It is not necessary that the pair 1602 move in a circular fashion. Rather, it is important that the satellite pair 1602 be able to move around the circumference of the roller 116.
  • the apparatus 1600 also simplifies such initial attachment.
  • the T- shaped structure 1608 is the 8-9 o'clock position, which would produce substantially no prewrap.
  • the carriage 1616 has been moved to the far left end of the track structure 1618, again, in phase with the movement of the pair 1602.
  • the facing 64 passes between the pair 1610, around the counterclockwise-rotating roller 1614 without contacting the roller 1612.
  • the facing 64 passes around the clockwise-rotating roller 1606, between the pair 1602 and around counterclockwise rotating roller 1604.
  • An end 1630 of the facing 64 is shown extending slightly beyond the roller 1604.
  • An adhesive for example, double-sided tape, is manually attached to the end 1630 of the facing 64, then the T-shaped structure 1608 is rotated slightly counterclockwise to compress the end 1630 of the facing 64 against the fibrous pack 110, as depicted in Fig. 13.
  • the pairs 1602 and 1610 are moved from the no-prewrap configuration of Fig. 13 to the large prewrap configuration of Fig. 10. Thereafter, the positions of the pairs 1602 and 1604 are adjusted as needed to vary the amount of prewrap.

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  • Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Acoustics & Sound (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Thermal Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Building Environments (AREA)

Abstract

L'invention concerne un produit d'isolation comprenant un panneau isolant (110) semi-rigide allongé en matériau d'isolation fibreux, et un coussin (64) collé à une surface principale dudit panneau isolant semi-rigide. Ce coussin est constitué d'un film barrière polymère coextrudé, et de couches de liaison (de préférence barrière), 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-butyl acrylate, un éthylène méthyle acrylate, un polyéthylène à faible densité, et un éthylène éthyle acrylate. Lorsque le coussin 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 coussin 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. Le préchauffage du coussin est régulé par variation de la partie de contact ou de pré-enroulement entre un rouleau chauffé (116) et ledit coussin. La partie de pré-enroulement est déterminée par la position d'une paire de rouleaux satellites agencés autour de la circonférence du rouleau chauffé.
PCT/US2000/018429 1999-07-29 2000-07-05 Technologie permettant de fixer un systeme de coussin a un produit d'isolation Ceased WO2001009423A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU59141/00A AU5914100A (en) 1999-07-29 2000-07-05 Technology for attaching facing system to insulation product

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US36418699A 1999-07-29 1999-07-29
US09/364,186 1999-07-29

Publications (1)

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WO2001009423A1 true WO2001009423A1 (fr) 2001-02-08

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3002378B1 (fr) 2008-08-12 2019-05-08 Knauf Insulation Produit d'isolation thermique
CN109849322A (zh) * 2019-01-14 2019-06-07 江山市标龙装饰材料有限公司 一种免漆门覆膜机
US20230287678A1 (en) * 2022-03-11 2023-09-14 Certainteed Llc Insulation standoffs and exterior insulation systems

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2788587A (en) * 1954-06-01 1957-04-16 Cons Electrodynamics Corp Apparatus for strip material
US3928747A (en) * 1973-02-23 1975-12-23 Sony Corp Thermal printing apparatus
US3946800A (en) * 1973-06-26 1976-03-30 Molins Machine Company, Inc. Preheater and method of controlling wrap of a web
US5277955A (en) 1989-12-08 1994-01-11 Owens-Corning Fiberglas Technology Inc. Insulation assembly
US5733624A (en) 1996-07-22 1998-03-31 Guardian Fiberglass, Inc. Mineral fiber insulation batt impregnated with coextruded polymer layering system
US5746854A (en) 1996-07-22 1998-05-05 Guardian Fiberglass, Inc. Method of making mineral fiber insulation batt impregnated with coextruded polymer layering system

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2788587A (en) * 1954-06-01 1957-04-16 Cons Electrodynamics Corp Apparatus for strip material
US3928747A (en) * 1973-02-23 1975-12-23 Sony Corp Thermal printing apparatus
US3946800A (en) * 1973-06-26 1976-03-30 Molins Machine Company, Inc. Preheater and method of controlling wrap of a web
US5277955A (en) 1989-12-08 1994-01-11 Owens-Corning Fiberglas Technology Inc. Insulation assembly
US5733624A (en) 1996-07-22 1998-03-31 Guardian Fiberglass, Inc. Mineral fiber insulation batt impregnated with coextruded polymer layering system
US5746854A (en) 1996-07-22 1998-05-05 Guardian Fiberglass, Inc. Method of making mineral fiber insulation batt impregnated with coextruded polymer layering system

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3002378B1 (fr) 2008-08-12 2019-05-08 Knauf Insulation Produit d'isolation thermique
CN109849322A (zh) * 2019-01-14 2019-06-07 江山市标龙装饰材料有限公司 一种免漆门覆膜机
CN109849322B (zh) * 2019-01-14 2020-01-10 江山市标龙装饰材料有限公司 一种免漆门覆膜机
US20230287678A1 (en) * 2022-03-11 2023-09-14 Certainteed Llc Insulation standoffs and exterior insulation systems

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