US20060059852A1 - Laminated building materials - Google Patents
Laminated building materials Download PDFInfo
- Publication number
- US20060059852A1 US20060059852A1 US10/947,186 US94718604A US2006059852A1 US 20060059852 A1 US20060059852 A1 US 20060059852A1 US 94718604 A US94718604 A US 94718604A US 2006059852 A1 US2006059852 A1 US 2006059852A1
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- US
- United States
- Prior art keywords
- film
- laminated article
- board
- building
- polyamide
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 239000004566 building material Substances 0.000 title claims abstract description 62
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 39
- 238000009413 insulation Methods 0.000 claims abstract description 34
- 238000004519 manufacturing process Methods 0.000 claims abstract description 30
- 238000000034 method Methods 0.000 claims description 92
- 239000000853 adhesive Substances 0.000 claims description 68
- 230000001070 adhesive effect Effects 0.000 claims description 68
- 239000000835 fiber Substances 0.000 claims description 40
- -1 polyethylene Polymers 0.000 claims description 26
- 239000000463 material Substances 0.000 claims description 13
- 229920002292 Nylon 6 Polymers 0.000 claims description 12
- 239000004698 Polyethylene Substances 0.000 claims description 12
- 229920000573 polyethylene Polymers 0.000 claims description 12
- 239000004952 Polyamide Substances 0.000 claims description 11
- 229920002647 polyamide Polymers 0.000 claims description 11
- 239000004743 Polypropylene Substances 0.000 claims description 10
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 10
- 229920001155 polypropylene Polymers 0.000 claims description 10
- 239000012528 membrane Substances 0.000 claims description 9
- 229920000098 polyolefin Polymers 0.000 claims description 9
- 229910052602 gypsum Inorganic materials 0.000 claims description 6
- 239000010440 gypsum Substances 0.000 claims description 6
- 239000000203 mixture Substances 0.000 claims description 6
- 239000000123 paper Substances 0.000 claims description 6
- 239000002245 particle Substances 0.000 claims description 6
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 claims description 5
- 229920003188 Nylon 3 Polymers 0.000 claims description 5
- 229920001007 Nylon 4 Polymers 0.000 claims description 5
- 239000011575 calcium Substances 0.000 claims description 5
- 229910052791 calcium Inorganic materials 0.000 claims description 5
- 239000001913 cellulose Substances 0.000 claims description 5
- 229920002678 cellulose Polymers 0.000 claims description 5
- 239000004568 cement Substances 0.000 claims description 5
- 239000011093 chipboard Substances 0.000 claims description 5
- 239000004744 fabric Substances 0.000 claims description 5
- 239000011094 fiberboard Substances 0.000 claims description 5
- 239000006260 foam Substances 0.000 claims description 5
- 239000004745 nonwoven fabric Substances 0.000 claims description 5
- 239000011120 plywood Substances 0.000 claims description 5
- 239000000377 silicon dioxide Substances 0.000 claims description 5
- 229920002994 synthetic fiber Polymers 0.000 claims description 5
- 239000012209 synthetic fiber Substances 0.000 claims description 5
- 239000002023 wood Substances 0.000 claims description 5
- 210000002268 wool Anatomy 0.000 claims description 5
- 239000002759 woven fabric Substances 0.000 claims description 5
- 230000001419 dependent effect Effects 0.000 abstract description 3
- 229920001169 thermoplastic Polymers 0.000 description 16
- 239000004416 thermosoftening plastic Substances 0.000 description 16
- 230000005540 biological transmission Effects 0.000 description 10
- 239000004831 Hot glue Substances 0.000 description 7
- 238000009792 diffusion process Methods 0.000 description 7
- 239000011152 fibreglass Substances 0.000 description 7
- 239000007921 spray Substances 0.000 description 7
- 238000012360 testing method Methods 0.000 description 7
- 230000003044 adaptive effect Effects 0.000 description 5
- 238000010438 heat treatment Methods 0.000 description 4
- 239000012943 hotmelt Substances 0.000 description 4
- 229920006284 nylon film Polymers 0.000 description 4
- 238000007655 standard test method Methods 0.000 description 4
- 230000003068 static effect Effects 0.000 description 4
- 230000008901 benefit Effects 0.000 description 3
- 238000010276 construction Methods 0.000 description 3
- 238000005520 cutting process Methods 0.000 description 3
- 238000002844 melting Methods 0.000 description 3
- 239000002557 mineral fiber Substances 0.000 description 3
- 230000015572 biosynthetic process Effects 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 238000001125 extrusion Methods 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 230000003472 neutralizing effect Effects 0.000 description 2
- 239000000779 smoke Substances 0.000 description 2
- 238000011282 treatment Methods 0.000 description 2
- 239000004677 Nylon Substances 0.000 description 1
- 239000004820 Pressure-sensitive adhesive Substances 0.000 description 1
- 229920006362 Teflon® Polymers 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 230000005611 electricity Effects 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 239000002655 kraft paper Substances 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 238000003475 lamination Methods 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 239000002985 plastic film Substances 0.000 description 1
- 229920006255 plastic film Polymers 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 229920006254 polymer film Polymers 0.000 description 1
- 238000005057 refrigeration Methods 0.000 description 1
- 238000009418 renovation Methods 0.000 description 1
- 210000004894 snout Anatomy 0.000 description 1
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- 238000003860 storage Methods 0.000 description 1
Images
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
- B29C63/02—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B38/00—Ancillary operations in connection with laminating processes
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
- E04B1/7654—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only comprising an insulating layer, disposed between two longitudinal supporting elements, e.g. to insulate ceilings
- E04B1/7658—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only comprising an insulating layer, disposed between two longitudinal supporting elements, e.g. to insulate ceilings comprising fiber insulation, e.g. as panels or loose filled fibres
- E04B1/7662—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only comprising an insulating layer, disposed between two longitudinal supporting elements, e.g. to insulate ceilings comprising fiber insulation, e.g. as panels or loose filled fibres comprising fiber blankets or batts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2250/00—Layers arrangement
- B32B2250/02—2 layers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2255/00—Coating on the layer surface
- B32B2255/10—Coating on the layer surface on synthetic resin layer or on natural or synthetic rubber layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2255/00—Coating on the layer surface
- B32B2255/26—Polymeric coating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/724—Permeability to gases, adsorption
- B32B2307/7242—Non-permeable
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2419/00—Buildings or parts thereof
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/625—Sheets or foils allowing passage of water vapor but impervious to liquid water; house wraps
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B2001/741—Insulation elements with markings, e.g. identification or cutting template
Definitions
- the present invention relates to a laminated article which includes a building material adhered with an adhesive to a water vapor retarder film having a permeance dependent on the ambient humidity adhered to the building material and a method of manufacturing the same.
- the facing materials used are kraft paper and other polymeric materials to provide both support for the underlying fibers and to provide a water and/or water vapor retarder.
- a vapor retarder such as polyamide films
- insulation or other building materials such as gypsum board, particle board, etc.
- This vapor retarder imparts a water vapor diffusion resistance, permeance and/or transmission which depend on the ambient humidity.
- the present invention relates to an improved method of manufacturing a laminated article, such as a laminated building material which can be performed at production speeds and which retains benefits of the permeance characteristics of the film component.
- the present invention provides a method of manufacturing a laminated article, comprising providing an adhesive to a film having permeance of up to about 1.73 perms as determined according to the dessicant method of ASTM E 96 Standard Test Methods for Water Vapor Transmission of Materials Method A and a permeance of not less than about 3.45 perms as determined by the water method of ASTM E 96 Method B, wherein the adhesive is provided in an amount of about 0.4 to about 1.0 g per lineal foot of the film based on a 15 inch application width; and contacting the film to at least one surface of a building material.
- the present invention also provides a laminated article comprising at least one film component having permeance of up to about 1.73 perms as determined according to the dessicant method of ASTM E 96 Method A and a permeance of not less than about 3.45 perms as determined by the water method of ASTM E 96 Method B; at least one building material component; and an adhesive which adheres the at least one film component and the at least one building material wherein the adhesive is present in an amount of about 0.4 to about 1.0 g per lineal foot of the film based on a 15 inch application width.
- the film provided to the building material retains at least 50% of its water vapor diffusion, permeance and/or transmission characteristics defined by permeance of up to about 1.73 perms as determined according to the dessicant method of ASTM E 96 Method A and a permeance of not less than about 3.45 perms as determined by the water method of ASTM E 96 Method B.
- the present invention also provides a vapor retarder to a structure by installing the laminated article.
- the present invention also provides a method of constructing and/or renovating a structure using the laminated article and building structures, such as a roof, wall, and/or floor with the laminated article.
- FIG. 1 is a diagrammatic elevation view showing one embodiment of the method and apparatus for manufacturing a laminated article according to the present invention.
- (B) is a diagrammatic view showing one embodiment of the pattern of adhesive application to the water vapor retarder film.
- FIG. 2 (A) is a diagrammatic elevation view showing another embodiment of the method and apparatus, including optional components, for manufacturing an laminated article according to the present invention.
- (B) is a diagrammatic view showing another embodiment of the vapor retarder film during the manufacturing process according to the invention.
- FIG. 3 is a diagrammatic elevation view showing another embodiment of the method and apparatus for manufacturing a laminated article according to the present invention.
- FIG. 4 is a diagrammatic elevation view showing another embodiment of the method and apparatus for manufacturing a laminated article according to the present invention.
- FIG. 5 is a diagrammatic elevation view showing another embodiment of the method and apparatus for manufacturing a laminated article according to the present invention.
- a building material 20 is fed through the process by a conveyer 27 in a predetermined linear path 10 .
- the water vapor retarder film is provided on a roll 21 and also fed into the adhesion process via rollers 23 .
- the thermoplastic, hot melt polymer adhesive is applied by a sprayer 22 and the film coated with adhesive is joined with the building material to form a laminated article 25 .
- the roller 24 can be a heated roller to provide additional adhesive strength.
- the roller provides heat in an amount sufficient to keep the adhesive soft, and increase the bonding strength between the film and the building material.
- the roller is heated to at least about 350° F. Variations in heating temperature can be adjusted depending on the adhesive used, the bonding strength required, and the vapor retarder film used.
- a building material 20 is fed through the process by a conveyor 26 in a predetermined linear path 10 .
- the water vapor retarder film is provided on a roll 21 and also fed into the adhesion process via rollers 23 .
- the building material and the laminated article can be moved along the production path via a series of optional conveyers 27 .
- the adhesive is applied by a sprayer 22 and the film coated with adhesive is joined with the building material to form a laminated article 25 .
- the spraying device e.g., nozzles, are in a horizontal line relative to the film.
- the roller 24 can be heated to provide additional adhesive strength.
- a bowed roller 47 can be included in the area of the process where the adhesive is applied to the film. In a preferred embodiment, the bowed roller is above the area where the adhesive is applied.
- At least one static neutralizing bar 41 and/or static neutralizing device 42 can be provided to reduce static on the vapor retarder film and/or the laminated article.
- a cutting device 44 such as a chopper can be included when the building material is an insulation roll or batt.
- a folding device 43 can also be included such as a batt folder when the building material is an insulation batt.
- the laminated article 25 is a folded laminated article.
- the film is provided with a printed pattern which can be provided on the roll 21 or be applied during the manufacturing process of the present invention via a printing device 40 such as an ink-jet print head.
- stapling tabs 52 may be provided via tab formation bars 46 .
- a building material 20 is fed through the process by converyers 26 in a predetermined linear path 10 .
- the vapor retarder film is provided on a roll 21 and fed into the adhesion process via tension rollers 23 .
- the building material and the laminated article can be moved along the production path via conveyers 26 and 27 .
- Spools of thermoplastic roving 70 can be provided and chopped in a roving chopper 73 .
- the chopped thermoplastic fibers 71 are attracted to the film by electrostatic attraction.
- the film with the thermoplastic fibers can be heated/preheated on a heated roller(s) 24 and/or the thermoplastic fibers are melted with an infrared heater 72 (such as that manufactured by Glenro Corporation) and contacted with the building material 20 to form a laminated article 25 .
- an infrared heater 72 such as that manufactured by Glenro Corporation
- the chopped fibers are melted or at least partially melted, the fibers upon cooling form a bond between the film and the building material.
- the chopped fibers are introduced into the process, i.e., attracted to the film, after the first roll 24 and preferably between the first roll 24 and heating element 72 .
- a building material 20 is fed through the process by conveyors 26 and 27 in a predetermined linear path 10 .
- the vapor retarder film is provided on a roll 21 and also fed into the adhesion process via tension rollers 23 .
- the building material and the laminated article can be moved along the production path via conveyors 26 and 27 (and conveyors).
- Spools of thermoplastic roving 70 can be provided and chopped in a roving chopper 73 .
- the chopped thermoplastic fibers 71 are attracted to the film by electrostatic attraction.
- the chopped fibers are introduced into the process, i.e., attracted to the film, after the last tensioning roll 23 and before the first heated roll 24 .
- the film is fed through the apparatus via rollers 23 and the film with the thermoplastic fibers are heated/preheated on a heated roller(s) 24 and /or the thermoplastic fibers are melted with an infrared heater 72 and contacted with the building material 20 to form a laminated article 25 .
- a bowed roller 47 can be included in the area of the process of heating element 72 . In a preferred embodiment, the bowed roller 47 is above the area where the adhesive is applied.
- a cutting device 44 such as a chopper when the building material is an insulation batt can be included.
- a folding device 43 can also be included such as a batt folder when the building material is an insulation batt.
- the film is provided with a printed pattern which can be provided on the roll 23 or be applied during the manufacturing process of the present invention via a printing device 40 such as an ink-jet print head.
- stapling tabs are formed in the vapor retarder film which can be approximately 11 ⁇ 4′′ wide folded away from the lamination surface and may be provided via tab formation bars 46 .
- FIG. 5 an alternative process for laminating the film component to the building material is depicted whereby the film is provided on a roll 21 and a roll 60 of a non-woven veil of thermoplastic fibers is also provided.
- the film and the non-woven veil are fed through the process via tension rollers 23 .
- they may be heated via roller(s) 24 and/or heated via heating element 52 (such as an infrared heater) to melt the thermoplastic veil which mediates adhesion to building material 20 thereby forming a laminated article 25 .
- heating element 52 such as an infrared heater
- the film component of the laminated article has a water vapor diffusion resistance, permeance, or transmission which is dependent on the ambient humidity and which has sufficient tensile and compressive strength for use in building and/or construction applications. Said another way, the film component is a “humidity adaptive film.”
- the humidity adaptive film as used herein means a film which has permeance of up to about 1.73 perms as determined according to the dessicant method of ASTM E 96 Method A, inclusive of up to 1.7, 1.6, 1.5, 1.3, 1.2, 1.1, 1.0, 0.5 and all values and ranges there between and a permeance of not less than about 3.45 perms, including not less than about 3.5, 3.7, 3.9, 4.0, 4.1 and all values and ranges there between as determined by the water method of ASTM E 96 Method B.
- the humidity adaptiveness of the film component may also be expressed as a water vapor diffusion resistance (s d -value) at a relative humidity of an atmosphere surrounding the vapor retarder in the region of 30% to 50% of 2 to 5 meters diffusion-equivalent air layer thickness, and, at a relative humidity in the region of 60% to 80% is ⁇ 1 meter diffusion-equivalent air layer thickness.
- the water vapor diffusion resistance of the film component can be determined in accordance with DIN 52615 in the dry range (3/50% relative humidity (RH)) and in the damp range (50/93% RH) as well as in damp ranges there between, for example 33/50% and 50/75% RH.
- any polymeric film can be used as the film component in the present invention, however, the film preferably meets the humidity adaptive criteria set forth above.
- the film is a polyamide film, and more preferably, the polyamide film is, for example, polyamide 6, polyamide 4 or polyamide 3.
- suitable films include nylon films such as nylon 6 or nylon 6.6 films. Combinations of polymeric materials or films are also possible.
- the thickness of the films will vary depending on the particular film chosen, however, the film can be from 10 ⁇ m to 2 mm, including 20 ⁇ m, 25 ⁇ m, 25.4 ⁇ m, 25.5 ⁇ m, 25.6 ⁇ m, 25.7 ⁇ m, 25.8 ⁇ m, 26 ⁇ m, 27 ⁇ m, 28 ⁇ m, 30 ⁇ m, 40 ⁇ m, 50 ⁇ m, 60 ⁇ m, 70 ⁇ m, 80 ⁇ m, 90 ⁇ m, 100 ⁇ m, 101.6 ⁇ m, 110 ⁇ m, 120 ⁇ m, 130 ⁇ m, 140 ⁇ m, 150 ⁇ m, 160 ⁇ m, 170 ⁇ m, 180 ⁇ m, 190 ⁇ m, 195 ⁇ m, 200 ⁇ m and all values and subranges there between, for example, 20 ⁇ m to 100 ⁇ m, 30 ⁇ m to 90 ⁇ m, 40 ⁇ m to 60 ⁇ m, 45.5 ⁇ m to 55.5 ⁇ m, etcetera.
- the film component can be provided with a surface structure and/or printed pattern, such as color or grayscale print.
- the printed pattern can be provided during the manufacture of the laminated article, such as via an ink jet or flexographic printing device.
- the film can be pre-printed before introduction into the manufacturing process of the present invention. Combinations of pre-printing and printing concurrent with the manufacturing process may also be utilized.
- the building material onto which the film component is adhered during the manufacture of the laminated article can be any commonly used building material used.
- the building material has a water vapor diffusion resistance which is less than the water vapor diffusion resistance of the film component.
- Non-limiting examples of suitable building materials that can be employed in the manufacturing process of the present invention include fiber reinforced cellulose materials, such as paper webs, membranes made from synthetic fiber spun fabrics or perforated polyethylene films, particle board, chip board, oriented strand board, plywood paneling, gypsum board (standard or fiber reinforced), fiber board, cement board, cementitious wood wool board, calcium silica board, fiber insulation batts or slabs, foam insulation slabs, wall paper, carpet and woven and non-woven fabrics.
- fiber reinforced cellulose materials such as paper webs, membranes made from synthetic fiber spun fabrics or perforated polyethylene films, particle board, chip board, oriented strand board, plywood paneling, gypsum board (standard or fiber reinforced), fiber board, cement board, cementitious wood wool board, calcium silica board, fiber insulation batts or slabs, foam insulation slabs, wall paper, carpet and woven and non-woven fabrics.
- the film is adhered to at least one surface of the building material.
- the film is adhered to at least one major or minor surface of the building material, preferably at least one major surface.
- major surface refers to the surface or surfaces of the material which have a larger surface area than a second surface and likewise a “minor surface” has a smaller surface area than another surface of the material.
- at least one surface of the building material is not adhered to the film component.
- the film can sandwich the building material component such that a film is adhered to two opposite sides, major or minor, of the building material. The film can also be sandwiched between two layers of building material.
- any polyolefin based adhesive may be used provided it adheres the film to the building material and permits the film to maintain at least a part of its water vapor transmission properties as described herein.
- the adhesive has a lower melting point than the film onto which the adhesive is applied to prevent the film from melting prior to its adhesion to the building material.
- a polypropylene-based or polyethylene-based adhesive may be used.
- Henkel adhesive #80-8273 Henkel Adhesives Elgin, Ill.
- the adhesive can be applied as a hot-melt which is sprayed onto the film, e.g., using elliptical and swirl spray devices.
- the adhesive can be provided as chopped thermoplastic fibers, which are subsequently heated to a point sufficient where the fibers are able to adhere the film to the building material.
- the adhesive can be provided as a non-woven thermoplastic veil which can also subsequently heated in a similar manner.
- the adhesive can be applied to the film so that the permeance properties of the film component are not occluded or prevented from functioning properly. While there may be some reduction of the permeance, it is preferred that the film retains at least about 50% of the water-vapor transmission properties relative to the film prior to the adhesive being provided and maintains a minimum of 3.45 perms when tested by the water method of ASTM E 96 Method B and a permeance of up to about 1.73 perms as determined according to the dessicant method of ASTM E 96 Method A. In alternative embodiments, the permeance of the film with adhesive retains at least about 60%, 70%, 80%, 90%, 95%, 97% and 99%, inclusive of all values and ranges there between.
- the adhesive can be provided in an amount of about 0.4 to about 1.0 g per lineal foot of the film based on a 15 inch application width. Further, the adhesive can be provided in an amount of about 0.5 to about 0.9 grams per lineal foot, inclusive of 0.6, 0.7, and 0.8 grams per lineal foot again based on a 15 inch application width.
- the adhesive when sprayed onto the film, can be provided substantially uniformly onto the film provided the above permeance and/or application criteria are maintained.
- the adhesive can be provided as shown in the embodiments in FIGS. 1B and 2B .
- the adhesive 30 is applied to the film at the edges in a swirl pattern where at the center of the film, the adhesive 30 is applied in an elliptical pattern.
- FIG. 2B shows the swirl pattern 30 is applied with a swirl gun 50 and the elliptical pattern is applied with an elliptical spray gun 51 .
- suitable spray guns include those hot melt spray guns sold by Nordson® Corporation.
- thermoplastics fibers include, for example, thermoplastics comprising polypropylene, polyethylene or their mixtures.
- the fibers may be virgin or recycled.
- the use of a small quantity of chopped fibers and the scattered distribution results in a light distribution onto the film thereby covering only a portion of the film which in turn permits the humidity adaptive aspect of the film component to function.
- the fibers would cover approximately less than 20% of the surface of the film, including less than 19, 18, 17, 16, 15, 14, 13, 12, 11, 10 and all values and subranges there between.
- the non-woven veil suitable for use in the present invention is a low-melting point veil composed of thermoplastic fibers.
- Suitable fibers include polypropylene, polyethylene and mixtures thereof.
- the fibers may be virgin or recycled.
- the laminated article can be cut into predetermined dimensions that would be preferable for storage, transport, sale, and end use (e.g., installation). If performed during the process, the cutting should preferably be after the film has adhered to the building material component. Further, it is also possible that certain building materials such as fiber insulation can be folded during or after the manufacturing process and would be preferably employed after the film has adhered to the building material component.
- the laminated article can also be treated to reduce the static electricity, for example, by incorporating anti-static devices and/or anti-static treatments which are commonly used in the art.
- a film with antistatic treatment that can be used is Honeywell Capran 200A.
- the laminated article comprises an insulation batt or slab adhered to the film
- the laminated article is packaged.
- insulation batts or slabs are packaged they are compressed.
- the laminated article is pushed through a snout, which is optionally coated with, for example, Teflon®, into a plastic bag.
- the present invention also provides a laminated article.
- the laminated article is composed of at least one film component as described herein and at least one building material component with an adhesive between the at least one film component and the at least one building material where the adhesive is present in an amount of about 0.4 to about 1.0 g per lineal foot of the film based on a 15 inch application width.
- the adhesive is present in an amount of about 0.5 to about 0.9 grams per lineal foot, inclusive of 0.6, 0.7, and 0.8 grams per lineal foot again based on a 15 inch application width.
- the laminated article is composed of at least one film component as described herein and at least one building material component with an adhesive between the at least one film component and the at least one building material where the adhesive is present in an amount such that at least 50% of the humidity adaptive properties relative to the film prior to the adhesive being provided and maintains a minimum of 3.45 perms when tested by the water method of ASTM E 96 Method B and a permeance of up to about 1.73 perms as determined according to the dessicant method of ASTM E 96 Method A.
- the permeance of the film with adhesive retains at least about 60%, 70%, 80%, 90%, 95%, 97% and 99%, inclusive of all values and ranges there between.
- the adhesive used for the laminated article of the present invention and the application thereof can also be chosen such that the adhesive is applied at the correct application which yields a laminated article having an ASTM E 84 maximum flame spread/smoke developed rating of 25/50 as determined by ASTM E 84 “Standard Test Method for Surface Burning Characteristics of Building Materials.”
- the laminated article described herein can be used to provide a vapor retarder to a building or portion of a building, e.g., a wall, roof or floor, or in any construction scenario where building materials, such as insulation are commonly employed.
- the laminated article can be used, in addition to buildings, in transportation or moving vehicles, such as automobiles, planes, and trains, and particularly those designed for refrigeration.
- appliances such as refrigerators and/or freezers may also benefit from the use of the laminated article of the present invention.
- building includes both commercial and residential buildings, such as office buildings, stores, houses and mobile homes.
- the laminated article of the present invention can be employed during the construction of a new building or renovation of an existing building.
- the laminated article would be provided to the appropriate location, e.g., between at least two studs of a wall or at least two rafters of a roof during the appropriate stage of the project.
- building components are commonly fabricated distant from the location of the actual location of the building (e.g., pre-fabricated building panels) and therefore, the laminated article can be employed during the manufacturing of those pre-fabricated building components and include, for example, a pre-fabricated wall, roof, or floor component.
- a roll of 2 mil nylon film is placed on an unwind stand in a pit underneath a fiberglass manufacturing line.
- Hot melt adhesive primarily composed of polypropylene is sprayed on the film at an application temperature of approximately 350° F.
- the film with the warm, tacky adhesive is then married to the bottom surface of a lane of mineral fiber insulation traveling above the nylon film on a conveyer line.
- the film with the adhesive is introduced to the mineral fiber insulation through a gap in the conveyer line.
- the film/mineral fiber laminate is further processed on the manufacturing line into batts or rolls and subsequently packaged.
- 0.002′′ thick nylon 6 films (blown extruded and cast extruded) that were laminated to fiber glass insulation with sprayed hot melt adhesive and then removed from the fiber glass were tested according to ASTM E 96 wet cup (water method) and dry cup (dessicant method) with different test chamber humidities at 23° C. to achieve average 25%, 35%, 45%, 75%, 85%, and 95% relative humidity exposures and compared to unlaminated 0.002′′ thick nylon 6 film (blown and cast) with no hot melt adhesive applied.
- the hot melt spray polypropylene adhesive was applied to the 2 mil nylon 6 film with a combination of elliptical and swirl spray guns. The film was laminated to fiber glass insulation and then removed from the fiber glass for water vapor transmission testing.
- the laminated articles were tested according to ASTM E 84 Standard Test Method for Surface Burning Characteristics of Materials resulting in a flame spread index of 15 and a smoke developed index of 5.
Abstract
Description
- 1. Field of the Invention
- The present invention relates to a laminated article which includes a building material adhered with an adhesive to a water vapor retarder film having a permeance dependent on the ambient humidity adhered to the building material and a method of manufacturing the same.
- 2. Description of the Background
- Building materials, such as fiber insulation batts and fiber insulation slabs attached to a facing material are known. For example, U.S. Pat. No. 5,545,279 describes the manufacture of an insulation where a fiber insulation pack and a polymer film are moved along a longitudinal path and adhered to each other with a pressure sensitive adhesive.
- In many instances of manufacture, the facing materials used are kraft paper and other polymeric materials to provide both support for the underlying fibers and to provide a water and/or water vapor retarder. For example, WO96/33321 describes the attachment of a vapor retarder, such as polyamide films, to insulation or other building materials such as gypsum board, particle board, etc. This vapor retarder imparts a water vapor diffusion resistance, permeance and/or transmission which depend on the ambient humidity.
- The present invention relates to an improved method of manufacturing a laminated article, such as a laminated building material which can be performed at production speeds and which retains benefits of the permeance characteristics of the film component.
- The present invention provides a method of manufacturing a laminated article, comprising providing an adhesive to a film having permeance of up to about 1.73 perms as determined according to the dessicant method of ASTM E 96 Standard Test Methods for Water Vapor Transmission of Materials Method A and a permeance of not less than about 3.45 perms as determined by the water method of ASTM E 96 Method B, wherein the adhesive is provided in an amount of about 0.4 to about 1.0 g per lineal foot of the film based on a 15 inch application width; and contacting the film to at least one surface of a building material.
- The present invention also provides a laminated article comprising at least one film component having permeance of up to about 1.73 perms as determined according to the dessicant method of ASTM E 96 Method A and a permeance of not less than about 3.45 perms as determined by the water method of ASTM E 96 Method B; at least one building material component; and an adhesive which adheres the at least one film component and the at least one building material wherein the adhesive is present in an amount of about 0.4 to about 1.0 g per lineal foot of the film based on a 15 inch application width.
- In another embodiment, the film provided to the building material retains at least 50% of its water vapor diffusion, permeance and/or transmission characteristics defined by permeance of up to about 1.73 perms as determined according to the dessicant method of ASTM E 96 Method A and a permeance of not less than about 3.45 perms as determined by the water method of ASTM E 96 Method B.
- The present invention also provides a vapor retarder to a structure by installing the laminated article.
- The present invention also provides a method of constructing and/or renovating a structure using the laminated article and building structures, such as a roof, wall, and/or floor with the laminated article.
- A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
-
FIG. 1 :(A) is a diagrammatic elevation view showing one embodiment of the method and apparatus for manufacturing a laminated article according to the present invention. (B) is a diagrammatic view showing one embodiment of the pattern of adhesive application to the water vapor retarder film. -
FIG. 2 :(A) is a diagrammatic elevation view showing another embodiment of the method and apparatus, including optional components, for manufacturing an laminated article according to the present invention. (B) is a diagrammatic view showing another embodiment of the vapor retarder film during the manufacturing process according to the invention. -
FIG. 3 is a diagrammatic elevation view showing another embodiment of the method and apparatus for manufacturing a laminated article according to the present invention. -
FIG. 4 is a diagrammatic elevation view showing another embodiment of the method and apparatus for manufacturing a laminated article according to the present invention. -
FIG. 5 is a diagrammatic elevation view showing another embodiment of the method and apparatus for manufacturing a laminated article according to the present invention. - Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views.
- Referring to
FIG. 1A , abuilding material 20 is fed through the process by aconveyer 27 in a predetermined linear path 10. The water vapor retarder film is provided on aroll 21 and also fed into the adhesion process viarollers 23. The thermoplastic, hot melt polymer adhesive is applied by asprayer 22 and the film coated with adhesive is joined with the building material to form a laminatedarticle 25. In one embodiment, theroller 24 can be a heated roller to provide additional adhesive strength. In one aspect, the roller provides heat in an amount sufficient to keep the adhesive soft, and increase the bonding strength between the film and the building material. For example, for polypropylene-based hot melt adhesives, the roller is heated to at least about 350° F. Variations in heating temperature can be adjusted depending on the adhesive used, the bonding strength required, and the vapor retarder film used. - Referring to
FIG. 2A , abuilding material 20 is fed through the process by aconveyor 26 in a predetermined linear path 10. The water vapor retarder film is provided on aroll 21 and also fed into the adhesion process viarollers 23. The building material and the laminated article can be moved along the production path via a series ofoptional conveyers 27. The adhesive is applied by asprayer 22 and the film coated with adhesive is joined with the building material to form a laminatedarticle 25. In one embodiment, the spraying device, e.g., nozzles, are in a horizontal line relative to the film. As above, theroller 24 can be heated to provide additional adhesive strength. In another embodiment depicted inFIG. 2A , a bowed roller 47 can be included in the area of the process where the adhesive is applied to the film. In a preferred embodiment, the bowed roller is above the area where the adhesive is applied. - In another embodiment, at least one static neutralizing
bar 41 and/or static neutralizing device 42 can be provided to reduce static on the vapor retarder film and/or the laminated article. - In another embodiment, a cutting device 44 such as a chopper can be included when the building material is an insulation roll or batt. In addition, a
folding device 43 can also be included such as a batt folder when the building material is an insulation batt. In one aspect of this embodiment, the laminatedarticle 25 is a folded laminated article. - In one aspect of the invention, the film is provided with a printed pattern which can be provided on the
roll 21 or be applied during the manufacturing process of the present invention via aprinting device 40 such as an ink-jet print head. - In another aspect of the invention, stapling tabs 52 (
FIG. 2B ) may be provided viatab formation bars 46. - Referring to
FIG. 3 , abuilding material 20 is fed through the process byconveryers 26 in a predetermined linear path 10. The vapor retarder film is provided on aroll 21 and fed into the adhesion process viatension rollers 23. The building material and the laminated article can be moved along the production path viaconveyers thermoplastic roving 70 can be provided and chopped in aroving chopper 73. The choppedthermoplastic fibers 71 are attracted to the film by electrostatic attraction. The film with the thermoplastic fibers can be heated/preheated on a heated roller(s) 24 and/or the thermoplastic fibers are melted with an infrared heater 72 (such as that manufactured by Glenro Corporation) and contacted with thebuilding material 20 to form a laminatedarticle 25. When the chopped fibers are melted or at least partially melted, the fibers upon cooling form a bond between the film and the building material. In an alternative embodiment, the chopped fibers are introduced into the process, i.e., attracted to the film, after thefirst roll 24 and preferably between thefirst roll 24 andheating element 72. - Referring to
FIG. 4 , abuilding material 20 is fed through the process byconveyors roll 21 and also fed into the adhesion process viatension rollers 23. The building material and the laminated article can be moved along the production path viaconveyors 26 and 27 (and conveyors). Spools of thermoplastic roving 70 can be provided and chopped in aroving chopper 73. The choppedthermoplastic fibers 71 are attracted to the film by electrostatic attraction. The chopped fibers are introduced into the process, i.e., attracted to the film, after thelast tensioning roll 23 and before the firstheated roll 24. The film is fed through the apparatus viarollers 23 and the film with the thermoplastic fibers are heated/preheated on a heated roller(s) 24 and /or the thermoplastic fibers are melted with aninfrared heater 72 and contacted with thebuilding material 20 to form alaminated article 25. - In another embodiment, a bowed roller 47 can be included in the area of the process of
heating element 72. In a preferred embodiment, the bowed roller 47 is above the area where the adhesive is applied. - In another embodiment, a cutting device 44 such as a chopper when the building material is an insulation batt can be included. In addition, a
folding device 43 can also be included such as a batt folder when the building material is an insulation batt. - In one aspect of the invention, the film is provided with a printed pattern which can be provided on the
roll 23 or be applied during the manufacturing process of the present invention via aprinting device 40 such as an ink-jet print head. - In another aspect of the process, stapling tabs are formed in the vapor retarder film which can be approximately 1¼″ wide folded away from the lamination surface and may be provided via tab formation bars 46.
- Referring to
FIG. 5 , an alternative process for laminating the film component to the building material is depicted whereby the film is provided on aroll 21 and aroll 60 of a non-woven veil of thermoplastic fibers is also provided. The film and the non-woven veil are fed through the process viatension rollers 23. After the non-woven veil and the film have contacted, they may be heated via roller(s) 24 and/or heated via heating element 52 (such as an infrared heater) to melt the thermoplastic veil which mediates adhesion tobuilding material 20 thereby forming alaminated article 25. - The film component of the laminated article has a water vapor diffusion resistance, permeance, or transmission which is dependent on the ambient humidity and which has sufficient tensile and compressive strength for use in building and/or construction applications. Said another way, the film component is a “humidity adaptive film.” The humidity adaptive film as used herein means a film which has permeance of up to about 1.73 perms as determined according to the dessicant method of ASTM E 96 Method A, inclusive of up to 1.7, 1.6, 1.5, 1.3, 1.2, 1.1, 1.0, 0.5 and all values and ranges there between and a permeance of not less than about 3.45 perms, including not less than about 3.5, 3.7, 3.9, 4.0, 4.1 and all values and ranges there between as determined by the water method of ASTM E 96 Method B.
- The humidity adaptiveness of the film component may also be expressed as a water vapor diffusion resistance (sd-value) at a relative humidity of an atmosphere surrounding the vapor retarder in the region of 30% to 50% of 2 to 5 meters diffusion-equivalent air layer thickness, and, at a relative humidity in the region of 60% to 80% is <1 meter diffusion-equivalent air layer thickness. The water vapor diffusion resistance of the film component can be determined in accordance with DIN 52615 in the dry range (3/50% relative humidity (RH)) and in the damp range (50/93% RH) as well as in damp ranges there between, for example 33/50% and 50/75% RH.
- Any polymeric film can be used as the film component in the present invention, however, the film preferably meets the humidity adaptive criteria set forth above. Preferably the film is a polyamide film, and more preferably, the polyamide film is, for example, polyamide 6, polyamide 4 or
polyamide 3. Further examples of suitable films include nylon films such as nylon 6 or nylon 6.6 films. Combinations of polymeric materials or films are also possible. - The thickness of the films will vary depending on the particular film chosen, however, the film can be from 10 μm to 2 mm, including 20 μm, 25 μm, 25.4 μm, 25.5 μm, 25.6 μm, 25.7 μm, 25.8 μm, 26 μm, 27 μm, 28 μm, 30 μm, 40 μm, 50 μm, 60 μm, 70 μm, 80 μm, 90 μm, 100 μm, 101.6 μm, 110 μm, 120 μm, 130 μm, 140 μm, 150 μm, 160 μm, 170 μm, 180 μm, 190 μm, 195 μm, 200 μm and all values and subranges there between, for example, 20 μm to 100 μm, 30 μm to 90 μm, 40 μm to 60 μm, 45.5 μm to 55.5 μm, etcetera.
- In one embodiment of the present invention, the film component can be provided with a surface structure and/or printed pattern, such as color or grayscale print. As discussed above, the printed pattern can be provided during the manufacture of the laminated article, such as via an ink jet or flexographic printing device. Alternatively, the film can be pre-printed before introduction into the manufacturing process of the present invention. Combinations of pre-printing and printing concurrent with the manufacturing process may also be utilized.
- The building material onto which the film component is adhered during the manufacture of the laminated article can be any commonly used building material used. Preferably, however, the building material has a water vapor diffusion resistance which is less than the water vapor diffusion resistance of the film component.
- Non-limiting examples of suitable building materials that can be employed in the manufacturing process of the present invention include fiber reinforced cellulose materials, such as paper webs, membranes made from synthetic fiber spun fabrics or perforated polyethylene films, particle board, chip board, oriented strand board, plywood paneling, gypsum board (standard or fiber reinforced), fiber board, cement board, cementitious wood wool board, calcium silica board, fiber insulation batts or slabs, foam insulation slabs, wall paper, carpet and woven and non-woven fabrics.
- The film is adhered to at least one surface of the building material. For example, the film is adhered to at least one major or minor surface of the building material, preferably at least one major surface. As used herein, “major surface” refers to the surface or surfaces of the material which have a larger surface area than a second surface and likewise a “minor surface” has a smaller surface area than another surface of the material. In a preferred embodiment, at least one surface of the building material is not adhered to the film component. In an alternative embodiment, the film can sandwich the building material component such that a film is adhered to two opposite sides, major or minor, of the building material. The film can also be sandwiched between two layers of building material.
- Any polyolefin based adhesive may be used provided it adheres the film to the building material and permits the film to maintain at least a part of its water vapor transmission properties as described herein. Preferably, the adhesive has a lower melting point than the film onto which the adhesive is applied to prevent the film from melting prior to its adhesion to the building material. For example, a polypropylene-based or polyethylene-based adhesive may be used. One example of such an adhesive is Henkel adhesive #80-8273 (Henkel Adhesives Elgin, Ill.).
- In one embodiment of providing the adhesive, the adhesive can be applied as a hot-melt which is sprayed onto the film, e.g., using elliptical and swirl spray devices. In another embodiment, the adhesive can be provided as chopped thermoplastic fibers, which are subsequently heated to a point sufficient where the fibers are able to adhere the film to the building material. In another embodiment, the adhesive can be provided as a non-woven thermoplastic veil which can also subsequently heated in a similar manner.
- The adhesive can be applied to the film so that the permeance properties of the film component are not occluded or prevented from functioning properly. While there may be some reduction of the permeance, it is preferred that the film retains at least about 50% of the water-vapor transmission properties relative to the film prior to the adhesive being provided and maintains a minimum of 3.45 perms when tested by the water method of ASTM E 96 Method B and a permeance of up to about 1.73 perms as determined according to the dessicant method of ASTM E 96 Method A. In alternative embodiments, the permeance of the film with adhesive retains at least about 60%, 70%, 80%, 90%, 95%, 97% and 99%, inclusive of all values and ranges there between.
- To accomplish the two-fold requirement of adhering the film to the insulation and maintaining at least a part of the water-vapor transmission properties of the film can be accomplished by providing the adhesive in an amount of about 0.4 to about 1.0 g per lineal foot of the film based on a 15 inch application width. Further, the adhesive can be provided in an amount of about 0.5 to about 0.9 grams per lineal foot, inclusive of 0.6, 0.7, and 0.8 grams per lineal foot again based on a 15 inch application width.
- The adhesive, when sprayed onto the film, can be provided substantially uniformly onto the film provided the above permeance and/or application criteria are maintained. In an alternative embodiment, the adhesive can be provided as shown in the embodiments in
FIGS. 1B and 2B . In these embodiments, the adhesive 30 is applied to the film at the edges in a swirl pattern where at the center of the film, the adhesive 30 is applied in an elliptical pattern.FIG. 2B shows theswirl pattern 30 is applied with a swirl gun 50 and the elliptical pattern is applied with an elliptical spray gun 51. Examples of suitable spray guns include those hot melt spray guns sold by Nordson® Corporation. - The thermoplastics fibers include, for example, thermoplastics comprising polypropylene, polyethylene or their mixtures. The fibers may be virgin or recycled. In this embodiment, the use of a small quantity of chopped fibers and the scattered distribution results in a light distribution onto the film thereby covering only a portion of the film which in turn permits the humidity adaptive aspect of the film component to function. For example, the fibers would cover approximately less than 20% of the surface of the film, including less than 19, 18, 17, 16, 15, 14, 13, 12, 11, 10 and all values and subranges there between.
- The non-woven veil suitable for use in the present invention, is a low-melting point veil composed of thermoplastic fibers. Suitable fibers include polypropylene, polyethylene and mixtures thereof. The fibers may be virgin or recycled. Once again, the application of the veil to the film component is provided such that the permeance and/or application criteria discussed above are maintained.
- During the manufacturing process of the present invention or subsequent to the process, the laminated article can be cut into predetermined dimensions that would be preferable for storage, transport, sale, and end use (e.g., installation). If performed during the process, the cutting should preferably be after the film has adhered to the building material component. Further, it is also possible that certain building materials such as fiber insulation can be folded during or after the manufacturing process and would be preferably employed after the film has adhered to the building material component.
- The laminated article can also be treated to reduce the static electricity, for example, by incorporating anti-static devices and/or anti-static treatments which are commonly used in the art. For example, a film with antistatic treatment that can be used is Honeywell Capran 200A.
- In one embodiment, where the laminated article comprises an insulation batt or slab adhered to the film, the laminated article is packaged. Commonly, when insulation batts or slabs are packaged they are compressed. In this situation, in one aspect of the present invention, the laminated article is pushed through a snout, which is optionally coated with, for example, Teflon®, into a plastic bag.
- The present invention also provides a laminated article. The laminated article is composed of at least one film component as described herein and at least one building material component with an adhesive between the at least one film component and the at least one building material where the adhesive is present in an amount of about 0.4 to about 1.0 g per lineal foot of the film based on a 15 inch application width. In further embodiments, the adhesive is present in an amount of about 0.5 to about 0.9 grams per lineal foot, inclusive of 0.6, 0.7, and 0.8 grams per lineal foot again based on a 15 inch application width.
- In an alternative embodiment, the laminated article is composed of at least one film component as described herein and at least one building material component with an adhesive between the at least one film component and the at least one building material where the adhesive is present in an amount such that at least 50% of the humidity adaptive properties relative to the film prior to the adhesive being provided and maintains a minimum of 3.45 perms when tested by the water method of ASTM E 96 Method B and a permeance of up to about 1.73 perms as determined according to the dessicant method of ASTM E 96 Method A. In alternative embodiments, the permeance of the film with adhesive retains at least about 60%, 70%, 80%, 90%, 95%, 97% and 99%, inclusive of all values and ranges there between.
- The adhesive used for the laminated article of the present invention and the application thereof can also be chosen such that the adhesive is applied at the correct application which yields a laminated article having an ASTM E 84 maximum flame spread/smoke developed rating of 25/50 as determined by ASTM E 84 “Standard Test Method for Surface Burning Characteristics of Building Materials.”
- Variations and other embodiments for the laminated article can be drawn from the description of the process provided above.
- The laminated article described herein can be used to provide a vapor retarder to a building or portion of a building, e.g., a wall, roof or floor, or in any construction scenario where building materials, such as insulation are commonly employed. For example, the laminated article can be used, in addition to buildings, in transportation or moving vehicles, such as automobiles, planes, and trains, and particularly those designed for refrigeration. In addition, appliances such as refrigerators and/or freezers may also benefit from the use of the laminated article of the present invention. As used herein, “building” includes both commercial and residential buildings, such as office buildings, stores, houses and mobile homes. Thus, the laminated article of the present invention can be employed during the construction of a new building or renovation of an existing building. The laminated article would be provided to the appropriate location, e.g., between at least two studs of a wall or at least two rafters of a roof during the appropriate stage of the project. In a further embodiment, building components are commonly fabricated distant from the location of the actual location of the building (e.g., pre-fabricated building panels) and therefore, the laminated article can be employed during the manufacturing of those pre-fabricated building components and include, for example, a pre-fabricated wall, roof, or floor component.
- A roll of 2 mil nylon film is placed on an unwind stand in a pit underneath a fiberglass manufacturing line. Hot melt adhesive primarily composed of polypropylene is sprayed on the film at an application temperature of approximately 350° F. The film with the warm, tacky adhesive is then married to the bottom surface of a lane of mineral fiber insulation traveling above the nylon film on a conveyer line. The film with the adhesive is introduced to the mineral fiber insulation through a gap in the conveyer line. The film/mineral fiber laminate is further processed on the manufacturing line into batts or rolls and subsequently packaged.
- 0.002″ thick nylon 6 films (blown extruded and cast extruded) that were laminated to fiber glass insulation with sprayed hot melt adhesive and then removed from the fiber glass were tested according to ASTM E 96 wet cup (water method) and dry cup (dessicant method) with different test chamber humidities at 23° C. to achieve average 25%, 35%, 45%, 75%, 85%, and 95% relative humidity exposures and compared to unlaminated 0.002″ thick nylon 6 film (blown and cast) with no hot melt adhesive applied. The hot melt spray polypropylene adhesive was applied to the 2 mil nylon 6 film with a combination of elliptical and swirl spray guns. The film was laminated to fiber glass insulation and then removed from the fiber glass for water vapor transmission testing. 3% antistat was also included in the 2 mil nylon 6 film produced by blown film extrusion. There was no antistat in the 2 mil nylon film produced by cast film extrusion. The results are presented in the Table below.
Laminated, Unlaminated Blown Unlaminated Cast Blown with with 3% antistat; Laminated, Cast without antistat; Mean RH % 3% antistat no adhesive without antistat no adhesive RESULTS OF ASTM E 96 Method B WET CUP TESTS (results are in perms) 75% 11.07 12.23 12.33 12.07 85% 16.57 20.53 17.40 18.23 95% 38.40 48.70 39.90 44.57 RESULTS OF ASTM E 96 Method A DRY CUP TESTS (results are in perms) 25% 0.63 0.76 0.76 0.83 35% 0.96 1.10 1.09 1.30 45% 2.10 2.47 2.32 2.85 - These data demonstrate that the laminated article retains significant levels of permeance relative to a product with no added adhesive.
- Testing was performed in accordance with ASTM F 1249-01, Standard Test Method for Water Vapor Transmission Rate Through Plastic Film and Sheeting Using a Modulated Infrared Sensor. 0.002″ thick nylon 6 cast extruded film with 3% anti-stat that was laminated to fiber glass insulation with sprayed hot melt adhesive and then removed from the fiber glass was tested according to ASTM F 1249-01. Also tested was 0.002″ thick nylon 6 cast extruded film with 3% antistat that was not laminated and did not have hot melt adhesive applied. Tests were performed with the film exposed to average relative humidities of 20, 25, 40, and 50%. The temperature was maintained at 23° C. (73.4° F.) for all testing. The results were as follows.
Sample Laminated Cast Laminated Cast with with 3% antistat, 3% antistat, and spray and no adhesive hot melt adhesive Mean RH % 25% 50% 20% 25% 40% 50% Water vapor 0.34 4.70 0.24 0.30 0.93 4.06 Transmission Grams/(100 m2*day) Mean - These data demonstrate that the laminated article retains significant levels of permeance relative to a product with no added adhesive.
- The laminated articles were tested according to ASTM E 84 Standard Test Method for Surface Burning Characteristics of Materials resulting in a flame spread index of 15 and a smoke developed index of 5.
Claims (50)
Priority Applications (16)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/947,186 US20060059852A1 (en) | 2004-09-23 | 2004-09-23 | Laminated building materials |
PL05799700T PL1799922T3 (en) | 2004-09-23 | 2005-09-23 | Laminated building materials |
CNA2005800322216A CN101375004A (en) | 2004-09-23 | 2005-09-23 | Laminated building materials |
EP05799700.9A EP1799922B1 (en) | 2004-09-23 | 2005-09-23 | Laminated building materials |
PCT/US2005/033912 WO2006034381A2 (en) | 2004-09-23 | 2005-09-23 | Laminated building materials |
DK05799700.9T DK1799922T3 (en) | 2004-09-23 | 2005-09-23 | Laminated building materials. |
JP2007533616A JP4991546B2 (en) | 2004-09-23 | 2005-09-23 | Laminated building materials |
UAA200704421A UA89796C2 (en) | 2004-09-23 | 2005-09-23 | Laminated building materials |
BRPI0515512A BRPI0515512B1 (en) | 2004-09-23 | 2005-09-23 | methods of making a laminated article and laminated article |
CA2581711A CA2581711C (en) | 2004-09-23 | 2005-09-23 | Laminated building materials |
AU2005286680A AU2005286680B2 (en) | 2004-09-23 | 2005-09-23 | Laminated building materials |
KR1020077006580A KR101276276B1 (en) | 2004-09-23 | 2005-09-23 | Laminated building materials |
EA200700709A EA011292B1 (en) | 2004-09-23 | 2005-09-23 | Laminated building materials |
ZA200702094A ZA200702094B (en) | 2004-09-23 | 2007-03-12 | Laminated building materials |
NO20072003A NO339908B1 (en) | 2004-09-23 | 2007-04-19 | Laminated building materials |
US11/955,909 US20080145681A1 (en) | 2003-11-06 | 2007-12-13 | Reinforced Humidity Adaptive Vapor Retarding Film and Method of Manufacture |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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US10/947,186 US20060059852A1 (en) | 2004-09-23 | 2004-09-23 | Laminated building materials |
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US11/182,383 Continuation-In-Part US20070015424A1 (en) | 2003-11-06 | 2005-07-15 | Building material having adaptive vapor retarder |
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US10/704,317 Continuation-In-Part US20050098255A1 (en) | 2003-11-06 | 2003-11-06 | Insulation product having nonwoven facing and process for making same |
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US20060059852A1 true US20060059852A1 (en) | 2006-03-23 |
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US10/947,186 Abandoned US20060059852A1 (en) | 2003-11-06 | 2004-09-23 | Laminated building materials |
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US (1) | US20060059852A1 (en) |
EP (1) | EP1799922B1 (en) |
JP (1) | JP4991546B2 (en) |
KR (1) | KR101276276B1 (en) |
CN (1) | CN101375004A (en) |
AU (1) | AU2005286680B2 (en) |
BR (1) | BRPI0515512B1 (en) |
CA (1) | CA2581711C (en) |
DK (1) | DK1799922T3 (en) |
EA (1) | EA011292B1 (en) |
NO (1) | NO339908B1 (en) |
PL (1) | PL1799922T3 (en) |
UA (1) | UA89796C2 (en) |
WO (1) | WO2006034381A2 (en) |
ZA (1) | ZA200702094B (en) |
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US20080145681A1 (en) * | 2003-11-06 | 2008-06-19 | Toas Murray S | Reinforced Humidity Adaptive Vapor Retarding Film and Method of Manufacture |
US9382713B2 (en) | 2004-02-23 | 2016-07-05 | Huber Engineered Woods Llc | Panel for sheathing system and method |
CN108859384A (en) * | 2018-08-30 | 2018-11-23 | 镇江领域智能装备有限公司 | Composite insulating board Intelligent Machining equipment attaching mechanism |
CN110526666A (en) * | 2019-09-25 | 2019-12-03 | 湖州乌米科技有限公司 | A kind of high strength sound foam concrete |
US10612251B2 (en) | 2017-09-26 | 2020-04-07 | Certainteed Corporation | Insulation-retaining sheet having integral vapor-retarding membrane |
US10711453B1 (en) | 2015-12-29 | 2020-07-14 | Georgia-Pacific Panel Products Llc | Building panel with a weather barrier |
US10787303B2 (en) | 2016-05-29 | 2020-09-29 | Cellulose Material Solutions, LLC | Packaging insulation products and methods of making and using same |
US10889501B2 (en) | 2016-02-24 | 2021-01-12 | Massachusetts Institute Of Technology | Solar thermal aerogel receiver and materials therefor |
US10988630B2 (en) | 2014-12-19 | 2021-04-27 | Certainteed Corporation | Coating compositions for building materials and coated building material substrates |
US11078007B2 (en) | 2016-06-27 | 2021-08-03 | Cellulose Material Solutions, LLC | Thermoplastic packaging insulation products and methods of making and using same |
US11136755B2 (en) | 2017-06-30 | 2021-10-05 | Certainteed Llc | Vapor retarding building materials and methods for making them |
US11170750B2 (en) | 2018-04-25 | 2021-11-09 | Massachusetts Institute Of Technology | Energy efficient soundproofing window retrofits |
US11414865B2 (en) | 2012-05-31 | 2022-08-16 | Huber Engineered Woods Llc | Insulated sheathing panel |
US11536028B2 (en) | 2004-02-23 | 2022-12-27 | Huber Engineered Woods Llc | Panel for sheathing system and method |
US11536035B2 (en) | 2017-01-09 | 2022-12-27 | Trade Fabrication Systems Ltd. | Film application method and construction panel |
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Cited By (28)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20080145681A1 (en) * | 2003-11-06 | 2008-06-19 | Toas Murray S | Reinforced Humidity Adaptive Vapor Retarding Film and Method of Manufacture |
US10415245B2 (en) | 2004-02-23 | 2019-09-17 | Huber Engineered Woods, Llc | Panel for sheathing system and method |
US9702140B2 (en) | 2004-02-23 | 2017-07-11 | Huber Engineered Woods Llc | Panel for sheathing system and method |
US11697939B2 (en) | 2004-02-23 | 2023-07-11 | Huber Engineered Woods Llc | Panel for sheathing system and method |
US9695588B2 (en) | 2004-02-23 | 2017-07-04 | Huber Engineered Woods Llc | Panel for sheathing system and method |
US11536028B2 (en) | 2004-02-23 | 2022-12-27 | Huber Engineered Woods Llc | Panel for sheathing system and method |
US10072415B2 (en) | 2004-02-23 | 2018-09-11 | Huber Engineered Woods Llc | Panel for sheathing system and method |
US9382713B2 (en) | 2004-02-23 | 2016-07-05 | Huber Engineered Woods Llc | Panel for sheathing system and method |
US9546479B2 (en) | 2004-02-23 | 2017-01-17 | Huber Engineered Woods Llc | Panel for sheathing system and method |
US9689159B2 (en) | 2004-02-23 | 2017-06-27 | Huber Engineered Woods Llc | Panel for sheathing system and method |
US11414865B2 (en) | 2012-05-31 | 2022-08-16 | Huber Engineered Woods Llc | Insulated sheathing panel |
US10988630B2 (en) | 2014-12-19 | 2021-04-27 | Certainteed Corporation | Coating compositions for building materials and coated building material substrates |
US10711453B1 (en) | 2015-12-29 | 2020-07-14 | Georgia-Pacific Panel Products Llc | Building panel with a weather barrier |
US11634903B2 (en) | 2015-12-29 | 2023-04-25 | Georgia-Pacific Panel Products Llc | Building panel with a weather barrier |
US10889501B2 (en) | 2016-02-24 | 2021-01-12 | Massachusetts Institute Of Technology | Solar thermal aerogel receiver and materials therefor |
US11851334B2 (en) | 2016-02-24 | 2023-12-26 | Massachusetts Institute Of Technology | Solar thermal aerogel receiver and materials therefor |
US10787303B2 (en) | 2016-05-29 | 2020-09-29 | Cellulose Material Solutions, LLC | Packaging insulation products and methods of making and using same |
US11078007B2 (en) | 2016-06-27 | 2021-08-03 | Cellulose Material Solutions, LLC | Thermoplastic packaging insulation products and methods of making and using same |
US11536035B2 (en) | 2017-01-09 | 2022-12-27 | Trade Fabrication Systems Ltd. | Film application method and construction panel |
US11136755B2 (en) | 2017-06-30 | 2021-10-05 | Certainteed Llc | Vapor retarding building materials and methods for making them |
US11795684B2 (en) | 2017-06-30 | 2023-10-24 | Certainteed Llc | Vapor retarding building materials and methods for making them |
US11274455B2 (en) | 2017-09-26 | 2022-03-15 | Certainteed Llc | Insulation-retaining sheet having integral vapor-retarding membrane |
US10612251B2 (en) | 2017-09-26 | 2020-04-07 | Certainteed Corporation | Insulation-retaining sheet having integral vapor-retarding membrane |
US11668108B2 (en) | 2017-09-26 | 2023-06-06 | Certainteed Llc | Insulation-retaining sheet having integral vapor-retarding membrane |
US11170750B2 (en) | 2018-04-25 | 2021-11-09 | Massachusetts Institute Of Technology | Energy efficient soundproofing window retrofits |
US11749247B2 (en) | 2018-04-25 | 2023-09-05 | Massachusetts Institute Of Technology | Energy efficient soundproofing window retrofits |
CN108859384A (en) * | 2018-08-30 | 2018-11-23 | 镇江领域智能装备有限公司 | Composite insulating board Intelligent Machining equipment attaching mechanism |
CN110526666A (en) * | 2019-09-25 | 2019-12-03 | 湖州乌米科技有限公司 | A kind of high strength sound foam concrete |
Also Published As
Publication number | Publication date |
---|---|
JP4991546B2 (en) | 2012-08-01 |
JP2008514453A (en) | 2008-05-08 |
BRPI0515512A (en) | 2008-07-29 |
CA2581711A1 (en) | 2006-03-30 |
KR20070053779A (en) | 2007-05-25 |
NO339908B1 (en) | 2017-02-13 |
PL1799922T3 (en) | 2015-12-31 |
CN101375004A (en) | 2009-02-25 |
KR101276276B1 (en) | 2013-06-25 |
WO2006034381A2 (en) | 2006-03-30 |
NO20072003L (en) | 2007-06-20 |
AU2005286680A1 (en) | 2006-03-30 |
EP1799922A4 (en) | 2013-09-11 |
DK1799922T3 (en) | 2015-08-24 |
EP1799922B1 (en) | 2015-07-15 |
WO2006034381A3 (en) | 2007-01-11 |
CA2581711C (en) | 2013-08-13 |
ZA200702094B (en) | 2008-11-26 |
AU2005286680B2 (en) | 2011-02-24 |
BRPI0515512B1 (en) | 2016-04-12 |
EP1799922A2 (en) | 2007-06-27 |
EA200700709A1 (en) | 2008-02-28 |
EA011292B1 (en) | 2009-02-27 |
UA89796C2 (en) | 2010-03-10 |
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