Paper-scrim-foil core having extruded polypropylene resin

Patent metadata

Field	Value
Publication number	US-10160191-B2
Application number	US-201514620454-A
Country	US
Kind code	B2
Filing date	Feb 12, 2015
Priority date	Feb 12, 2015
Publication date	Dec 25, 2018
Grant date	Dec 25, 2018

Abstract

Embodiments of the invention provide a facer used as protective covering for an insulation product. The facer may include a metallic foil layer, a scrim layer, and a paper layer positioned adjacent the scrim layer. The facer may also include a polypropylene material forming a polypropylene layer positioned adjacent the paper layer and heat bonded to an exposed major surface of the paper layer such that a portion of the polypropylene extends into pores of the paper layer to assist in coupling the polypropylene material to the paper layer.

First claim

What is claimed is:

1. A method of manufacturing a facer used as a protective covering for an insulation product, the method comprising:
providing a jacketing material comprising:
a metallic foil layer;
a fiberglass reinforcing scrim layer; and
a paper layer positioned adjacent the scrim layer, wherein the fiberglass reinforcing scrim layer is positioned between the metallic foil layer and the paper layer, wherein the paper layer has a primary face and a secondary face, and wherein the secondary face faces the fiberglass reinforcing scrim layer and the primary face faces away from the fiberglass reinforcing scrim layer;

coating an exposed surface of a primary face of the paper layer of the jacketing material with a layer of melted polypropylene that forms an outermost layer of the facer;
applying pressure to the coated jacketing material using a cooled nip-roll assembly such that the layer of melted polypropylene solidifies into a polypropylene film to form the facer, wherein a portion of the polypropylene film extends into pores of the paper layer, and wherein the polypropylene film forms a face that is exposed to the environment.

2. The method of manufacturing a facer used as a protective covering for an insulation product according to claim 1 , further comprising:
grafting maleic anhydride onto pellets formed from polypropylene prior to being melted to form the melted polypropylene.

3. The method of manufacturing a facer used as a protective covering for an insulation product according to claim 1 , wherein:
the nip-roll assembly comprises a chill roller and a rubber coated backside pressure roller.

4. The method of manufacturing a facer used as a protective covering for insulation products according to claim 3 , wherein:
the chill roller imparts a matte finish on the coated facer.

5. The method of manufacturing a facer used as a protective covering for an insulation product according to claim 3 , wherein:
the chill roller is between about 150° F. and 225° F.

6. The method of manufacturing a facer used as a protective covering for an insulation product according to claim 1 , wherein:
the facer comprises a flap having a releasable liner on an underside of the flap such that when the releasable liner is removed, a pressure sensitive adhesive is exposed; and
the pressure sensitive adhesive is configured to adhere to the polypropylene film to secure the facer when the facer is wrapped around a conduit.

7. The method of manufacturing a facer used as a protective covering for an insulation product according to claim 6 , further comprising:
exposing the polypropylene to one or more of a corona treatment or a plasma treatment to increase the adherence between the polypropylene and the pressure sensitive adhesive.

8. The method of manufacturing a facer used as a protective covering for an insulation product according to claim 1 , wherein:
a surface energy of the exposed surface of the polypropylene layer is at least about 40 dyne/cm.

9. The method of manufacturing a facer used as a protective covering for an insulation product according to claim 1 , wherein:
a surface energy of the exposed surface of the polypropylene layer is between about 46 dyne/cm and 70 dyne/cm.

Assignees

• Johns Manville

Inventors

• Fay Ralph Michael
• Moore Anthony Edward
• Bright Edward Albert

Classifications

• B32B27/10

  of paper or cardboard · CPC title

• B32B3/04

  characterised by {at least one} layer folded at the edge, e.g. over another layer {; characterised by at least one layer enveloping or enclosing a material} · CPC title

• B32B2255/12

  on paper layer · CPC title

• F16L59/145

  providing fire-resistance · CPC title

• B32B2307/304

  Insulating · CPC title