Classifications

• • 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
  • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
  • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured 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
  • B32B15/00—Layered products comprising a layer of metal
  • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
  • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
  • B32B15/09—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising polyesters
• • 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
  • B32B15/00—Layered products comprising a layer of metal
  • B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
• • 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
  • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
• • 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
  • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
  • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
  • F16L59/00—Thermal insulation in general
  • F16L59/02—Shape or form of insulating materials, with or without coverings integral with the insulating materials
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
  • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
  • F16L59/00—Thermal insulation in general
  • F16L59/02—Shape or form of insulating materials, with or without coverings integral with the insulating materials
  • F16L59/029—Shape or form of insulating materials, with or without coverings integral with the insulating materials layered
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
  • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
  • F16L59/00—Thermal insulation in general
  • F16L59/08—Means for preventing radiation, e.g. with metal foil
• • 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
  • B32B2307/40—Properties of the layers or laminate having particular optical properties
  • B32B2307/416—Reflective
• • 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
  • B32B2323/00—Polyalkenes
  • B32B2323/04—Polyethylene

Definitions

• the present invention relates to thermally insulative materials and, more particularly, to an improved sheet insulation of the reflective bubble type for use, for instance, in arenas, etc.
• Conduction is direct heat flow through matter (molecular motion). It results from actual physical contact of one part of the same body with another part, or of one body with another. For instance, if one end of an iron rod is heated, the heat travels by conduction through the metal to the other end; it also travels to the surface and is conducted to the surrounding air which is another, but less dense, body.
• An example of conduction through contact between two solids is a cooking pot on the solid surface of a hot stove. The greatest flow of heat possible between materials is where there is direct conduction between solids. Heat is always conducted from warm to cold; never from cold to warm and always moves via the shortest and easiest route.
• Convection is the transport of heat within a gas or liquid, caused by the actual flow of the material itself (mass motion). In building spaces, natural convection heat flow is largely upward, somewhat sideways, not downwards. This is called “free convection”. For instance, a warm stove, person, floor, wall, etc., loses heat by conduction to the cooler air in contact with it. This added heat activates (warms) the molecules of the air which expand, becoming less dense, and rise. Cooler, heavier air rushes in from the side and below to replace it. Convection may also be mechanically induced, as by a fan. This is called “forced convection” .
• Radiation is the transmission of electromagnetic rays through space. Infrared rays occur between light and radar waves, i.e. between the 3 and 15 micron portion of the spectrum. Henceforth, when we speak of radiation, we refer only to infrared rays.
• the amount of radiation emitted is a function of the emissivity factor of the source's surface.
• Emissivity is the rate at which radiation (emission) is given off.
• Absorption of radiation by an object is proportional to the absorptivity factor of its surface which is the reciprocal of its emissivity.
• the surface of aluminum has the ability not to absorb, but to reflect, 95% of the infrared rays which strike it. Since aluminum foil has such a low mass to air ratio, very little conduction can take place, particularly when only 5% of the rays are absorbed.
• Reflection and emissivity by surfaces can only occur in space.
• the ideal space is any dimensioned 3/4" or more. Smaller spaces are also effective, but decreasingly so.
• a reflective surface of a material is attached to a ceiling, floor or wall, that particular surface ceases to have radiant insulation value at the points in contact. Therefore, care must be exercised, when installing foil insulation, that it be stretched sufficiently to insure that any inner air spaces are properly opened up and that metal does not touch metal. Otherwise, conduction through solids will result at the point of contact.
• Heat control with aluminum foil is made possible by taking advantage of its low thermal emissivity and the low thermal conductivity of air. It is possible with layered foil and air to practically eliminate heat transfer by radiation and convection.
• Aluminum foil with its reflective surfaces can block the flow of radiation. Some foils have higher absorption and emissivity qualities than others. The variations run from 2% to 72%, a differential of 2000%.
• Water vapor is the gas phase of water. As a gas, it will expand or contract to fill any space it may be in. In a given space, with the air at a given temperature, there is a limited amount of vapor that can be suspended. Any excess will turn into water. The point just before condensation commences is called 100% saturation. The condensation point is called dew point. Condensation forms whenever and wherever vapor reaches the dew point.
• the U factor represents the rate of heat flow in BTU ' s in one hour through a one square foot area of ceiling, roof, wall or floor, including insulation (if any) resulting from a 1°F temperature difference between the air inside and the air outside.
• the R factor, or resistance to heat flow is the reciprocal of U; in other words, 1/U. The smaller the U factor fraction, the larger the R factor, the better the insulation's ability to stop conductive heat flow, however, these neither of these factors include radiation or convection flow.
• the R value of a mass type insulation is reduced by over 35% with only a l*s% moisture content (i.e. from R13 to R8.3).
• the moisture content of insulation materials in homes typically exceeds 1*5%.
• Aluminum foil is one of the few insulating materials that is not affected by humidity and, consequently, its insulating value remains unchanged from the "bone dry" state to very high humidity conditions.
• United States Patent No. 4,281,802 issued on August 4, 1996 to Burley discloses a membranous thermal barrier for placement on an ice surface and comprising a flexible, sheet-like covering having low moisture permeability and thermal insulation properties sufficient to substantially reduce heat transfer to the ice surface when positioned thereon during non-use hours.
• the thermal barrier can be of the foamed polymers in sheet form, such as closed cell foamed polymeric plastics, a layer of which is provided on one of its surface with a fabric scrim bonded thereto, and on its other surface with an aluminum film.
• a high reflectivity insulative material comprising an outer polyester sheet means, an insulation layer means, and an aluminum film means between an inner surface of said polyester sheet means and an outer surface of said insulation layer means, wherein said polyester sheet means has a high smoothness such that said aluminum film means is substantially uniformly coated thereon, whereby said insulative material has a high reflectivity even with said polyester sheet means facing outwardly thereof.
• a method for producing a high reflectivity insulative material comprising the steps of: a) providing and heating a high melt polyester film; b) depositing a high density coating of aluminum on the heated polyester film; and c ) providing a thermally insulative layer on said aluminum coating opposite said polyester film.
• Figure 1 is a schematic view of an improved insulation in accordance with the present invention, wherein the various layers thereof are shown in part in a separated relation for illustration purposes.
• Figure 1 illustrates a roll of flexible insulation I comprising a series of layers which include first and second layers 10 and 12 made of multicellular plastic film (i.e. closed cell air bubbles or bubble-pack) and laminated on both sides of a white 1 mil thick polyethylene film 14; a pair of aluminum foil layers 16 and 18 laminated on the outer surfaces of the bubble-pack layers 10 and 12, and 1 mil thick clear polyester layers 20 and 22 coated on the outer surfaces of the aluminum layers 16 and 18, respectively.
• the aluminum layers 16 and 18 are vapor deposited on the polyester layers 22 and 24 and are assembled to the bubble-pack layers 10 and 12 which are, in turn, adhered to the central polyethylene film 14.
• the outer polyester coatings 20 and 22 protect the aluminum layers 16 and 18 such as to prevent any aluminum from rubbing off the insulation I and also prevent the aluminum layers 16 and 18 from oxidizing. Furthermore, the polyester coatings 20 and 22 provide an hygiene barrier for the insulation I.
• the insulation I of the present invention is very efficient, affordable, flexible and washable. It can be installed by way of glue, tacks, staples, nails, bolts, tapes, VelcroTM, etc.
• the insulation I can be used to insulate garage doors, barns, well-head wraps, ice fishing huts, motor homes, cottages, arenas, cold rooms, etc.; it can be used under cement, as duct wrap, coasters, can coolers, place mats, boot insoles, in survival blankets, to wrap food for shipping, etc.
• the emissivity is a measurement of the radiation emitted by a surface. The lower the value of a product on the emissivity scale, the better the insulation and greater will be the energy cost reduction.
• the "ultimate" insulation will possess the ability to reflect a high degree of heat or cold energy. It will insulate against any remaining passage of heat or cold, and will have excellent white light reflectance. Also, it will be non- corrosive.
• polyester coatings, 20 and 22 embodied in the insulation I of the present invention, there is no oxidization of the aluminum coatings or layers 16 and 18.
• the polyester coating constitutes partly a barrier which reduces the reflectivity of the non-coated aluminum below its 97% +/-1% mark. It is therefore desirable to try to increase as much as possible the reflectivity of the laminated assembly made up of the polyester and aluminum layers.
• the polyester coating 20/22 also renders the insulation I non- conductive to electricity.
• the present I of the present invention has extremely high performance in all three above-noted areas, i.e. high reflectivity, low emissivity and high white light reflectance.
• the present insulation I has an emissivity value of around 0.14 +/-0.02 and a reflectivity of around 90 to 95% with a 5/8" sheet of insulation I typically having an insulative value of 12R; the insulation I has a very high white light reflectance of around 85%; and it forms a perfect vapor barrier, whereby the installation of a layer of another product is not required with the presence of the present insulation I.
• a higher reflectivity of the outer surfaces of the insulation I is achieved as, with its smoothness, the polyester film 20,22 can be heated to a higher temperature thereby allowing for a more uniform coating of aluminum (i.e. the aluminum layers 16 and 18) to be applied thereon, whereby a thicker aluminum layer can be deposited.
• the surface of the polyester film being very smooth and flat allows the aluminum to be vapor deposited at a higher density or finer grain density thereby resulting in a lower emissivity and in higher reflective values.
• the polyester film's smoothness and high melt temperature produces a layer 20,22 of high optical density of approximately 3.30 (and between 3.10 and 3.50; tests have even showed an average optical density of 3.5 up to a present maximum of 4.0) at 75°F and a laminate composed of the polyester film 20,22 and of the aluminum layer or coating 16,18 having a reflectivity possibly as high as 95%.
• the Colon FPO- ⁇ polyester sheet has a high melt point of around 400 °F and a tensile modulus of 600,000 psi.
• the aluminum can be deposited on the polyester sheet with a thickness of approximately 250°A.
• the glue used to adhere the polyethylene layer 14 to the bubble-pack layers 10 and 12 can be, for instance, Swift's 2H436 pressure sensitive hot melt adhesive which is typically applied at temperatures of 250-325 °F, having a melt point of 214°F, and which has a viscosity of 650 cps at 300°F.
• the melted glue is sprayed on the bubble- pack layers 10 and 12 which are then adhered to the polyethylene central layer 14, the high melt point of the glue providing a flame retardant barrier for the insulation I which meets the standards.
• bubble-pack layers 10 and 12 when manufactured come out at around 700 °F at which point the aluminum/polyester laminates 16/20 and 18/22 are applied thereon with a cooling being effected by way of chilling rollers to prevent the aluminum/polyester laminates 16/20 and 18/22 from melting. Thereafter, the two bubble- pack/aluminum/polyester laminates 10/16/20 and 12/18/22 are mounted to the polyethylene layer 14 with the hot melt glue, as described hereinabove.

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Cited By (19)

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Citations (4)

• 1997
  • 1997-07-25 CA CA002211549A patent/CA2211549C/en not_active Expired - Fee Related
  • 1997-09-03 WO PCT/CA1997/000625 patent/WO1998010216A1/en active Application Filing
  • 1997-09-03 AU AU41081/97A patent/AU4108197A/en not_active Abandoned

Patent Citations (4)

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