U.S. patent application number 14/538185 was filed with the patent office on 2015-03-05 for corrugated metallic foil tape.
The applicant listed for this patent is Shurtape Technologies, LLC. Invention is credited to Muzaffer Fidan.
Application Number | 20150064384 14/538185 |
Document ID | / |
Family ID | 42131790 |
Filed Date | 2015-03-05 |
United States Patent
Application |
20150064384 |
Kind Code |
A1 |
Fidan; Muzaffer |
March 5, 2015 |
CORRUGATED METALLIC FOIL TAPE
Abstract
A metallic foil tape having a top surface and a bottom surface
with an adhesive applied to at least one of the top surface or the
bottom surface of the metallic foil tape and corrugations in the
metallic foil tape providing for expansion of the corrugated
metallic foil tape in a circular or semi-circular shape. The
corrugated metallic foil tape is suitable to be applied to
contoured or three-dimensional surfaces, and is particularly
suitable for use in sealing or joining components of heat,
ventilation, and air conditioning (HVAC) units.
Inventors: |
Fidan; Muzaffer; (Hickory,
NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Shurtape Technologies, LLC |
Hickory |
NC |
US |
|
|
Family ID: |
42131790 |
Appl. No.: |
14/538185 |
Filed: |
November 11, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13406575 |
Feb 28, 2012 |
8894790 |
|
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14538185 |
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|
12290842 |
Nov 4, 2008 |
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13406575 |
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Current U.S.
Class: |
428/41.1 ;
156/206 |
Current CPC
Class: |
B32B 2355/00 20130101;
Y10T 156/1002 20150115; B32B 2333/04 20130101; B32B 2375/00
20130101; Y10T 156/10 20150115; Y10T 428/24694 20150115; B32B 3/28
20130101; B32B 38/0012 20130101; B32B 2319/00 20130101; B32B
2311/24 20130101; B32B 2317/22 20130101; B32B 37/14 20130101; B32B
37/12 20130101; Y10T 156/1028 20150115; C09J 2475/00 20130101; Y10T
156/1016 20150115; B32B 2386/00 20130101; C09J 2421/00 20130101;
Y10T 428/1443 20150115; B32B 37/20 20130101; C09J 7/28 20180101;
C09J 2431/00 20130101; Y10T 156/1018 20150115; C09J 2433/00
20130101; Y10T 428/24537 20150115; C09J 2483/00 20130101; B32B
2405/00 20130101 |
Class at
Publication: |
428/41.1 ;
156/206 |
International
Class: |
C09J 7/02 20060101
C09J007/02; B32B 37/20 20060101 B32B037/20; B32B 38/00 20060101
B32B038/00; B32B 37/12 20060101 B32B037/12 |
Claims
1. A corrugated metallic foil tape prepared by a process
comprising: obtaining a flat metallic aluminum foil tape having a
top surface and a bottom surface, obtaining a release liner having
a pressure sensitive adhesive applied directly thereon, applying
the release liner to the flat metallic aluminum foil tape wherein
the pressure sensitive adhesive is between the flat metallic
aluminum foil tape and the release liner, feeding the flat metallic
aluminum foil tape with the release liner to a corrugator, and
corrugating the flat metallic aluminum foil tape with the release
liner to form corrugations in the flat metallic aluminum foil tape
and the release liner.
2. The tape according to claim 1, wherein the corrugations in the
corrugated metallic foil tape provide for expansion of the
corrugated metallic foil tape in a circular or semi-circular
shape.
3. The tape according to claim 1, wherein the pressure sensitive
adhesive is selected from the group consisting of acrylic,
synthetic rubber, natural rubber, polyurethane, styrene-butadiene
rubber (SBR), synthetic isoprene rubber, ethylene vinyl acetate
copolymers, and silicone.
4. The tape according to claim 1, wherein the corrugations are
parallel to one another.
5. A corrugated metallic foil tape having a top surface and a
bottom surface prepared by a process comprising: obtaining a flat
metallic foil tape, obtaining a release liner having a pressure
sensitive adhesive applied directly thereon, applying the release
liner to the flat metallic foil tape wherein the pressure sensitive
adhesive is between the flat metallic foil tape and the release
liner, feeding the flat metallic foil tape with the release liner
to a corrugator, and corrugating the flat metallic foil tape with
the release liner to form corrugations in the flat metallic foil
tape and the release liner, wherein the corrugations are parallel
to one another.
6. The tape according to claim 5, wherein the corrugations in the
corrugated metallic foil tape provide for expansion of the
corrugated metallic foil tape in a circular or semi-circular
shape.
7. The tape according to claim 5, wherein the pressure sensitive
adhesive is selected from the group consisting of acrylic,
synthetic rubber, natural rubber, polyurethane, styrene-butadiene
rubber (SBR), synthetic isoprene rubber, ethylene vinyl acetate
copolymers, and silicone.
8. The tape according to claim 5, wherein the flat metallic foil
tape is an aluminum foil tape.
9. A corrugated metallic foil tape prepared by the process
comprising: obtaining a flat metallic aluminum foil tape having a
top surface and a bottom surface, applying a pressure sensitive
adhesive to at least one of the top surface or the bottom surface
of the flat metallic aluminum foil tape using a release liner
having the pressure sensitive adhesive applied directly thereon,
and corrugating the flat metallic aluminum foil tape with the
release liner to form corrugations in the flat metallic aluminum
foil tape and the release liner.
10. The tape according to claim 9, wherein the corrugations in the
corrugated metallic foil tape provide for expansion of the
corrugated metallic foil tape in a circular or semicircular
shape.
11. The tape according to claim 9, wherein the pressure sensitive
adhesive is selected from the group consisting of acrylic,
synthetic rubber, natural rubber, polyurethane, styrene-butadiene
rubber (SBR), synthetic isoprene rubber, ethylene vinyl acetate
copolymers, and silicone.
12. The tape according to claim 9, wherein the corrugations are
parallel to one another.
13. The tape according to claim 9, wherein the release liner is
applied to the flat metallic aluminum foil tape by lamination prior
to corrugation.
14. A corrugated metallic foil tape prepared by the process
comprising: obtaining a flat metallic aluminum foil tape having a
top surface and a bottom surface, laminating a release liner having
a pressure sensitive adhesive applied directly thereon to at least
one of the top surface or the bottom surface of the flat metallic
aluminum foil tape, and corrugating the flat metallic aluminum foil
tape with the release liner to form corrugations in the flat
metallic aluminum foil tape with the release liner.
15. The tape according to claim 14, wherein the corrugations in the
corrugated metallic foil tape provide for expansion of the
corrugated metallic foil tape in a circular or semicircular
shape.
16. The tape according to claim 14, wherein the pressure sensitive
adhesive is selected from the group consisting of acrylic,
synthetic rubber, natural rubber, polyurethane, styrene-butadiene
rubber (SBR), synthetic isoprene rubber, ethylene vinyl acetate
copolymers, and silicone.
17. The tape according to claim 14, wherein the corrugations are
parallel to one another.
18. A corrugated metallic foil tape prepared by a process
comprising: obtaining a flat metallic foil tape having a top
surface and a bottom surface, applying a pressure sensitive
adhesive to at least one of the top surface or the bottom surface
of the flat metallic foil tape using a release liner having the
pressure sensitive adhesive applied directly thereon, and
corrugating the flat metallic foil tape with the release liner to
form corrugations in the flat metallic aluminum foil tape and the
release liner.
19. A corrugated metallic foil tape prepared by the process
comprising: obtaining a flat metallic foil tape having a top
surface and a bottom surface, laminating a release liner having a
pressure sensitive adhesive applied directly thereon to at least
one of the top surface or the bottom surface of the flat metallic
foil tape, and corrugating the flat metallic foil tape with the
release liner to form corrugations in the flat metallic foil tape
and the release liner.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 13/406,575, filed on Feb. 28, 2012. U.S.
patent application Ser. No. 13/406,575 is a divisional of and
claims priority from U.S. patent application Ser. No. 12/290,842,
filed on Nov. 4, 2008. The disclosures of which are incorporated
herein by reference in their entireties.
FIELD OF THE INVENTION
[0002] The present invention relates to a corrugated metallic foil
tape, more particularly to a corrugated metallic foil tape for use
in heating, ventilation, and air conditioning units, or related
applications.
BACKGROUND OF THE INVENTION
[0003] It is of growing global concern not only to conserve energy
but also to mitigate loss of energy. One such example is with loss
of energy in residential or commercial buildings.
[0004] There are many known approaches in use today to attempt to
address this problem of mitigating energy loss. It is known to use
sealants, duct mastic and caulking for sealing around the joints of
a heating, ventilation and air conditioner (HVAC) unit. Common
sealants include butyl, polyurethane and acrylic sealants. In the
case of a sealant, the sealant is typically applied by painting the
joint or crack around the heating, ventilation, and air
conditioning unit, particularly around joints or seams at the
plenum, trunk registers or other duct branches. The sealant is
subsequently cured after being applied. Among the disadvantages
with such sealants and mastics, for example, are that they are
often cumbersome and messy to apply and, once applied, are
typically not readily removable or adjustable.
[0005] There are also known disadvantages associated with duct
tape. It is often advised not to use duct tape in HVAC
applications. According to the International Energy Conservation
Code published by the International Code Council in IECC 2003
803.2.8 for Duct and Plenum Insulation and Sealing: "All joints,
longitudinal and transverse seams, and connections in ductwork,
shall be securely fastened and sealed with welds, gaskets, mastics
(adhesives), mastic-plus-embedded fabric systems, or tapes. Tapes
and mastics used to seal ductwork shall be listed and labeled in
accordance with UL 181A or UL 181B. Duct connections to flanges of
air distribution equipment shall be sealed and mechanically
fastened . . . duct tape is not permitted as a sealant on any metal
ducts." For example, over time conventional duct tape cracks and
results in leaks in the system. This creates problems as the joints
or seams in a HVAC unit are often inaccessible after
installation.
[0006] There are also known disadvantages associated with flat HVAC
rated aluminum tapes. Such flat aluminum tapes when applied around
a circular vent or air duct, for example, leave gaps through which
energy can escape. These tapes are often time consuming to apply to
minimize gaps around contoured surfaces. Furthermore, they are not
easily pliable around such surfaces and readily tear.
[0007] Since most duct leakage occurs at the connection to
registers, plenums or branches in the duct system, at each of these
connections a method of sealing the duct system is required. Field
examination of duct systems have typically shown that these seals
tend to fail over extended periods of time. ASTM Test Method E
2342-03, which is the standard test method for "Durability Testing
of Duct Sealants," evaluates the durability of duct sealants by
blowing heated air into test sections, combined with a pressure
difference between the test sections and their surroundings. In the
Method E 2342-03, the temperatures and pressures were chosen to
expose the test sections to typical conditions that are found in
residential duct systems. The duct leakage site geometry represents
a leakage site commonly found in duct systems. Therefore, there is
a need for a more efficient and reliable method to seal joints, and
hence mitigate energy loss, in a HVAC unit, particularly in the
plenum, trunk registers or other duct branches of a HVAC unit.
SUMMARY OF THE INVENTION
[0008] The present invention relates to a metallic foil tape having
a top surface and a bottom surface with an adhesive applied to at
least one of the top surface or the bottom surface of the metallic
foil tape and corrugations in the metallic foil tape providing for
expansion of the corrugated metallic foil tape in a circular or
semi-circular shape. The corrugated metallic foil tape is suitable
to be applied to contoured or three-dimensional surfaces, and is
particularly suitable for use in sealing or joining components of
heat, ventilation, and air conditioning (HVAC) units.
[0009] The present invention also relates to a method of making the
corrugated metallic foil tape and a method of using the same.
[0010] The corrugated metallic foil tape of the present invention
solves the problems associated with energy loss in HVAC units and
provides an efficient, clean, and resilient alternative to known
tapes and sealants used in such applications.
[0011] Further areas of applicability of the present invention will
become apparent from the detailed description provided hereinafter.
It should be understood that the detailed description and specific
examples, while indicating the preferred embodiment of the
invention, are intended for purposes of illustration only and are
not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The present invention will become more fully understood from
the detailed description and the accompanying drawings,
wherein:
[0013] FIG. 1 is an illustrative drawing of a corrugated metallic
foil adhesive tape in accordance with the present invention.
[0014] FIG. 2A illustrates corrugations in a corrugated metallic
foil adhesive tape in accordance with the present invention.
[0015] FIG. 2B illustrates the profile of the corrugated metallic
foil adhesive tape of FIG. 2A.
[0016] FIG. 3 illustrates corrugations at other than a ninety
degree angle in a corrugated metallic foil adhesive tape in
accordance with the present invention.
[0017] FIG. 4A is an illustrative drawing of another corrugated
metallic foil adhesive tape in accordance with the present
invention.
[0018] FIG. 4B illustrates the profile of the corrugated metallic
foil adhesive tape of FIG. 4A.
[0019] FIG. 5 is an illustration of a single continuous piece of
corrugated metallic foil tape in accordance with the present
invention applied in a circular or semi-circular shape to the vent
of an air duct.
[0020] FIG. 6 is a photograph of a corrugated metallic foil tape in
accordance with the present invention configured in a form of a
semi-circle.
[0021] FIG. 7 is a photograph of a conventional foil tape
configured in a form of an arc of a circle.
[0022] FIG. 8 is a photograph of a single continuous piece of
corrugated metallic foil tape in accordance with the present
invention applied in a circular or semi-circular shape to the vent
of an air duct.
[0023] FIG. 9 is a photograph of pieces of conventional foil tape
applied in a circular or semi-circular shape around the vent of an
air duct.
DETAILED DESCRIPTION OF THE INVENTION
[0024] The following detailed description of the embodiment(s) is
merely exemplary in nature and is in no way intended to limit the
invention, its application, or uses.
[0025] The tape of the present invention is a corrugated metallic
tape for sealing joint or seams in a heating, ventilation and air
conditioner (HVAC) unit. The joint or seam is typically associated
with the plenum, trunk register or other duct branches in the HVAC
unit. The tape of the present invention is particularly suited for
sealing the HVAC collar to the plenum or to other parts of the HVAC
unit where there are contoured, angled, or three-dimensional
surfaces to which the tape needs to be applied. A plenum typically
refers to a sealed chamber at the inlet or outlet of an air unit to
which ductwork is attached.
[0026] The metallic foil tape of the present invention is
corrugated to have corrugations. The terms "corrugated" and
"corrugations," as used herein, refer to regular indentations or
markings including, but not limited to, folds, grooves, ridges, or
furrows. Referring now to the figures, FIG. 1 illustrates a
corrugated metallic foil tape 100 in accordance with the present
invention. As illustrated in FIG. 2A, it is preferred that the
corrugations are parallel to one another. FIG. 2B illustrates the
profile of the corrugated metallic tape of FIG. 2A. The
corrugations may be at a 90 degree angle as measured from the
lengthwise edge(s) 20 of the corrugated metallic foil tape 200 as
shown in FIG. 2A. Alternatively, the corrugations may be at an
angle other than a 90 degree angle as measured from the lengthwise
edge(s) 30 of the corrugated metallic foil tape 300 as shown in
FIG. 3. FIG. 2A also illustrates the widthwise edge(s) 22 of the
corrugated metallic foil tape 200 and FIG. 3 also illustrates the
widthwise edge(s) 32 of the corrugated metallic foil tape 300.
[0027] As illustrated in FIGS. 2B and 4B, the corrugations in the
tape may be of different shapes, sizes, and pitches. An advantage
of the corrugated metallic foil tape of the present invention is
that due to being corrugated, the tape is easier to stretch and
conform without tearing, hence making the tape more durable, which
is an improvement over the conventional flat metallic tapes that
are being used in the industry. Commercially available flat
metallic foil tapes may be obtained and subsequently corrugated in
accordance with the method of the present invention. Examples of
flat metallic foil tapes that are suitable for use in accordance
with the present invention include, but are not limited to, Ideal
IS 2000, Ideal 587A, Ideal 490, Nashua 324, Polyken 339, Fasson
0810, Fasson 0800, Venture 1581A,
[0028] Compac 340, 3M-Scotch 3326, Shurtape AF 100, Venture 1581A,
Ideal Seal 2000, Ideal Seal-587A/B, Fasson 0810, Covalence, Nashua
324A.
[0029] The metallic foil tape typically has a thickness in the
range of from about 1/2 mil to about 5 mil, preferably about 2 mil
in thickness. An example of a metallic foil tape suitable for use
in the present invention is an aluminum foil tape.
[0030] Prior to being corrugated, a flat metallic foil tape may be
directly coated with an adhesive then laminated to a release liner
or indirectly coated with an adhesive by laminating the foil to a
release liner with adhesive on it. The adhesive is generally
applied to the flat metallic foil tape before corrugation. As
discussed above herein, the corrugated metallic foil tape comprises
a top surface and a bottom surface. Either the top surface or the
bottom surface of the corrugated metallic foil tape comprises an
adhesive coating.
[0031] Preferably, the adhesive is a high shear adhesive or an
adhesive having holding power. For example, an adhesive that has
good holding power would have the ability to withstand greater
shear stress (i.e. forces applied parallel or tangential to a face
of a material). ASTM D 3654 is a standard test method for Holding
Power of Pressure Sensitive Tapes. A high shear adhesive is
preferred over a low shear adhesive in HVAC unit applications
because a high shear adhesive works at low temperature and high
temperature conditions. Typically, a tape with a low shear adhesive
has a tendency to tear or split under such conditions.
[0032] Preferably, the high shear adhesive is a pressure sensitive
adhesive (PSA). The term "pressure sensitive adhesive," as used
herein refers to, a material which in dry form is generally
aggressively and permanently tacky at room temperature and firmly
adheres to a variety of dissimilar surfaces upon mere contact
without the need of more than typically finger or hand pressure. A
pressure sensitive adhesive typically does not require activation
by solvents or heat and adheres firmly to a wide variety of
surfaces.
[0033] The pressure sensitive adhesive may be solvent based, water
based, or in 100% solid form. Suitable types of pressure sensitive
adhesives include, but are not limited to, acrylic, butyl rubber,
natural rubber, polyurethane, styrene-butadiene rubber (SBR),
synthetic isoprene rubber, ethylene vinyl acetate copolymers, and
silicones.
[0034] The adhesive is applied to form a coating having a thickness
of about 0.1 mil to about 5 mil, preferably about 1.5 to 2.5 mils.
The adhesive coating is applied by any means known to one of
ordinary skill in the art including, but not limited to, reverse
roll, knife over roll, and extrusion coating onto a release liner
which can be based on paper, clay, coated paper, glassine, film or
any other material known in the art, then laminated to foil.
[0035] Referring to the figures, FIG. 2B and 4B illustrate a
corrugated metallic foil tape in accordance with the present
invention having different cross-sectional views. FIG. 2B, for
example, illustrates that the corrugated metallic foil tape has a
top surface 24 and a bottom surface 26. As shown in FIG. 2A, the
corrugated metallic foil tape 200 also has opposing edges both
lengthwise 20 and widthwise 22. Each of these figures illustrate
the corrugations in the tape may be of different shapes, sizes, and
pitches.
[0036] The present invention also provides a method of making a
corrugated metallic foil tape. The method comprises obtaining a
flat metallic foil tape, and corrugating the flat metallic foil
tape. The metallic tape is corrugated either manually or
automatically to make regular indentations or markings in the tape.
For example, one such method of corrugating the tape is a press
with roller bars through which the uncorrugated tape is run,
wherein the roller bars have demarcations or raised portions on the
surfaces of the roller bars such that when the tape is fed between
the roller bars, corrugations are made in the metallic tape. Manual
or automated means can be used to run the tape through the rollers.
Alternatively, presses or other mechanical devices or equipment may
be used to apply pressure to the tape as it is corrugated.
[0037] As discussed previously herein, there has been a growing
need to solve the problems associated with energy loss,
particularly in HVAC units. Among the numerous advantages
associated with the corrugated metallic foil tape of the present
invention is that it is able to conform to and against curved and
three-dimensional surfaces without tearing and without destroying
the integrity of the tape. FIG. 5 illustrates the corrugated
metallic foil tape 500 of the present invention applied in a
circular or semi-circular shape to an HVAC unit. The corrugated
metallic foil tape of the present invention offers improved
performance over conventional foil tapes as shown below in the
examples where, particularly in these HVAC applications, a more
durable, easily removable, and more efficient alternative is
desired.
[0038] In the present invention, the tape is particularly suitable
to be applied in a circular shape or into semi-circular segments or
shapes. By having been corrugated, the metallic foil tape is easier
to stretch and conform to a contoured, angled, or three-dimensional
surface. By being corrugated, the metallic foil tape can be
extended outward to form a smaller inside diameter and a larger
outside diameter. There can be different angles and different
shapes to the corrugations. The pitch can also be adjusted.
[0039] For example, as shown in FIG. 5, the corrugated metallic
foil tape 500 of the present invention mates with the exterior
dimensions of the collar flange of the plenum. The corrugated
metallic foil tape 500 expands and stretches such that it conforms
and is flush to the contoured, angled, or three-dimensional surface
of the HVAC unit.
EXAMPLE--METAL TAPES
[0040] FIG. 6 is a photograph of a corrugated metallic foil tape in
accordance with the present invention configured in a form of a
semi-circular segment or shape.
[0041] For comparative purposes, FIG. 7 is a photograph of a
conventional foil tape configured in a form of an arc of a circle.
It can be seen from FIG. 7 that the foil tape tears when trying to
conform it in the shape of a circle.
[0042] FIG. 8 is a photograph of a single continuous piece of
corrugated metallic foil tape in accordance with the present
invention applied around the circular vent of an air duct. The
corrugated foil tape shown in FIG. 8 was applied in one continuous
piece and had an installation time of two minutes and nine
seconds.
[0043] For comparative purposes, FIG. 9 is a photograph of pieces
of conventional foil tape applied around the circular vent of an
air duct. The installation time for the standard foil tape shown in
FIG. 9 required five pieces of tape, Shurtape AF 100, and had an
installation time of three minutes and 54 seconds.
[0044] EXAMPLE--DUCT TAPE
[0045] An experiment was conducted for the following tapes in
accordance with ASTM E2342 and the results of the experiment are
set forth in Table 1.
TABLE-US-00001 TABLE 1 Tape (Tested to the Time to Failure
requirements of in Days (Minimum 60 ASTM E2342) days required by
the test) Duct Tape [Covalence Nashua 557, 1-13 Covalence Nashua
558 CA, Shurtape PC 857, and Shurtape PC 858 CA] Duct tape backing
with acrylic adhesive 1-35 Corrugated foil tape with acrylic
adhesive 69+ in accordance with the present invention (using
Shurtape AF 100 aluminum foil tape prior to corrugation)
[0046] It will therefore be readily understood by those persons
skilled in the art that the present invention is suitable for broad
utility and application. Many embodiments and adaptations of the
present invention other than those herein described, as well as
many variations, modifications and equivalent arrangements, will be
apparent from or reasonably suggested by the present invention and
the foregoing description thereof, without departing from the
substance or scope of the present invention. Accordingly, while the
present invention has been described herein in detail in relation
to its preferred embodiment, it is to be understood that this
disclosure is only illustrative and exemplary of the present
invention and is made merely for purposes of providing a full and
enabling disclosure of the invention. The foregoing disclosure is
not intended or to be construed to limit the present invention or
otherwise to exclude any such other embodiments, adaptations,
variations, modifications and equivalent arrangements.
* * * * *