U.S. patent application number 10/980537 was filed with the patent office on 2005-03-24 for insulating composite materials and methods for producing and using same.
Invention is credited to Kannankeril, Charles.
Application Number | 20050064172 10/980537 |
Document ID | / |
Family ID | 26939268 |
Filed Date | 2005-03-24 |
United States Patent
Application |
20050064172 |
Kind Code |
A1 |
Kannankeril, Charles |
March 24, 2005 |
Insulating composite materials and methods for producing and using
same
Abstract
A composite material wherein one or more backing materials are
disposed in generally contiguous relation to an insulating
material. Methods for forming composite materials comprising
securing one or more backing materials to an insulating material
such that the backing materials are in generally contiguous
relation to the insulating material. Methods for using the
composite materials of the present invention wherein a structure is
wrapped with a composite material of the present invention.
Inventors: |
Kannankeril, Charles; (North
Caldwell, NJ) |
Correspondence
Address: |
Sealed Air Corporation
P.O. Box 464
Duncan
SC
29334
US
|
Family ID: |
26939268 |
Appl. No.: |
10/980537 |
Filed: |
November 3, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10980537 |
Nov 3, 2004 |
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09998807 |
Nov 1, 2001 |
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6852391 |
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60248306 |
Nov 14, 2000 |
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Current U.S.
Class: |
428/304.4 ;
428/311.11; 428/315.5; 428/318.4 |
Current CPC
Class: |
E04B 2001/7691 20130101;
Y10T 428/239 20150115; Y10T 428/249962 20150401; Y10T 428/31681
20150401; B32B 3/26 20130101; Y10T 428/24479 20150115; Y10T
428/24661 20150115; Y10T 428/249987 20150401; Y10T 442/50 20150401;
Y10T 428/249981 20150401; Y10T 428/24628 20150115; Y10T 428/249978
20150401; E04B 1/78 20130101; Y10T 428/234 20150115; Y10T 442/3724
20150401; Y10T 428/249953 20150401; Y10T 428/24496 20150115; Y10T
428/24562 20150115; E04B 1/625 20130101 |
Class at
Publication: |
428/304.4 ;
428/318.4; 428/315.5; 428/311.11 |
International
Class: |
B32B 003/00; B31F
001/22; B32B 003/26; B32B 005/24; D21H 011/00; D21H 013/00; B32B
009/00 |
Claims
1. An article comprising: an insulating sheet comprising a material
selected from open-cell foam and close-cell foam, wherein: the
close-cell foam defines a plurality of perforations through the
close-cell foam; and the insulating sheet allows water vapor to
pass through the insulating sheet; and a backing sheet secured to
the insulating sheet in generally contiguous relation to the
insulating sheet, wherein the backing sheet allows water vapor to
pass through the backing sheet while preventing liquid water from
passing through the backing sheet.
2. The article of claim 1 wherein the insulating sheet comprises
open-cell foam.
3. The article of claim 1 wherein the insulating sheet comprises
close-cell foam.
4. The article of claim 1 wherein the backing sheet comprises high
density polyethylene.
5. The article of claim 1 wherein the backing sheet comprises a
thermoplastic polymer.
6. The article of claim 1 wherein the backing sheet comprises an
olefinic polymer.
7. The article of claim 6 wherein the olefinic polymer comprises a
polymer selected from one or more of polyethylene and
polypropylene.
8. The article of claim 1 wherein the backing sheet comprises
thermoplastic fibers.
9. The article of claim 8 wherein the thermoplastic fibers comprise
olefinic polymer fibers.
10. The article of claim 9 wherein the olefinic polymer fibers are
selected from the group consisting of polyethylene fibers and
polypropylene fibers.
11. The article of claim 1 wherein portions of the backing sheet
and the insulating sheet are adhesively secured to each other.
12. The article of claim 1 wherein portions of the backing sheet
are laminated to the insulating sheet.
13. The article of claim 1 wherein the backing sheet comprises a
non-woven polyester.
14. The article of claim 1 further comprising an adhesive along at
least a portion of the insulating sheet for securing the article to
a structure.
15. The article of claim 1 further comprising an adhesive along at
least a portion of the backing sheet for securing the composite
material to a structure.
16-45. (Canceled).
46. A method of forming the article of claim 1 comprising the steps
of: providing the insulating sheet; providing the backing sheet;
and securing the backing sheet generally superposed, contiguous
relation to the insulating sheet.
47. (Canceled).
48. A method for insulating a structure comprising the step of at
least partially wrapping the structure with the article of claim
1.
49. The method of claim 48 wherein the article is secured to the
structure with an adhesive.
50. The method of claim 48 wherein the structure comprises a
building.
Description
[0001] This application claims priority from and the benefit of
U.S. Provisional Patent Application Ser. No. 60/248,306 filed Nov.
14, 2001, which is incorporated herein in its entirety by
reference.
FIELD OF THE INVENTION
[0002] The present invention relates to composite materials and
methods for making and using the same. In particular, the present
invention relates to composite materials providing insulating
properties and methods for making and using the same.
BACKGROUND OF THE INVENTION
[0003] With the ever rising costs of heating and the increasing
emphasis on conservation of natural resources, there is a continued
need to provide improved building materials for insulating
edifices. Such building materials should be inexpensive to
manufacture and easy to install. The building materials should also
provide additional beneficial and desirable characteristics such as
non-abrasiveness, softness, hydrophilicity, hydrophobicity,
breathability, opacity, ultraviolet reflectivity, heat
reflectivity, and/or toughness.
SUMMARY OF THE INVENTION
[0004] In one of its aspects, the present invention relates to a
composite material comprising one or more backing materials
disposed in generally contiguous relation to an insulating
material. The insulating material comprises a foam, a fiberglass
mat, a macerated paper mat, a cork mat, or an air cellular
material.
[0005] In another of its aspects, the present invention relates to
a method of forming a composite material wherein an insulating
material and one ore more backing materials are secured such that
the backing materials are in generally superposed, contiguous
relation to the insulating material.
[0006] In yet another of its aspects, the present invention relates
to a method for insulating a structure wherein the structure is
wrapped with a composite material of the present invention.
[0007] Additional features and embodiments of the present invention
will become apparent to those skilled in the art in view of the
ensuing disclosure and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The numerous objects and advantages of the present invention
may be better understood by those skilled in the art by reference
to the accompanying detailed description and the following
drawings, in which:
[0009] FIG. 1 is a top plan view of a section of composite material
in accordance with the present invention;
[0010] FIG. 2 is an enlarged cross-sectional view of the composite
material of FIG. 1 taken along the A-A line;
[0011] FIG. 3 is an enlarged cross-sectional view of an alternate
embodiment of the composite material of the present invention;
[0012] FIG. 4 is an enlarged cross-sectional view of a further
embodiment of the composite material of the present invention;
[0013] FIG. 5 is an enlarged cross-sectional view of still another
alternate embodiment of the composite material of the present
invention; and
[0014] FIG. 6 is an enlarged cross-sectional view of yet a further
alternate embodiment of the composite material of the present
invention.
DETAILED DESCRIPTION OF THE INVENTION
[0015] In one of its aspects, the present invention relates to
composite materials comprising a backing material disposed in
generally contiguous relation to an insulating material. In the
embodiment depicted in FIGS. 1 and 2, the insulating material 10
comprises an air cellular material. The air cellular material
defines a plurality of gas-filled cavities 12 having land areas 13
separating the cavities 12. As best shown in FIG. 2, the air
cellular material comprises first and second thermoplastic films,
15 and 16, respectively. A plurality of spaced apart concave
sections 18 are formed in the first thermoplastic film 15. The
second thermoplastic film 16 is superposed onto the first
thermoplastic film 15 and secured to the land areas 13 between and
around the concave sections 18. The second thermoplastic film 16
thereby covers the concave sections 18 to form the gas-filled
cavities 12. The thermoplastic films, 15 and 16, are secured
together using any of a variety of conventional techniques. For
example, the thermoplastic films, 15 and 16, can be laminated
(e.g., heat sealed) together to form the air cellular material.
[0016] However, the air cellular material may be formed in many
different ways by different methods.
[0017] Examples of such methods are disclosed in U.S. Pat. Nos.
2,585,915; 2,776,451; 2,776,452; 3,026,231; 3,208,898; 3,285,793;
3,405,020; 3,416,984; and 5,116,444, each of which is incorporated
herein by reference in its entirety. In one embodiment, the first
and second thermoplastic films, 15 and 16, are coextruded to form
the air cellular material in accordance with the method described
in U.S. Pat. No. 5,116,444. Air cellular material is manufactured
by a number of different manufacturers, including Sealed Air
Corporation, the assignee of the present invention.
[0018] Suitable thermoplastic films include, but are not limited
to, polyvinyl chloride films, polyvinylidene chloride films,
olefinic polymer films, other coextruded films (e.g., films
comprising nylon and/or similar barrier films), and combinations
thereof. Suitable olefinic polymer films include, but are not
limited to, polyethylene and polypropylene polymer films.
[0019] The gas-filled cavities 12 can be of a variety of sizes,
shapes, and arrangements. However, the cavities 12 are generally
hemispherical in shape having a diameter of between about 0.2 cm
and about 4 cm, preferably between about 0.2 cm and about 2 cm.
Further, the insulating properties of the composite material will
be affected by the bubble height (larger bubble heights provide
better insulation). Accordingly, although the bubble height can be
varied over a considerable range, bubble heights of between about
1.5 mm and about 12.7 mm are preferred.
[0020] The backing material 8 is any of a variety of known
materials which can be utilized to provide one or more
characteristics desired for the composite material. Examples of
characteristics which may be found desirable include, but are not
limited to, non-abrasiveness, softness, hydrophilicity,
hydrophobicity (i.e., moisture resistance), opacity, ultraviolet
reflectivity, heat reflectivity, and toughness. In one embodiment,
the backing material 8 comprises a material that acts as a moisture
barrier by preventing or retarding water moisture from penetrating
the backing material 8 while still enabling water vapor to pass
through the backing material 8.
[0021] Suitable materials for the backing material 8 include, but
are not limited to, fibrous and non-fibrous materials (e.g.,
thermoplastic materials comprising thermoplastic fibers such as
olefinic polymer fibers (e.g., polyethylene and/or polypropylene
fibers)), woven and non-woven materials, spun and non-spun
materials, foils (e.g., metallic foils), and microporous films. In
one particularly preferred embodiment, the backing material
comprises TYVEK.RTM. (available from E.I. DuPont de Nemours &
Co.). As is known to those of skill in the art, Tyvek.RTM. brand
protective material is made from very fine, continuous, 100%
high-density polyethylene fibers that are randomly distributed and
non-directional and that are flash-spun and heat-bonded into a
fabric that is permeable to air and water vapor, yet water-,
chemical-, puncture-, tear-, and abrasion-resistant.
[0022] In another embodiment, the backing material 8 comprises a
non-woven polyester material. The non-woven polyester material is
optionally coated with a hydrophobic material to provide a backing
material that is both breathable and moisture resistant.
[0023] An alternate embodiment of the composite material is shown
in FIG. 6. The composite material of FIG. 6 is in many respects
similar to the composite material of FIG. 2. However, the backing
material 408 of the composite material depicted in FIG. 6 is
attached to the tips of the cavities 412. In addition, the
composite material of FIG. 6 comprises a second backing material
425 secured to the second thermoplastic film 416 of the insulating
material 410. The composite material of FIG. 6 is particularly
useful for applications wherein a composite material having a
combination of desired properties is required. For example,
breathability and water-resistance can be provided by utilizing a
backing material 408 comprising a breathable and water-resistant
material (e.g., TYVEK.RTM.). At the same time, reflective
insulation properties can be provided by utilizing a second backing
material comprising a foil. One or both of the backing material 408
and the second backing material 425 optionally define perforations
which are substantially similar to perforations 120 described in
connection with FIG. 3 below.
[0024] Yet another alternate arrangement of the composite material
is shown in FIG. 3. The first thermoplastic film 115, the second
thermoplastic film, 116, and the backing material 108 of the
composite material of FIG. 3 are essentially the same as the
corresponding elements of the composite material of FIGS. 1 and 2.
However, in the embodiment depicted in FIG. 3, perforations 120 are
formed in the land areas 113 to more freely allow vapor to pass
through the first and second thermoplastic films, 115 and 116, of
the insulating material. The size and arrangement of the
perforations 120 can vary depending upon the particular application
for which the composite material is to be utilized. Typically, the
perforations 120 are arranged substantially uniformly throughout
the land areas 113 of the insulating material. The diameters of the
perforations 120 are generally between about 0.001 mm and about 0.5
mm and, preferably, between about 0.01 mm and about 0.3 mm.
[0025] The embodiment of FIG. 5 is in many respects similar to the
composite material of FIG. 3, except that the backing material 308
of the composite material depicted in FIG. 5 is attached to the
tips of the cavities 312. The composite material of FIG. 5
therefore allows vapor passing through the perforations 320 to
interact with a larger portion of the surface of the backing
material 308. Accordingly, the embodiment of FIG. 5 is particularly
useful for applications requiring a breathable composite
material.
[0026] In yet another alternate embodiment depicted in FIG. 4, the
insulating material 210 comprises a foam, a fiberglass mat, a
macerated paper mat, a cork mat, or other similarly insulative
material. Suitable foams include, but are not limited to,
polyolefin, polyurethane, polystyrene, open-cell, and closed-cell
foams. When it is desired to provide a composite material that
allows vapor to pass therethrough, the foam 210 is preferably an
open-cell foam. Suitable open-cell foams include, but are not
limited to, polyolefin, polyurethane, and polystyrene foams.
Alternatively, the foam can be perforated to provide
breathability.
[0027] The backing material, 8, 108, 208, 308 and 408, is disposed
in generally contiguous relation to the insulating material, 10,
110, 210, 310 and 410, using any of a variety of techniques. For
example, at least portions of the backing material and the
insulating material can be laminated together. When both the
insulating material and the backing material comprise similar
materials (i.e., both comprise thermoplastics, or are otherwise
compatible), the backing material preferably has a fusion
temperature at least slightly above a fusion temperature associated
with the insulating material. Accordingly, when both the insulating
material and the backing material comprise thermoplastics, the
insulating material preferably comprises a low density
thermoplastic while the backing material preferably comprises a
high density thermoplastic.
[0028] Alternatively, an adhesive can be utilized to secure at
least portions of the backing material to the insulating material.
Referring to FIG. 4, when used, the adhesive 222 is preferably
applied as a separate layer between the insulating material 210 and
the backing material 208. The adhesive used will depend, at least
in part, on the composition of the backing and insulating materials
as well as on the particular application for which the composite is
to be used. For example, when the insulating material is a foam,
suitable adhesives include, but are not limited to, hot melt
adhesives (e.g., styrene block copolymer adhesives,
ethylene-vinylacetate copolymer adhesives, and poly-alpha-olefin
based adhesives), and water-based or solvent-based adhesives (e.g.,
acrylates and vinyl acetates). When it is desired to provide a
composite material that allows vapor to pass therethrough, the
adhesive is preferably a breathable adhesive such as a foamable
adhesive (e.g., an adhesive that incorporates a blowing agent).
[0029] The backing material can be secured to the insulating
material over substantially the entirety of the contiguous surfaces
of the backing material and the insulating material. Alternatively,
only portions of the backing material may be secured to the
insulating material by, for example, intermittent heat sealing or
the intermittent use of adhesive. When the backing material is
applied to the tips of the cavities of an air cellular material,
the adhesive is preferably applied only to the insulating material
at the tips of the cavities.
[0030] In another of its aspects, the present invention relates to
methods of forming composite materials wherein an insulating
material and a backing material are secured together such that the
backing material is in generally superposed, contiguous relation to
the insulating material. The insulating material is formed by any
of a number of methods. See, for example, U.S. Pat. Nos. 3,026,231;
3,142,599; 3,208,898; 3,294,387; and 3,416,984, each of which is
incorporated herein by reference in its entirety. The composite
material is then formed by attaching the backing material to the
insulating material. In one embodiment, the composite material is
formed by passing the insulating material and the backing material
through a nip formed between two drums or rolls. The backing and/or
insulating materials are optionally preheated prior to being fed
between the drums. When the insulating material is formed from two
separate laminated (e.g., heat sealed) films, the backing material
is preferably laminated to the insulating material at substantially
the same time that the films are laminated to form the insulating
material.
[0031] In yet another of its aspects, the present invention relates
to a method for insulating a structure with a composite material in
accordance with the present invention. The method comprises the
step of wrapping at least a portion of the structure with the
composite material. The structure is preferably wrapped so that the
composite material covers substantially all of the exterior
surfaces of the structure with the insulating material adjacent the
structure. The composite material is optionally secured to the
structure using any of a variety of techniques. For example, the
composite material can be nailed or tacked to the structure.
Alternatively, an adhesive coating can be applied to the composite
material along at least a portion of the surface of the composite
material that contacts the structure to facilitate attachment of
the composite material to the structure. In one particular
embodiment, the composite material comprises a backing material
that is breathable and moisture-resistant (e.g., TYVEK.RTM.). A
composite material comprising a moisture-resistant backing material
is particularly useful for wrapping structures such as buildings or
edifices (e.g., dwellings or houses).
EXAMPLES
[0032] Composite materials in accordance with the present invention
were prepared by securing sections of TYVEK.RTM. film to an air
cellular material. The air cellular material was separately formed
from coextruded thermoplastic films. The coextruded films each
comprised a buried nylon barrier film sandwiched between
polyethylene films. In a first example, the TYVEK.RTM. film was
laminated to the tips of the bubbles of the air cellular material
by heating the TYVEK.RTM. and the air cellular material with hot
air to a temperature near the fusion temperature of the air
cellular material. In a second example, the TYVEK.RTM. film was
laminated to the tips of the bubbles of the air cellular material
using a pressure sensitive adhesive.
[0033] Those skilled in the art will appreciate that numerous
changes and modifications may be made to the preferred embodiments
of the invention and that such changes and modifications may be
made without departing from the spirit of the invention. It is
therefore intended that the appended claims cover all equivalent
variations as fall within the true scope and spirit of the
invention.
* * * * *