U.S. patent application number 10/848172 was filed with the patent office on 2005-11-24 for packaging for insulation products.
Invention is credited to Brooks, Jon Michael, Duncan, Richard, Ruid, John O..
Application Number | 20050260368 10/848172 |
Document ID | / |
Family ID | 34968087 |
Filed Date | 2005-11-24 |
United States Patent
Application |
20050260368 |
Kind Code |
A1 |
Ruid, John O. ; et
al. |
November 24, 2005 |
Packaging for insulation products
Abstract
A packaged insulation product is provided comprising at least
one insulation product oriented for storage or transportation and
disposed in a package, wherein the package comprises a
vapor-permeable membrane.
Inventors: |
Ruid, John O.;
(Schwenksville, PA) ; Duncan, Richard;
(Royersford, PA) ; Brooks, Jon Michael;
(Danielsville, GA) |
Correspondence
Address: |
DUANE MORRIS, LLP
IP DEPARTMENT
30 SOUTH 17TH STREET
PHILADELPHIA
PA
19103-4196
US
|
Family ID: |
34968087 |
Appl. No.: |
10/848172 |
Filed: |
May 18, 2004 |
Current U.S.
Class: |
428/35.7 ;
428/74 |
Current CPC
Class: |
Y10T 428/1352 20150115;
Y10T 428/237 20150115; B65D 2565/388 20130101; Y10T 428/1303
20150115; Y10T 428/1359 20150115; Y10T 428/139 20150115; Y10T
428/13 20150115; B65D 85/07 20180101 |
Class at
Publication: |
428/035.7 ;
428/074 |
International
Class: |
B65D 001/00 |
Claims
What is claimed is:
1. A packaged insulation product, comprising: an insulation product
oriented for storage or transportation and disposed in a removable
package, said package comprising a vapor-permeable membrane.
2. The packaged insulation product of claim 1, wherein said
vapor-permeable membrane is a smart vapor retarder.
3. The packaged insulation product of claim 2, wherein the moisture
vapor permeability of said smart vapor retarder increases with
increases in ambient humidity.
4. The packaged insulation product of claim 2, wherein said
vapor-permeable membrane comprises a nylon film.
5. The packaged insulation product of claim 1, wherein said package
comprises a bag and said vapor-permeable membrane comprises
0.1-100% of the surface area of said bag.
6. The packaged insulation product of claim 1, wherein said
insulation product comprises at least one insulation mat having a
facing layer, said insulation mat secured in roll or folded form by
a tape disposed around said insulation mat and contacting said
facing layer, said tape comprising a water-based or activated
adhesive.
7. The packaged insulation product of claim 6, wherein said facing
layer comprises a FSK or PSK layer.
8. The packaged insulation product of claim 1, wherein said
removable package is non-perforated.
9. A packaging for storage or transportation of an insulation
product in roll or folded form, comprising a vapor-permeable
membrane sized to envelope a portion of said insulation
product.
10. The packaging of claim 9, wherein said vapor-permeable membrane
is a smart vapor retarder.
11. The packaging of claim 10, wherein the moisture vapor
permeability of said smart vapor retarder increases with increases
in ambient humidity.
12. The packaging of claim 10, wherein said vapor-permeable
membrane comprises a nylon film.
13. The packaging of claim 10, wherein said package comprises a bag
and said vapor-permeable membrane comprises 0.1-100% of the surface
area of said bag.
14. The packaging of claim 9, wherein said membrane is
non-perforated.
15. A method of packaging an insulation product, comprising:
providing at least one insulation product in rolled or folded form
for storage or transportation, disposing said provided insulation
product in a removable package comprising a vapor-permeable
membrane; and closing said package.
16. The method of claim 15, wherein said vapor-permeable membrane
is a smart vapor retarder.
17. The method of claim 16, wherein the moisture vapor permeability
of said smart vapor retarder increases with increases in ambient
humidity.
18. The method of claim 16, wherein said vapor-permeable membrane
comprises a nylon film.
19. The method of claim 15, wherein said package comprises a
polyolefin bag having a patch thereon which contains said
vapor-permeable membrane.
20. The method of claim 15, wherein said insulation product
comprises an insulation mat having a facing layer, said insulation
mat secured in roll or folded form by a tape disposed around said
insulation mat and contacting said facing layer, said tape
comprising a water-based or activated adhesive.
21. The method of claim 20, wherein said facing layer comprises a
FSK or PSK layer.
22. The method of claim 15, wherein said membrane is
non-perforated.
23. The method of claim 14, wherein said membrane is a film.
24. A packaged insulation product, comprising: an insulation
product comprising a fiberglass mat and a facing layer bonded to a
first major surface thereof, said insulation product compressed in
roll or folded form for storage or transportation thereof and
secured by a tape disposed around said insulation mat and
contacting said facing layer, said tape comprising a water-based or
activated adhesive, said insulation product disposed in a removable
package, said package comprising a non-perforated smart vapor
retarder membrane, wherein the moisture vapor permeability of said
smart vapor retarder membrane increases with increases in ambient
humidity.
25. The packaged insulation product of claim 24, wherein said
vapor-permeable membrane comprises a nylon film.
26. The packaged insulation product of claim 24, wherein said
facing layer comprises a FSK or PSK layer.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to packaging, and more
particularly to packaging for insulation products.
BACKGROUND OF THE INVENTION
[0002] Many insulation products, such as fiberglass insulation
mats, are produced and sold in roll form. Prior to packaging, these
products are typically wound on a winding machine, such as a Dyken
winder, named after the inventor of a rug rolling winder described
in U.S. Pat. No. 2,215,174 to Dyken, issued Sep. 17, 1940. The
rolled insulation product is held in roll form with a paper tape
applied to the circumference of the roll. The wound product is then
packaged in a plastic bag, typically comprising a polyolefin, such
as polyethylene, to protect it from damage and keep the insulation
clean and dry.
[0003] Current packaging, such as the aforementioned polyethylene
bag, protect the insulation well but can trap moisture in the
insulation or in the tape applied to the insulation, which utilizes
a water-based adhesive. There are two problems associated with this
trapped moisture. First, many insulation products are characterized
by an odor that has been shown to greatly increase in the presence
of moisture. Second, as noted, the tape used to hold the product in
roll form is typically water activated. When the tape is applied to
a FSK (foil-scrim-Kraft) facing layer, which is on a major surface
of the product, the tape can form a strong adhesive bond to the FSK
layer and is not easily removable, particularly, as it has been
observed, if the water is allowed to dry slowly. Removal of the
tape can cause tearing in the FSK layer, thereby compromising the
integrity of the vapor barrier layer. It is believed that sealing
the plastic bags before the water has completely dried prolongs the
drying process and is a main cause of the adhesion problem.
However, it is neither practical nor preferred to delay packaging
of the product to employ a drying process, which necessarily adds
costs and time to the manufacturing process.
[0004] Therefore, there is presently a need for a new packaging for
products that may be adversely affected by trapping water
therewith, particularly insulation products bound in roll form with
a water-based adhesive tape.
SUMMARY OF THE INVENTION
[0005] A packaged insulation product comprising an insulation
product oriented for storage or transportation and disposed in a
removable package is provided. The package includes a
vapor-permeable membrane. In one embodiment, the packaged
insulation product comprises an insulation product comprising a
fiberglass mat and a facing layer bonded to a first major surface
thereof. The insulation product is compressed in roll or folded
form for storage or transportation thereof and secured by a tape
disposed around the insulation mat and contacting the facing layer.
The tape includes a water-based or activated adhesive and the
insulation product is disposed in a removable package comprising a
non-perforated smart vapor retarder membrane, wherein the moisture
vapor permeability of the smart vapor retarder membrane increases
with increases in ambient humidity.
[0006] This vapor-permeable membrane allows drying to occur through
the process of vapor diffusion, thereby improving the speed of
drying of the adhesive that couples the tape to the facing layer,
which, it is believed, prevents the undesired strong bond
therebetween that can lead to tearing of the facing layer upon
removal of the tape. The membrane also allows other trapped
moisture to escape from the packaging, thereby limiting odors in
the insulation mat typically associated with excess trapped
moisture. In an exemplary embodiment, the membrane comprises a
smart vapor retarder such as a Nylon film not only because of its
excellent moisture vapor permeability characteristics, but for its
other physical characteristics as well. Nylon is a rather tough
plastic material with a high tensile strength. Nylon films also
exhibit low flammability even without any fire protecting
chemicals. The film can typically be used without any additives,
which improves its recyclability. The use of a packaging comprising
a smart vapor barrier also allows for packaging of the product
immediately or soon after winding rather than temporarily setting
the product aside unpackaged for air drying.
[0007] A packaging for storage or transportation of an insulation
product in roll or folded form is also provided comprising a
vapor-permeable membrane sized to envelope the insulation
product.
[0008] A method of packaging an insulation product is also provided
and comprises the steps of providing an insulation product in
rolled or folded form for storage or transportation, disposing the
insulation product in a removable package comprising a
vapor-permeable membrane, and closing the package.
[0009] The above and other features of the present invention will
be better understood from the following detailed description of the
preferred embodiments of the invention that is provided in
connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The accompanying drawings illustrate preferred embodiments
of the invention, as well as other information pertinent to the
disclosure, in which:
[0011] FIG. 1 is a side elevational view of a rolled insulation
product;
[0012] FIG. 1A is a front elevational view of the rolled insulation
product of FIG. 1;
[0013] FIG. 2 is an exploded view illustrating the placement of the
rolled insulation product of FIG. 1 into a packaging;
[0014] FIG. 3 is a cross-sectional view of the rolled insulation
product of FIG. 1 taken along Line 3-3;
[0015] FIG. 4 is a perspective view of a packaged insulation
product;
[0016] FIG. 5 illustrates a packaged product comprising an
alternative embodiment of a vapor-permeable packaging; and
[0017] FIG. 6 illustrates a packaged product comprising a plurality
of insulation products therein.
DETAILED DESCRIPTION
[0018] As used herein, the following terms are defined:
[0019] "Nylon" means synthetic materials that are strong tough
elastic materials comprising polyamides typically prepared from a
dicarboxylic acid and a diamine, or from omega-amino acid or its
lactone, that can be formed from a melt or solution into fibers,
filaments, bristles, fabrics, filaments, or sheets;
[0020] "Smart Vapor Retarder" is a film that changes its moisture
vapor permeability with increases and/or decreases of the ambient
humidity conditions; and
[0021] "Removable Package" means packaging for surrounding one or
more rolled or folded insulation products, as opposed to a
"package" that may be formed around an insulation product, forms a
part thereof and is not removed during installation and use of the
product.
[0022] FIG. 1 is a side elevational view of a rolled insulation
product or batt 10 comprising insulation mat 8 rolled for storage
and/or transportation after packaging. Although not limited
thereto, insulation mat 8 is generally provided in lengths between
about 50-150' with a width between about 2-6'. In one embodiment,
insulation mat 8 is a low density product having a density in the
range of about 0.5-2.5 lb/ft.sup.3 (8-40 kg/m.sup.3). The thickness
of the insulation mat 8 is generally proportional to the insulated
effectiveness or "R-value" of the insulation. Although also not
limited thereto, in one embodiment, the insulation mat has a
thickness in the range of about 1-3".
[0023] Insulation mat 8 is preferably formed from organic fibers
such as polymeric fibers or inorganic fibers such as rotary spun
glass fibers, textile glass fibers, stonewool (also known as
rockwool) or a combination thereof. Mineral fibers, such as glass,
are preferred. The fibers are often bound together with a heat
cured binder, such as known resinous phenolic materials, like
phenolformaldehyde resins or phenol urea formaldehyde (PUFA).
Melamine formaldehyde, acrylic, polyester, nylon, urethane and
furan binder may also be utilized in some embodiments.
[0024] Referring to FIG. 1A, which is a front elevational view of
rolled batt 10, and to FIG. 3, which is a cross-sectional view of
batt 10 taken along Line 3-3 in FIG. 1, insulation mat 8 has a
facing layer 6, typically a vapor retarder facing layer, adhered to
a major surface thereof. Reference 12 identifies the end of the
rolled mat 8. In one embodiment, the facing layer comprises a
laminate layer such as a FSK (foil (e.g., aluminum)-scrim-Kraft
paper) or PSK (plastic-scrim-Kraft paper) laminate layer. The FSK
or PSK layer may be coated with a bituminous adhesive material,
such as asphalt, for securing the laminate layer to the mat 8 or,
more typically, a water based adhesive such as an acrylic or
polyvinyl acetate. Optionally, the facing layer 6 can be secured to
the major surface of the insulation mat 8 by a hot-melt
adhesive.
[0025] The insulation mat 8 is typically compressed after
manufacture and then packaged, so as to minimize the volume of the
product during storage and shipping and to make handling and
installation of the insulation product easier. Up to seven or more
mats 8 can be stored within the same packaging. The diameter "D" of
each rolled product 10 is typically between about 1.5-3', more
typically about 20-30", with a width "W" typically around 48".
After the packaging is removed, the insulation product tends to
quickly "fluff up" to its prescribed label thickness for
insulation. Prior to packaging, the mat 8 is wound on a winding
machine, such as a Dyken winder, and the rolled insulation product
is held in roll form with one or more paper tape strips applied to
the circumference of the roll. The tape 14 is wrapped around the
circumference of each of the rolled products and coupled to facing
layer 6, specifically, to the foil or plastic portion of the FSK or
PSK laminate layer, respectively. Each product includes one or more
strips of tape, typically two strips of tape 14 as shown in FIGS. 1
and 1A.
[0026] The tape 14 is typically a paper tape with a water based or
activated adhesive, such as a gummed, non-reinforced heavy duty
paper tape available from Holland Manufacturing Co., Succasunna,
N.J.
[0027] In an exemplary embodiment, the wound product, which is held
in place by the tape 14, is then packaged in a removable package,
such as bag 16 (as shown in FIG. 2), to protect it from damage and
keep the insulation clean and dry. Bag 16 preferably comprises a
non-perforated vapor-permeable membrane that allows water from the
water based or activated adhesive on tape 14 and other water
present in rolled batt 10 to evaporate from bag 16 into the
surrounding environment. The vapor-permeable membrane can be from
0.1-100% of the surface area of the bag 16. For example, the
vapor-permeable membrane can be a patch on a standard polyethylene
bag, for example, as shown in FIG. 6 described below. An example of
a water vapor permeable but substantially liquid impermeable
material includes a polyurethane film. In one embodiment, the film
can be treated for improving the water-resistant properties while
not reducing its ability to be water vapor permeable. Examples of
materials which have been reported as being effective for improving
the water-resistant properties of layers are the following:
lattices of vinyl acetate, vinyl chloride, acrylics, acrylonitrile,
and ethylene in addition to the monomers of styrene, butadiene, and
isoprene, poly(vinyl alcohol), with or without a minor amount of
poly(vinyl acetate); metallic resinates; wax or asphalt or mixtures
thereof; a mixture of wax and/or asphalt and also cornflower and
potassium permanganate; water insoluble thermoplastic organic
materials such as petroleum and natural asphalt, coal tar, and
thermoplastic synthetic resins such as poly(vinyl acetate),
poly(vinyl chloride) and a copolymer of vinyl acetate and vinyl
chloride and acrylic resins; a mixture of metal rosin soap, a water
soluble alkaline earth metal salt, and residual fuel oil; a mixture
of petroleum waxes in the form of an emulsion and either residual
fuel oil and rosin, aromatic isocyanates and diisocyanates;
organohydrogenpolysiloxanes; silicone oils and emulsions; a
wax-asphalt emulsion with or without such materials as potassium
sulfate, alkali and alkaline earth aluminates; a wax-asphalt
emulsion prepared by adding to a blend of molten wax and asphalt an
oil-soluble, water-dispersing emulsifying agent, and admixing the
forementioned with a solution of casein which contains, as a
dispersing agent, an alkali sulfonate of a polyarylmethylene
condensation product.
[0028] In an exemplary embodiment, the vapor-permeable membrane
comprises a smart vapor-permeable membrane, i.e., a membrane that
changes its moisture vapor permeability with the ambient humidity
condition, such as Nylon. In one embodiment, the bag 16, or portion
of the bag 16, is formed from a material such as the MEMBRAIN.TM.
Smart Vapor Retarder available from CertainTeed Corporation of
Valley Forge, Pa. This smart vapor retarder is a polyamide film,
specifically about 99-100% by weight Nylon 6, blown to
approximately 2-mil thickness. The film changes its permeability
with the ambient humidity condition. The product's permeance is 1
perm or less when tested in accordance with ASTM E96, dry cup
method, and increases to greater than 10 perms using the wet cup
method. This process allows the closed packaging to increase its
drying potential dependent upon the presence of water inside the
package, such as water from the adhesive tape 14. The product
reacts to relative humidity by altering pore size, allowing water
vapor to pass through it. This transformation allows drying to
occur through the process of vapor diffusion, thereby improving,
after packaging, the speed of drying of the adhesive that couples
the tape 14 to the foil or plastic layer of facing layer 6, which,
it is believed, prevents the undesired strong bond therebetween
that can lead to tearing of facing layer 6 upon removal of the tape
14. The film also allows other trapped moisture to escape from the
packaging, thereby limiting odors in the insulation mat typically
associated with excess trapped moisture.
[0029] Nylon film smart vapor retarders are preferred not only
because of their moisture vapor permeability characteristics, but
for other physical characteristics as well. Nylon is a rather tough
plastic material with a high tensile strength. A membrane of about
50 .mu.m (2 mils) has mechanical properties equivalent to a
polyethylene film of 150 .mu.m (6 mils) thickness. Nylon films also
exhibit low flammability even without any fire protecting
chemicals. The film can typically be used without any additives,
which improves its recyclability.
[0030] Tests have shown that once significantly dried, the tape 14
is not easily reactivated by humidity. Therefore, although it is
preferred that the packaging environment have relatively low
humidity, which promotes diffusion of water from the packaged
product (i.e., the higher humidity environment) to the surrounding
low humidity environment, once the packaging is closed, storing the
product in higher humidity environments should not be a problem
after the water has substantially diffused out of packaged product.
The use of a packaging comprising a smart vapor barrier also allows
for packaging of the product immediately or soon after winding
rather than temporarily setting the product aside unpackaged for
air drying.
[0031] FIG. 4 is a perspective view of a packaged insulation
product 18, i.e., a rolled insulation batt 10 disposed in a sealed
package 16. As shown in FIG. 4, the package 16 is sealed or
otherwise closed at any open ends, such as by a wire tie 20 or
other means for closing or sealing the package 16.
[0032] As described above, the preferred packaging 16 includes a
non-perforated smart vapor retarder layer. Although not preferred,
in some embodiments, the packaging may includes perforations for
allowing water vapor to escape.
[0033] FIGS. 1, 1A, and 2 illustrate the insulation mat 8 as being
provided in rolled form for packaging. However, other orientations
suitable for packaging for transportation or storage and not
specifically show, such as folded orientations or other stacked
orientations, may also be employed. Further, although preferred,
there is no requirement that the insulation product be secured in
its orientation by a tape and in some embodiments, no tape or other
sealing means may be used prior to packaging.
[0034] FIG. 5 is a perspective view of a packaged product 18A
comprising an alternative embodiment of a package. In this
embodiment, package 16A comprises a bag, such as a conventional
polyolefin (e.g., polyethylene) bag having one or more patches 22
comprising a vapor-permeable membrane as described above. The patch
22 may be stitched, heat sealed or otherwise coupled in any other
viable manner to bag 16A to provide a vapor window to the outside
environment for diffusion of water thereto.
[0035] FIG. 6 illustrates an embodiment of a packaged insulation
product 18B comprising more than one insulation batt 10 within a
bag 16. The insulation batts 10 are shown in phantom.
[0036] Although the invention has been described in terms of
exemplary embodiments, it is not limited thereto. Rather, the
appended claims should be construed broadly to include other
variants and embodiments of the invention that may be made by those
skilled in the art without departing from the scope and range of
equivalents of the invention
* * * * *