U.S. patent application number 13/872536 was filed with the patent office on 2013-09-19 for film for construction and film combination.
This patent application is currently assigned to Ewald Dorken AG. The applicant listed for this patent is Ewald Dorken AG. Invention is credited to Jorn Schroer.
Application Number | 20130244518 13/872536 |
Document ID | / |
Family ID | 39995718 |
Filed Date | 2013-09-19 |
United States Patent
Application |
20130244518 |
Kind Code |
A1 |
Schroer; Jorn |
September 19, 2013 |
FILM FOR CONSTRUCTION AND FILM COMBINATION
Abstract
A film (1) for construction with at least one functional layer
(2) and optionally at least one other layer, especially a carrier
layer and/or reinforcing layer (3), the functional layer (2) having
a water vapor diffusion resistance (s.sub.d value) that is
dependent on the ambient humidity. The functional layer (2) has at
least one material (4) that can be obtained from a renewable raw
material, especially at least one polymer based on a renewable raw
material. A method of applying a functional layer to building
construction involves installing the functional layer as a vapor
control layer over rafters of a building either inside, outside or
in a loop shape, or alternatively, installing the functional layer
as a vapor control layer barrier in a sheeted roof, ceiling or
facade region of a building as at least one of an underform web and
a counter ceiling web.
Inventors: |
Schroer; Jorn; (Herdecke,
DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Ewald Dorken AG |
Herdecke |
|
DE |
|
|
Assignee: |
Ewald Dorken AG
Herdecke
DE
|
Family ID: |
39995718 |
Appl. No.: |
13/872536 |
Filed: |
April 29, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
12679392 |
Mar 22, 2010 |
|
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13872536 |
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Current U.S.
Class: |
442/85 ; 156/71;
428/423.1; 428/480; 428/532 |
Current CPC
Class: |
E04B 7/00 20130101; B32B
27/36 20130101; Y10T 428/31971 20150401; E04B 1/625 20130101; B32B
5/022 20130101; B32B 2307/7163 20130101; Y10T 428/31786 20150401;
Y10T 442/2213 20150401; B32B 2419/00 20130101; Y10T 442/60
20150401; B32B 2262/065 20130101; E04B 1/665 20130101; Y10T
428/249953 20150401; B32B 27/12 20130101; Y10T 428/24942 20150115;
Y10T 428/31504 20150401; B32B 27/06 20130101; Y10T 428/254
20150115; Y10T 428/31551 20150401; Y10T 428/249921 20150401; B32B
2307/724 20130101 |
Class at
Publication: |
442/85 ; 156/71;
428/480; 428/423.1; 428/532 |
International
Class: |
E04B 7/00 20060101
E04B007/00 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 26, 2007 |
DE |
10 2007 046 175.7 |
Claims
1. A building comprising a roof, said roof comprising rafters and a
vapor control film combination comprising at least one functional
layer and at least one carrier or reinforcing layer, the at least
one functional layer having a water vapor diffusion resistance
(s.sub.d value) that is dependent on ambient humidity, wherein the
functional layer is formed of a biodegradable polymer selected from
the group consisting of a biodegradable polyester, a biodegradable
polyhydroxyalkanoate, a biodegradable polylactide, a biodegradable
polyester urethane and a biodegradable polysaccharide.
2. The building of claim 1, wherein the vapor control film
combination is disposed over the rafters of said roof
3. The building of claim 1, wherein the vapor control film
combination is disposed in a loop shape over said rafters.
4. Method of applying a functional layer to building construction
as at least one of a vapor control layer, an underform web and a
counter ceiling web, comprising the steps of: providing an
indefinite length of a functional layer having a water vapor
diffusion resistance s.sub.d value that is dependent on ambient
humidity and a static water column water tightness of at least 10
cm, wherein the functional layer is formed of at least one
renewable raw material, and at least one of the following steps:
installing the functional layer as a vapor control layer inside,
outside or in a loop shape over rafters of a building, installing
the functional layer as a vapor control layer barrier in a sheeted
roof, ceiling or facade region of a building as at least one of an
underform web and a counter ceiling web.
5. Method of applying a functional layer to building construction
according to claim 4, wherein both of said steps of installing the
functional layer as a vapor control layer inside, outside or in a
loop shape over rafters of a building, and installing the
functional layer as a vapor control layer barrier in a sheeted
roof, ceiling or facade region of a building as at least one of an
underform web and a counter ceiling web are performed.
6. Method of applying a functional layer to building construction
according to claim 4, wherein said step of installing the
functional layer as a vapor control layer inside, outside or in a
loop shape over rafters of a building is performed.
7. Method of applying a functional layer to building construction
according to claim 4, wherein said step of installing the
functional layer as a vapor control layer barrier in a sheeted
roof, ceiling or facade region of a building as at least one of an
underform web and a counter ceiling web is performed.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional of co-pending U.S. patent
application Ser. No. 12/679,392.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a film for construction, especially
a vapor control layer, a counter ceiling web and an underform web,
with at least one functional layer, and optionally, at least one
other layer, especially a carrier layer and/or reinforcing layer,
the functional layer having a water vapor diffusion resistance
(s.sub.d value) that is dependent on the ambient humidity.
Moreover, this invention relates to a film combination with at
least one film of the aforementioned type, and optionally, with at
least one other film connected to the film and/or with at least one
carrier connected to the film, as well as to a method of applying
such a functional layer to a building construction.
[0004] 2. Description of Related Art
[0005] Heat insulation measures are known on buildings, parts and
equipment in order to save energy, on the one hand, and on the
other hand, to protect components against damage, for example, by
condensate formation when moisture penetrates by convection or by
diffusion. Therefore, control of convection and diffusion processes
plays a decisive role in the construction field. In particular,
insulation can thus be improved and its function can be permanently
maintained.
[0006] In particular, controlling water vapor diffusion can prevent
moisture damage. For this purpose, if vapor barriers with high
diffusion resistance are used, the construction is indeed protected
against penetrating moisture due to diffusion processes; but, vapor
barriers have the disadvantage that drying of the inside is
prevented or hindered. If vapor control layers with low diffusion
resistance are used, redrying is possible, but there is the danger
of overly great wetting as a result of diffusion processes.
[0007] In this connection, the prior art discloses films with
variable water vapor permeability. Vapor control layers are
preferably used here with a water vapor diffusion resistance or
variable s.sub.d values that are dependent on the ambient humidity
and they can also be located around the rafters in an undulating
manner, for example, in the roof area in addition to installation
over or under the rafters.
[0008] German Utility Model DE 296 11 626 U discloses a barrier for
prevention of air convection and emission of pollutants from
components in the rooms of buildings, on the room side there being
a polyamide film. The film can consist of polyamide 3, 4, 6, or 12
or of a mixed polyamide. At a film thickness of 50 microns the film
under measurement conditions according to DIN 52650 in a dry region
at an average relative humidity of roughly 30% has a water vapor
diffusion resistance (s.sub.d value) of 4.5 m and in a humid region
at an average relative humidity of roughly 70% has a water vapor
diffusion resistance (s.sub.d) of 0.5 m of a diffusion-equivalent
air layer thickness.
[0009] German Patent DE 102 39 985 B4 discloses suitable sealing
strips 5 to 20 cm wide for construction engineering that are formed
of at least three flat layers, the middle layer consisting of a
film of an ionomer that has a lower water vapor diffusion
resistance at higher relative atmospheric humidity than at a lower
relative atmospheric humidity, the film at 72.5% relative
atmospheric humidity having a s.sub.d value from 0.1 to 5 m and at
25% relative atmospheric humidity having a s.sub.d value from 1 to
10 m and the difference of the two values being 0.5 m or greater.
The two outer layers that protect and carry the middle layer
consist of the same or different material and have a s.sub.d value
that is below the lowest s.sub.d value of the film. Moreover there
can optionally be other layers of water vapor-permeable framing
materials and/or process engineering auxiliary materials.
Comonomers can be different synthetically based monomers.
[0010] German Patent Application DE 101 11 319 A1 discloses a
material for a film for lining buildings or for covering
components, such as walls, floors, rooves and ceilings in buildings
or for a vapor control layer for heat insulation in buildings, at
least some of the material consisting of polar materials and having
a water vapor diffusion resistance (s.sub.d value) that is
dependent on the ambient humidity. At a relative humidity in the
range from 20% to 60% or 30% to 50% the s.sub.d value is 5 to 10 m
diffusion-equivalent air layer thickness and at a relative humidity
in the range from 50% to 95% the s.sub.d value is less than 2 m or
less than 1 m diffusion equivalent air layer thickness. Some of the
material can consist of a polymer in which polar ingredients such
as an ionomer resin with ethylene and methacrylic acid are
contained. Moreover, some of the material can consist of an
ethylene-based polymer or copolymer material, such as polyethylene
or polypropylene to which acrylic acid is added.
[0011] German Patent Application DE 102 31 769 A1 describes a vapor
control layer film with increased breaking elongation in the
lengthwise and transverse directions and with variable water vapor
permeability. The vapor control layer film consists of a
copolyamide, by which increased breaking elongation in the
lengthwise and transverse direction of the vapor control layer film
will be achieved. The vapor control layer film at an ambient
atmosphere pressure of 100% and an ambient temperature of 0.degree.
C. should have a water vapor diffusion resistance in the range from
4.5 to 8 g/(m.sup.2d) and at a relative humidity of the atmosphere
surrounding the vapor control layer film of 85% and an ambient
temperature of 23.degree. C. should have a water vapor diffusion
resistance in the range from 11 to 23 g/(m.sup.2d).
[0012] The vapor control layers and films known from the prior art
generally contain petrochemical-based polymers that must be
disposed of after their use with high energy expenditure and with
great complexity. This is associated with high costs. With
petrochemical-based polymers, only amide or ionic functionalities
are used.
SUMMARY OF THE INVENTION
[0013] The object of this invention is to provide a film and a film
combination of the initially named type that can be produced
economically with low energy use and can be easily and economically
disposed of after their use, and over the function of the film or
the film combination in the construction field will be essentially
ensured the expected service life. Otherwise, another object of
this invention is to provide a film or film combination that is
characterized by high elongation.
[0014] A further object is to provide a method of applying a
functional layer to building construction involves installing the
functional layer as a vapor control layer over rafters of a
building.
[0015] The aforementioned objects are achieved in a first
embodiment of a film of the initially named type in that the
functional layer has at least one material that can be obtained
from a renewable raw material, especially at least one polymer
based on a renewable raw material. In one alternative embodiment,
in accordance with the invention, a film of the initially named
type is provided with a functional layer that has at least one
biodegradable material, especially a biodegradable polymer, and the
biodegradable material according to DIN EN 13432:2000 can
disintegrate upon aerobic composting of the degradable material
after a composting interval of more than 12 weeks and at most 80
weeks that has been prolonged compared to DIN EN 13432:2000, a
maximum 10% of the original dry weight of the biodegradable
material can be found in the screen fraction of the composted
material greater than 2 mm. Otherwise, the aforementioned objects
are achieved by a film combination with at least one film of the
aforementioned type, and optionally, at least one other film and/or
at least one carrier. Compostability in the sense of the invention
relates simply to the biodegradable component(s) in the film or in
the film combination.
[0016] The above described film and film combination can be
produced with low energy use, and after expiration of the expected
service life or after use can be easily and economically disposed
of For example, when using the film or film combination in
accordance with the invention in a roof or facade, in ageing tests,
it was shown that it does not decompose over the expected service
life of up to 20-30 years, and essentially, its functionality is
maintained even when the film or film combination comes into
contact with condensing water over a longer time. This can be
attributed to the fact that the materials that can be obtained from
renewable raw materials and that are used in the film or film
combination or the biodegradable materials used have a limited
water absorption capacity that is related otherwise to the absence
of decomposing microorganisms. The film in accordance with the
invention and the film combination moreover have variable water
vapor permeability and high elongation, its having been
surprisingly shown that functionalities, other than amidic or
ionic, can also be used if polymers are used as the material of the
functional layer.
[0017] The film in accordance with the invention comprises a
functional layer that, itself, can be a film or a correspondingly
coated carrier, for example, and optionally, a carrier layer or
reinforcing layer that is connected to the functional layer. The
film can be present as a flat product, especially web-like as
rolled goods, and can have a bendability or deformability that is
high enough for processing in the construction field.
[0018] The method of applying the functional later to a building
involves applying it either inside, outside or in a loop shape, or
alternatively, installing the functional layer as a vapor control
layer barrier in a sheeted roof, ceiling or facade region of a
building as at least one of an underform web and a counter ceiling
web.
[0019] One embodiment of a film in accordance with the invention is
explained in detail below with reference to the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a schematic cross-sectional view of the film in
accordance with the invention for construction and
[0021] FIG. 2 is a tabulation of s.sub.d values in [m] for
different applications of the film or the film combination in
accordance with the invention and for different types of
installations.
DETAILED DESCRIPTION OF THE INVENTION
[0022] FIG. 1 is a cross-sectional view of the film 1 in accordance
with the invention for construction that can be used, for example,
as a vapor control layer, underform web or counter ceiling web. The
film 1 has a functional layer 2 with a water vapor diffusion
resistance (s.sub.d value) that is dependent on the ambient
humidity and a carrier or reinforcing layer 3 that is connected to
the functional layer 2.
[0023] In order to ensure production of the film 1 with low energy
use and simple and economical disposal after the useful life has
expired, in the film shown in FIG. 1 it is provided that the
functional layer 2 has a material 4 that can be obtained from a
renewable raw material and is preferably biodegradable, and the
biodegradable polymer according to DIN 13432:2000 can disintegrate
with aerobic composting and a prolonged composting interval of more
than 12 weeks and at most 80 weeks. It goes without saying that the
material that can be obtained from a renewable raw material
according to DIN 13432:2000 with correspondingly prolonged test
duration can be biodegradable, as has been described above.
Otherwise, it goes without saying that the functional layer can
have at least one material that can be obtained from a renewable
raw material and in addition optionally another biodegradable
material.
[0024] The functional layer can have at least one polymer based on
a renewable raw material and/or at least one biodegradable polymer
or also a mixture of different polymers based on renewable raw
materials and/or different biodegradable polymers. Otherwise, the
functional layer can contain a mixture of biodegradable polymers
and/or polymers based on renewable raw materials with conventional
synthesized polymers. Preferably, the polymers indicated below can
be used:
TABLE-US-00001 Polymer Type Monomer or Base Manufacturer Trade Name
Polyesters Butylene Adipate BASF Ecoflex Terephthalate Butylene
Succinate Showa Bionolle Adipate Butylene Succinate Novamont Eastar
Bio Terephthalate Butylene Succinate IReChem EnPol Adipate
Polyhydroxy- Hydroxyalkanoate PHB Metabolix alkanoates (Metabolix)
Hydroxybutyrate- Nodax Hydroxyhexanoate Polylactides Aliphatic
Polyesters Narureworks Based on Lactic (Cargill) Acid Polyester
Urethanes Aliphatic Polyester Simadzu PEU- Urethane Enfresin
Polysaccharides Starch-Based BIOP Biopar (BioPolymer Technologies)
Polysaccharides Mixture of Corn BASF Ecovio Starch Base and
Ecoflex
[0025] Additives for polymers can be conventional ones, such as
pigments, dyes, fillers and reinforcing substances, reinforcing
fibers, stabilizers, lubricants or the like, preferably the
additives can be renewable raw materials and/or substances that are
biodegradable according to DIN EN 13432:2000 with a prolonged
composting interval of more than 12 weeks and at most 80 weeks.
[0026] Since the film in accordance with the invention and film
combination are preferably long-lived products for construction, a
test interval that has been prolonged compared to DIN EN 13432:2000
of more than 12 weeks can be easily tolerated. Preferably the
prolonged composting interval should be at most 60 weeks,
furthermore preferably at most 48 weeks, especially at most 18
weeks. In this connection, the water vapor permeability of the
functional layer and/or of the film or film combination after at
least 5 years in use in construction, preferably after at least 10
years, furthermore preferably after 20 years, should be roughly 30
to 70%, preferably roughly 50%, of the water vapor permeability or
the s.sub.d value in the new state of the film. Furthermore, the
tearing force of the functional layer and/or of the film or film
combination after at least 5 years of use in construction,
preferably after at least 10 years, especially after 20 years,
should be roughly 10 to 50 N/5 cm. This ensures that operation of
the film in accordance with the invention or film combination
should be essentially preserved over the entire service life or
useful life.
[0027] The proportion of the material that can be obtained from
renewable raw materials in the functional layer and/or the
proportion of biodegradable material in the functional layer can be
greater than 40% by weight, preferably greater than 60% by weight,
furthermore preferably greater than 80% by weight, and especially
greater than 95% by weight. The proportion of the material that can
be obtained from renewable raw materials in the film or in the film
combination and/or the proportion of biodegradable material in the
film or in the film combination in this connection can be greater
than 10% by weight, preferably greater than 30% by weight,
furthermore preferably greater than 60% by weight, and especially
greater than 95% by weight. In this way, production of the film in
accordance with the invention with low energy use and its simple
and economical disposal after the useful life has expired is
ensured.
[0028] In order to ensure adequate processability and function of
the film in accordance with the invention over the expected service
life, the minimum elongation of the functional layer and/or of the
film or film combination according to DIN EN 2311 should be greater
than 5% by weight, preferably greater than 20%, furthermore
preferably greater than 50%, and especially greater than 100%. The
maximum elongation of the functional layer and/or of the film or
the film combination according to DIN 12311 can be less than 1000%,
preferably less than 600%, furthermore preferably less than
200%.
[0029] In order to ensure that the film in accordance with the
invention or the film combination is not decomposed even upon
contact with condensed water over the expected service life and
essentially preserves its function, the water absorption of the
functional layer and/or of the film or the film combination
according to DIN 53714 at 50% relative humidity and saturation can
be between 0.45 to 40%, preferably between 1.0 to 30%, furthermore
preferably between 1.5 to 20%, especially between 2 to 8% or
between 10 to 40%.
[0030] The functional layer and/or the film or film combination can
have a thickness between 1 to 1000 microns, preferably between 2 to
500 microns, furthermore preferably between 5 to 100 microns. This
ensures sufficiently high water vapor permeability. The weight per
unit area of the functional layer and/or of the film or film
combination can be 1 to 1000 g/m.sup.2, preferably 2 to 500
g/m.sup.2, furthermore preferably 5 to 100 g/m.sup.2. In order to
ensure sufficiently high load capacity of the film the tearing
force of the functional layer and/or of the film or film
combination can have a value from 10 to 1500 N/5 cm, preferably 50
to 800 N/5 cm, furthermore preferably 80 to 500 N/5 cm.
[0031] In order to be able to use the film in accordance with the
invention or the film combination in construction, the functional
layer and/or the film or the film combination for a static water
column of at least 10 cm, preferably of at least 1 m, furthermore
preferably of at least 1.5 m, should be watertight.
[0032] As has already been pointed out, the functional layer itself
can be composed of different layers. Here the same or different
layers can be located next to one another and/or on top of one
another. For a multilayer structure, different functionalities can
be combined in the functional layer. Fundamentally it is of course
also possible for the functional layer to have a single-layer
structure.
[0033] The film in accordance with the invention has as a further
layer, preferably as a carrier layer for the functional layer, a
textile layer, a fabric layer, a nonwoven layer or an optionally
perforated further film. Here, the further layer is preferably
formed of at least one material that can be obtained from renewable
raw materials, especially from a polymer based on renewable raw
materials, and/or has at least one biodegradable material,
especially a biodegradable polymer, the biodegradable material
according to DIN EN 13432:2000 being able to disintegrate, and upon
aerobic composting of the degradable material after a composting
interval of more than 12 weeks and at most 80 weeks, preferably at
most 60 weeks, furthermore preferably of at most 48 weeks,
especially of at most 18 weeks, which interval has been prolonged
relative to DIN EN 13432:2000, a maximum 10% of the original dry
weight of the biodegradable material can be found in the screen
fraction of the composted material greater than 2 mm. This ensures
that the film or film combination in accordance with the invention
can be produced with low energy use and/or can be disposed of
easily and economically.
[0034] The water vapor permeability of the further layer can be
less than the water vapor permeability of the functional layer in
order not to influence the water vapor permeability of the film or
the film combination.
[0035] The film in accordance with the invention can be easily and
economically produced by cast film extrusion, blown film extrusion,
pouring and drying of emulsions or dispersions. Otherwise the film
can be obtained by cementing or bonding of at least one functional
layer with at least one further layer or by extrusion coating or
paste coating of at least one carrier layer with at least one
functional layer or by spraying at least one functional layer onto
at least one carrier layer. Films or film combinations with several
identical or different layers that can be located next to one
another and/or on top of one another can be produced.
[0036] The film or film combination in accordance with the
invention can be used as a vapor control layer with installation
over the rafters running inside or outside or with installation in
a loop shape over the rafters, the term "rafters" being defined as
all longitudinal construction elements in the roof and facade
region, preferably of wood materials. The film or film combination
can be made as a vapor control layer barrier, the film or film
combination acting as a vapor control layer in a humid climate and
as a vapor barrier in a dry climate. Otherwise, the film and film
combination can be made as a vapor control layer counter ceiling
web, i.e., diffusion-open counter ceiling web in a humid climate,
and a vapor control layer in a dry climate. Installation of the
film in accordance with the invention and the film combination in
accordance with the invention made as a counter ceiling web is
possible over the rafters outside or inside or in a loop shape over
the rafters. In all cases installation in a sheeted roof region or
in the facade region is possible. Furthermore, the film or film
combination can also be used on concrete rooves, in wood post or
lattice-type constructions in the base region. Preferred values for
the water vapor permeability of the film in accordance with the
invention or of the film combination are listed in the Table shown
in FIG. 1.
Exemplary Embodiment 1
[0037] A cast film with a weight per unit area of 100 g/m.sup.2 is
extruded from a polyester with the trade name Ecoflex from BASF. At
a relative humidity of 60% at 23.degree. C., a s.sub.d value of 1.1
m is measured. In a dry region the s.sub.d value at a relative
humidity of 25% is 3.5 m. The film that has been obtained in this
way can be used as a variable vapor control layer with looped
installation around the rafters or as a vapor control layer over
the rafters inside.
Exemplary Embodiment 2
[0038] A nonwoven with a weight per unit area of 100 g/m.sup.2 of
needled hemp fibers is extrusion-coated with a film with a weight
per unit area of 80 g/m.sup.2 from a polyester with the trade name
Ecoflex from BASF. At a relative humidity of 70% at 23.degree. C. a
s.sub.d value of 0.8 m is measured. In a dry region the s.sub.d
value at a relative humidity of 30% is 2.5 m.
* * * * *