Paper-scrim-foil core having extruded polypropylene resin

Patent metadata

Field	Value
Publication number	US-2016236455-A1
Application number	US-201514620454-A
Country	US
Kind code	A1
Filing date	Feb 12, 2015
Priority date	Feb 12, 2015
Publication date	Aug 18, 2016
Grant date	—

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 facer used as protective covering for an insulation product, the facer comprising:
a metallic foil layer; a scrim layer; a paper layer positioned adjacent the scrim layer; 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; and a treatment on an exposed surface of the polypropylene layer by plasma or enhanced plasma.

2 . The facer used as a protective covering for an insulation product according to claim 1 , further comprising:
one or more of a fire retardant, titanium dioxide, calcium carbonate, an ultra violet stabilizer, a heat stabilizer, antistatic agent, or a metal deactivator.

3 . The facer used as a protective covering for an insulation product according to claim 1 , wherein:
the polypropylene layer is transparent.

4 . The facer used as a protective covering for an insulation product according to claim 1 , wherein:
the polypropylene layer is between about 0.0009 inches and 0.0018 inches thick.

5 . The facer used as a protective covering for an insulation product according to claim 1 , further comprising:
a flap extending from an end of the facer, the 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, wherein the pressure sensitive adhesive is configured to adhere to a portion of the polypropylene layer to secure the facer when the facer is wrapped around a conduit.

6 . The facer used as a protective covering for an insulation product according to claim 1 , wherein:
the polypropylene layer comprises a matte finish.

7 . The facer used as a protective covering for an insulation product according to claim 1 , wherein:
the facer is substantially free of a separate adhesive between the polypropylene layer and the paper layer.

8 . The 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 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.

10 . 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;
coating an exposed major surface of the paper layer of the jacketing material with a layer of melted polypropylene; 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.

11 . The method of manufacturing a facer used as a protective covering for an insulation product according to claim 8 , further comprising:
grafting maleic anhydride onto polypropylene pellets prior to being melted to form the melted polypropylene.

12 . The method of manufacturing a facer used as a protective covering for an insulation product according to claim 10 , wherein:
the nip-roll assembly comprises a chill roller and a rubber coated backside pressure roller.

13 . The method of manufacturing a facer used as a protective covering for insulation products according to claim 12 , wherein:
the chill roller imparts a matte finish on the coated facer.

14 . The method of manufacturing a facer used as a protective covering for an insulation product according to claim 12 , wherein:
the chill roller is between about 150° F. and 225° F.

15 . The method of manufacturing a facer used as a protective covering for an insulation product according to claim 10 , 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.

16 . The method of manufacturing a facer used as a protective covering for an insulation product according to claim 10 , 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.

17 . The method of manufacturing a facer used as a protective covering for an insulation product according to claim 10 , wherein:
a surface energy of the exposed surface of the polypropylene layer is at least about 40 dyne/cm.

18 . The method of manufacturing a facer used as a protective covering for an insulation product according to claim 10 , wherein:
a surface energy of the exposed surface of the polypropylene layer is between about 46 dyne/cm and 70 dyne/cm.

19 . A method of applying a protective facer to an insulation product, the method comprising:
wrapping an insulation product and a facer around a conduit, the insulation product comprising a first end and a second end separated by a gap such that the insulation product is separable to receive the conduit through the gap, wherein the facer wraps around the insulation product such that a flap extending from a first end of the facer overlaps a second end of the facer, wherein the facer comprises:
a metallic foil layer;
a scrim layer;
a paper layer positioned adjacent the scrim layer; and
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 facilitate coupling of the polypropylene to the paper layer; and
securing the flap to the polypropylene layer.

20 . The method of applying a protective facer to an insulation product according to claim 19 , wherein:
securing the flap to the polypropylene layer comprises:
removing a releasable liner to expose a pressure sensitive adhesive on an underside of the flap; and
positioning the pressure sensitive adhesive against a portion of the polypropylene layer such that the pressure sensitive adhesive bonds to the portion of the polypropylene layer.

21 . The method of applying a protective facer to an insulation product according to claim 19 , wherein:
the facer comprises one or more of a fire retardant, titanium dioxide, calcium carbonate, an ultra violet stabilizer, a heat stabilizer, antistatic agent, or a metal deactivator.

22 . The method of applying a protective facer to an insulation product according to claim 19 , wherein:
the polypropylene layer is transparent.

23 . The method of applying a protective facer to an insulation product according to claim 19 , wherein:
the polypropylene layer is between about 0.0009 inches and 0.0018 inches thick.

24 . The method of applying a protective facer to an insulation product according to claim 19 , wherein:
the polypropylene layer comprises a matte finish.

25 . The method of applyin

Assignees

• Johns Manville

Inventors

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

Classifications

• B32B38/0012

  Mechanical treatment, e.g. roughening, deforming, stretching · CPC title

• F16L59/145

  providing fire-resistance · CPC title

• B32B2255/12

  on paper layer · CPC title

• B32B2597/00

  Tubular articles, e.g. hoses, pipes · CPC title

• B32B29/02

  next to a fibrous or filamentary layer · CPC title