U.S. patent application number 10/972774 was filed with the patent office on 2006-05-18 for perforated closed cell foam insulation, apparatus and method for perforating closed cell foam insulation, and insulated article.
Invention is credited to T. Scott Miller.
Application Number | 20060101748 10/972774 |
Document ID | / |
Family ID | 36384665 |
Filed Date | 2006-05-18 |
United States Patent
Application |
20060101748 |
Kind Code |
A1 |
Miller; T. Scott |
May 18, 2006 |
Perforated closed cell foam insulation, apparatus and method for
perforating closed cell foam insulation, and insulated article
Abstract
The present invention is directed to perforated closed cell foam
insulation. A sheet of closed cell foam insulation has opposing
first and second major surfaces, and a plurality of spaced openings
extending from the first major surface to the second major surface.
Apparatus and methods for perforating a sheet of closed cell foam
insulation are also disclosed. The present invention also relates
to an insulated metal panel including the disclosed perforated
closed cell foam insulation.
Inventors: |
Miller; T. Scott;
(Henderson, KY) |
Correspondence
Address: |
BERENATO, WHITE & STAVISH, LLC
6550 ROCK SPRING DRIVE
SUITE 240
BETHESDA
MD
20817
US
|
Family ID: |
36384665 |
Appl. No.: |
10/972774 |
Filed: |
October 26, 2004 |
Current U.S.
Class: |
52/309.4 |
Current CPC
Class: |
E04B 2001/8245 20130101;
B32B 2419/00 20130101; B32B 3/266 20130101; B32B 7/12 20130101;
B32B 29/007 20130101; E04B 1/90 20130101; B32B 2266/08 20130101;
E04B 2001/8461 20130101; B32B 5/18 20130101; B32B 15/043 20130101;
B32B 3/263 20130101; B32B 2307/304 20130101; B32B 7/06 20130101;
E04B 1/88 20130101 |
Class at
Publication: |
052/309.4 |
International
Class: |
E04C 1/00 20060101
E04C001/00 |
Claims
1. Perforated closed cell foam insulation, comprising: a sheet of
closed cell foam insulation having opposing first and second major
surfaces; and a plurality of spaced openings extend from said first
major surface through said second major surface.
2. The insulation of claim 1, further comprising an adhesive layer
covering at least one of said major surfaces.
3. The insulation of claim 2, further comprising a liner material
releasably attached to said adhesive layer.
4. The insulation of claim 3, wherein said liner material is
selected from the group consisting of silicone coated release
paper, polyethylene coated release paper, and mylar.
5. The insulation of claim 3, wherein said liner material and said
adhesive layer include a plurality of openings aligned with said
plurality of spaced openings.
6. The insulation of claim 2, wherein said adhesive layer is water
based acrylic adhesive.
7. The insulation of claim 1, wherein said sheet has a thickness of
at least about 0.030 inch.
8. The insulation of claim 7, wherein said sheet has a thickness of
between about 0.030 inch and about 2.0 inch.
9. The insulation of claim 1, wherein said sheet is polyethylene
closed cell foam insulation.
10. An apparatus for perforating a sheet of closed cell foam
insulation, comprising: a supply section for holding sheet
insulation; a nip roller spaced from said supply section, said nip
roller having a cylindrical configuration and a motor operably
associated therewith for causing axial rotation of said nip roller;
an aerator roller having a plurality of spaced projections, said
aerator roller parallel to said nip roller and spaced from said nip
roller a sufficient distance so that the sheet insulation is
perforated by said spaced projections when passing
therebetween.
11. The apparatus of claim 10, wherein said supply section includes
a rod for holding a roll of the sheet insulation.
12. The apparatus of claim 10, further comprising a guide roller
for aligning an adhesive coated release material with a side of the
insulation.
13. The apparatus of claim 12, wherein said guide roller is
upstream said nip roller so that the sheet insulation and the
release material are simultaneously perforated by said aerator
roller.
14. The apparatus of claim 13, further comprising first and second
compression rollers intermediate and aligned with said nip roller
and said guide roller, said rollers positioned so that the sheet
insulation and release material are pressed together while passing
therebetween.
15. The apparatus of claim 12, wherein said guide roller is
downstream said nip roller so that the release material is adhered
to perforated insulation.
16. The apparatus of claim 15, further comprising first and second
compression rollers intermediate and aligned with said nip roller
and said guide roller, said rollers positioned so that the
perforated sheet insulation and release material are pressed
together while passing therebetween.
17. The apparatus of claim 10, wherein said spaced projections are
uniformly spaced from each other by at least about 0.125 inch.
18. The apparatus of claim 10, wherein said spaced projections are
formed from a material selected from the group consisting of
polypropylene, steel, and aluminum.
19. The apparatus of claim 10, wherein said aerator roller has a
length at least equal to the width of the sheet insulation.
20. The apparatus of claim 10, wherein said apparatus includes at
least two of said aerator rollers axially aligned with each other,
said rollers having a total length at least equal to the width of
the sheet insulation.
21. A method of perforating closed cell foam insulation, comprising
the steps of: providing a supply of closed cell foam sheet
insulation; providing a pair of rollers parallel and adjacent to
each other, one of the rollers having a plurality of spaced
projections; and passing the sheet insulation between the rollers
so that the spaced projections perforate the sheet insulation.
22. The method of claim 21, including the further steps of:
providing a supply of adhesive coated release material; aligning
the release material with the sheet insulation; bonding the aligned
release material to the sheet insulation; and perforating the
bonded release material and sheet insulation simultaneously during
said passing step.
23. The method of claim 21, including the further steps of:
providing a supply of adhesive coated release material; aligning
the release material with the perforated sheet material; bonding
the aligned release material to the perforated sheet
insulation.
24. An insulated metal panel, comprising: a metal planar portion;
and a sheet of closed cell foam insulation having a first major
surface adhered to said metal planar portion and an opposing second
major surface, said sheet having a plurality of spaced openings
extending from said first major surface through said second major
surface.
25. The metal panel of claim 24, wherein said panel comprises a
portion of a metal cabinet.
26. The metal panel of claim 24, wherein said metal cabinet is
associated with an HVAC unit.
27. The metal panel of claim 24, wherein said openings are
uniformly distributed throughout said sheet.
28. An apparatus for perforating a sheet of closed cell foam
insulation, comprising: a supply section for holding sheet
insulation; a press spaced from said supply section, said press
having a major surface including a plurality of spaced projections;
an actuator operably associated with said press for causing said
major surface to contact the sheet insulation when passing under
said press so that the sheet insulation is perforated by said
spaced projections.
29. The apparatus of claim 28, wherein said press includes an upper
die and a lower die, at least one of said dies having said major
surface including said spaced projections.
30. A method of perforating closed cell foam insulation, comprising
the steps of: providing a supply of closed cell foam sheet
insulation; providing a press having a major surface including a
plurality of spaced projections; disposing the sheet insulation
under the press; pressing the sheet insulation against the major
surface so that the sheet insulation is perforated by the spaced
projections.
Description
FIELD OF THE INVENTION
[0001] The present invention is directed to perforated closed cell
foam insulation. A sheet of closed cell foam insulation has
opposing first and second major surfaces, and a plurality of spaced
openings extending from the first major surface to the second major
surface. Apparatus and methods for perforating a sheet of closed
cell foam insulation are also disclosed. The present invention also
relates to an insulated metal panel including the disclosed
perforated closed cell foam insulation.
BACKGROUND OF THE INVENTION
[0002] Closed cell foam insulation (CCF) is used in various
applications as a thermal and acoustic insulator, such as in HVAC
appliances. CCF is a generic term used interchangeably for either
elastomeric or polyethylene based insulation having a closed cell
structure. It is typically produced using polymeric materials and
blowing agents. When the blowing agent is introduced into the
polymer, closed cell air pockets are formed. It is commonly
available in sheets, rolls, and tubing. CCF has a smooth, durable
external surface that resists dirt and moisture accumulation. The
closed cell structure does not absorb any significant amounts of
moisture. Rather, conventional CCF provides a barrier to vapor
exchange, and therefore does not "breath" as does open cell
insulation.
[0003] CCF is a preferred insulation for many applications.
However, it may be difficult to install relatively large sheets of
CCF without creating air pockets between the surface being
insulated and the sheet of insulation, particularly when it is
applied using an adhesive. Any air pockets that are created from
improper installation may compromise the insulating properties of
the insulation. In addition, the insulation tends to delaminate
from the substrate in areas having air pockets. Any trapped air
will not permeate out through the CCF due to its "non-breathable"
and impermeable characteristics. In addition, any condensation
and/or other moisture that develops on portions of the substrate in
areas where air pockets were created will not permeate out through
the CCF.
SUMMARY OF THE INVENTION
[0004] The present invention is directed to perforated closed cell
foam insulation. A sheet of closed cell foam insulation has
opposing first and second major surfaces, and a plurality of spaced
openings extending from the first major surface to the second major
surface.
[0005] An apparatus for perforating a sheet of closed cell foam
insulation is also disclosed. The apparatus includes a supply
section for holding sheet insulation, a nip roller spaced from the
supply section, and an aerator roller. The nip roller has a
cylindrical configuration and a motor operably associated therewith
for causing axial rotation of the nip roller. The aerator roller
has a plurality of spaced projections. The aerator roller is
parallel to the nip roller and spaced from the nip roller a
sufficient distance so that the sheet insulation is perforated by
the spaced projections when passing therebetween.
[0006] An apparatus for perforating a sheet of closed cell foam
insulation according to another embodiment is provided. The
apparatus includes a supply section for holding sheet insulation,
and a press spaced from the supply section. The press has a major
surface including a plurality of spaced projections. An actuator is
operably associated with the press, and causes the major surface to
contact the sheet insulation when passing under the press so that
the sheet insulation is perforated by the spaced projections.
[0007] A method of perforating closed cell foam insulation is
provided. A supply of closed cell foam sheet insulation and a pair
of rollers parallel and adjacent to each other are provided. One of
the rollers has a plurality of spaced projections. The sheet
insulation is passed between the rollers so that the spaced
projections perforate the sheet insulation.
[0008] Another method of perforating closed cell foam insulation is
disclosed. A supply of closed cell foam sheet insulation is
provided. A press having a major surface including a plurality of
spaced projections is provided. The sheet insulation is disposed
under the press. The sheet insulation is pressed against the major
surface so that the sheet insulation is perforated by the spaced
projections.
[0009] The present invention also relates to an insulated metal
panel, such as a panel of a HVAC cabinet. The panel includes a
metal planar portion and a sheet of closed cell foam insulation.
The insulation has a first major surface, which is adhered to the
metal planar portion, and an opposing second major surface. A
plurality of spaced openings extend from the first major surface to
the second major surface.
BRIEF DESCRIPTION OF THE FIGURES
[0010] FIG. 1 is a perspective view of a perforated sheet of CCF
according to the present invention;
[0011] FIG. 2 is a sectional view of a perforated sheet of CCF
having an adhesive layer covering a major surface of the sheet, and
a releasable liner material covering the adhesive layer;
[0012] FIG. 3 is a sectional view of an apparatus for perforating a
sheet of CCF according to a first embodiment;
[0013] FIG. 4 is an elevational view of an aerator roller;
[0014] FIG. 5 is a sectional view of an apparatus for perforating a
sheet of CCF according to another embodiment;
[0015] FIG. 6 is a fragmentary sectional view of a portion of the
apparatus shown in FIG. 5;
[0016] FIG. 7 is a perspective view of an insulated metal panel
according to the present invention;
[0017] FIG. 8 is a sectional view of an apparatus for perforating a
sheet of CCF according to another embodiment; and
[0018] FIG. 9 is a perspective view of a press for perforating a
sheet of CCF according to another embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS(S)
[0019] As best shown in FIG. 1, the present invention is directed
to perforated closed cell foam insulation (CCF) comprising a sheet
of CCF 10 having opposing first and second major surfaces 12, 14. A
plurality of spaced openings 16 extend through sheet 10 from first
major surface 12 to second major surface 14. Sheet 10 preferably
has a thickness of at least about 0.030 inches, more preferably a
thickness of between about 0.0625 inch and up to about 2.0 inch.
Preferably, sheet 10 is formed from a polyethylene material.
[0020] I prefer that the openings 16 be uniformly distributed over
sheet 10. The ultimate use of sheet 10 may not be known in advance,
because individual pieces or shapes may be cut, punched or
otherwise formed from sheet 10 to meet the requirements of a
particular application. Due to the uniform distribution of openings
16 throughout sheet 10, any ultimately converted shape will
likewise have uniformly distributed openings to allow air and
moisture communication. Also, because of the uniform distribution
of openings 16 there is no tendency for air or moisture to
accumulate preferentially during application of the shape to the
end use part. The openings 16 should be large enough to permit air,
gas and moisture to pass therethough. Openings 16 preferably are
circular in plan and have a diameter of less that about 0.030
inches in order to preserve structural integrity of sheet 10.
[0021] As best shown in FIG. 2, sheet 10 may also include a layer
of adhesive 18 covering at least one of major surfaces 12, 14.
Adhesive 18 may be water based acrylic adhesive, hot melt and/or
solvent based adhesive. Preferably, a liner material 20 is
releasably attached to the exteriorly disposed surface of adhesive
layer 18. For example, liner material 20 may be a silicone coated
release paper, polyethylene coated release paper, mylar, or some
other material that is easily detached to expose adhesive 18 when
attaching sheet 10 to a surface.
[0022] An apparatus A for forming perforated CCF is best shown in
FIG. 3. Apparatus A includes a supply section 22 for holding sheet
insulation 24, a cylindrical nip roller 26 spaced from supply
section 22, and an aerator roller 28. A motor 30 is operably
associated with nip roller 26 via belt 32 for causing axial
rotation of nip roller 26. Supply section 22 may include a rod for
holding a roll 24R of the sheet insulation 24.
[0023] As best shown in FIG. 4, aerator roller 28 includes a
plurality of spaced projections 34. Preferably, projections 34 are
uniformly spaced from each other. For example, projections 34 may
be spaced from each other by at least about 0.125 inch. Projections
34 may be formed from polypropylene, steel, aluminum, or any
material having sufficient rigidity sufficient to pierce sheet
insulation 24. Projections 34 have a length sufficient to pierce
through insulation 24. Projections 34 may be either tapered or
cylindrical.
[0024] Aerator roller preferably has a length at least equal to the
width of sheet insulation 24. Alternatively, two or more aerator
rollers 28 may be axially aligned with each other so that rollers
28 have a combined total length at least equal to the width of
sheet insulation 24. In this way, the entire surface of sheet
insulation 24 may be perforated. Aerator roller 28 is parallel to
nip roller 26 and spaced from nip roller 26 a sufficient distance
so that the sheet insulation is perforated by projections 34 when
passing therebetween to form perforated sheet 10, as best shown in
FIG. 3.
[0025] Apparatus A may also include a guide roller 36 for guiding
an adhesive coated release material 38 between first and second
compression rollers 40, 42. Release material 38 preferably includes
adhesive layer 18 and liner material 20. A roll 38R of release
material 38 may be provided for supplying release material 38 to
guide roller 36. Rollers 40, 42 are positioned so that release
material 38 engages roller 42, and sheet 10 engages roller 40.
Rollers 40, 42 are parallel to and aligned with nip roller 26 and
guide roller 36, and rotate so that release material 38 and sheet
10 are compressed together therebetween. Rollers 40, 42 are
sufficiently spaced so that release material 38 is compressed
against and adhered to second major surface 14 of sheet 10. The
adhesive of adhesive layer 18 may be pressure activated so that
release material 38 is bonded to sheet 10 when they are passed
between rollers 40, 42.
[0026] As shown in FIG. 3, guide roller 36 and compression rollers
40, 42 may be downstream of nip roller 26, so that release material
38 is adhered to perforated sheet 10. As such, release material 38
is not perforated after it is attached to sheet 10. An apparatus A'
according to another embodiment is configured so that release
material 38 is bonded to sheet insulation 24 prior to perforation,
as best shown in FIG. 5. Guide roller 36 and compression rollers
40, 42 are upstream of nip roller 26. Sheet insulation 24 and
release material 38 are first bonded together between compression
rollers 40, 42, and then simultaneously perforated by aerator
roller 28.
[0027] Release material 38 is aligned with sheet insulation 24
prior to passing through rollers 40, 42 via guide roller 36.
Release material 38 and insulation 24 are then compressed together
by rollers 40, 42. The resulting multi-layer material, which
includes insulation 24, adhesive layer 18 and liner material 20, is
then passed between nip roller 26 and aerator roller 28, and
pierced by projections 34 to form spaced openings 16, as best shown
in FIG. 6. As noted above, nip roller 26 is preferably operably
associated with motor 30 via belt 32, which causes nip roller 26 to
rotate in a first direction D1. Aerator roller 28 rotates in a
second direction D2 opposite the first direction as sheet
insulation 24 passes therebetween, as shown by arrows D1, D2 in
FIG. 6.
[0028] It should be understood that various apparatus
configurations may be provided to form perforated CCF 10. An
apparatus 80 for forming perforated CCF sheets 10 according to
another embodiment is best shown in FIG. 8. Instead of using
aerator roller 28 for forming openings 16 in sheet insulation 24,
apparatus 80 includes a press 82 having a major surface 84
including a plurality of spaced projections 86 extending therefrom.
Projections 86 are similar to projections 34, and may be uniformly
spaced from each other. Projections 86 have sufficient rigidity to
pierce sheet insulation 24, and have a length sufficient to pierce
through insulation 24. Apparatus 80 may include supply section 22
spaced from press 82. Supply section 22 may include roll 24R of
sheet insulation, as described above. An actuator 88 is operably
associated with press 82 for causing major surface 84 to contact
the sheet insulation 24 when passing under press 82. The sheet
insulation is pressed against major surface 84, thereby perforating
the sheet insulation by spaced projections 86 to form perforated
CCF 10.
[0029] An apparatus 90 for forming perforated CCF sheets 10
according to another embodiment is best shown in FIG. 9. Instead of
press 82, apparatus 90 includes a press having an upper die 92 and
a lower die 94. Each of dies 92, 94 has a major surface 96, and
major surface 96 of at least one of dies 92, 94 includes spaced
projections 98 extending therefrom. Projections 98 are similar to
projections 34 and 86, as described above. As shown in FIG. 9,
lower die 94 includes projections 98. However, it should be
understood that upper die 92 may include projections 98 instead, or
both upper and lower dies 92, 94 may include projections 98. In
addition, each projection 98 extending from one of dies 92, 94 may
align with and be received in a corresponding recess in the other
die when upper and lower dies 92, 94 are closed together. Apparatus
90 may also include supply section 22. Sheet insulation 24 is
disposed between upper and lower dies 92, 94, and pressed
therebetween so that major surfaces 96 of dies 92, 94 contact
opposing sides of the sheet insulation so that projections 98
perforate the insulation thereby forming perforated CCF 10.
[0030] The perforated CCF sheet 10 is particularly useful for
insulating metal panels or cabinets, particularly cabinets
associated with HVAC applications. However, sheet 10 may be used in
other applications requiring thermal and/or acoustic insulation,
for example for insulating pipe, compressors, clothes dryers,
dishwashers, etc. An insulated metal panel P according to the
present invention is best shown in FIG. 7. Panel P includes a metal
planar portion 50. Perforated sheet 10 is provided, having first
major surface 12 exteriorly disposed and second major surface 14
adhered to portion 50 via adhesive layer 18. Openings 16 in sheet
10 permits any air to escape, which may otherwise be trapped
between sheet 10 and surface 50. In this way, proper contact
between sheet 10 and surface 50 is ensured, thereby achieving a
proper fit and minimizing the possibility of de-lamination. In
addition, surface 50 remains breathable to the environment adjacent
first major surface 12, thereby reducing the possibility of
microbial growth on panel P.
[0031] It will be apparent to one of ordinary skill in the art that
various modifications and variations can be made in construction or
configuration of the present invention without departing from the
scope or spirit of the invention. Thus, it is intended that the
present invention cover such modifications and variations, and as
may be applied to the central features set forth above, provided
they come within the scope of the following claims and their
equivalents.
* * * * *