AU2010100393A4

AU2010100393A4 - Rebonded foam product

Info

Publication number: AU2010100393A4
Application number: AU2010100393A
Authority: AU
Inventors: Joe Fernandes; Ian Shannon
Original assignee: Pacific Brands Clothing Pty Ltd
Current assignee: Pacific Brands Clothing Pty Ltd
Priority date: 2010-04-29
Filing date: 2010-04-29
Publication date: 2010-06-03
Anticipated expiration: 2018-04-29

Description

P/00/011 Regulation 3.2 AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION INNOVATION PATENT Invention Title: Rebonded foam product The following statement is a full description of this Invention, Including the best method of performing it known to us: 2 Rebonded foam product Field of the invention The present invention relates to a rebonded foam product and to a method of producing. 5 Background of the invention Rebonded foam is made from scrap foam, which is converted into crumb foam through a granulation process. The crumb foam is mixed with a binder and compressed into a mould. Heating via steam cures the binder and forms a solid block of foam. Typically rebonded foam is used to create a dense foam, the density of which is able to 10 be controlled. Typically, rebonded foam is used in flooring applications, particularly as flooring underlay. The required density for a particular application can be altered, therefore making it an adaptable product to use in different flooring applications. It is a preferred object of the present invention to provide an alternative rebonded foam product. 15 Summary of the invention The present invention lies in the realisation that rebonded foam could find application for insulation purposes. Accordingly, the present invention provides an insulation product, including a core layer of rebonded foam laminated with at least one outer layer. 20 Advantageously, the core layer is laminated between a first and second outer layer, each preferably including a foil sheet. Preferably, the rebonded foam is polyurethane. The binder used in the rebonded foam is preferably a urethane adhesive.

3 The density of the foam is typically in the range of 60kgs/m 3 to 200kgs/m 3 . Preferably products are provided in several densities, more particularly two, such as 69kgs/m 3 and 120kgs/m 3 . The thickness of the core layer is preferably in the range of 3mm to 15mm. It may be offered in a range of sizes, such as 5mm, 7mm and 9mm. 5 The outer layer(s) are preferably foil laminates, which may comprise an aluminium foil sheet, a polypropylene layer, a polypropylene weave layer and an adhesive layer. Advantageously, the first foil sheet is a high reflective aluminium foil and the second foil sheet is a low reflective aluminium foil. Preferably, an anti-glare backing is provided on one side. 10 The insulation product is preferably 450mm to 1800mm wide and 10 to 30 metres in length. However, it will be appreciated that any size is encompassed within the present invention. The insulation product is preferably an 'insulation roll', a term commonly used in the trade for a product of substantial length that is delivered in a roll form. According to a second aspect, the present invention provides a method of 15 manufacturing an insulation product, including: a) providing a core layer of rebonded foam; b) placing a first outer layer on a first side of the core layer, the first outer layer including a foil sheet; c) placing a second outer layer on a second side of the core layer, the second outer 20 layer including a foil sheet; and d) feeding the assembled core layer and outer layers through a lamination process consisting of a top and bottom heated roller applying pressure and creating a destructive bond between the core layer and the outer layers. Prior to step a), a rebonded foam block is preferably sliced to the required thickness 25 creating the core layer.

4 After step d), the insulation product is preferably rolled up and wrapped in a plastic sheet. Brief description of the drawings The invention will now be described, by way of example only, with reference to the 5 accompanying drawings, in which: Figure 1 is a perspective view of an insulation product according to the present invention; and Figure 2 is an exploded perspective view of an insulation product according to the present invention. 10 Detailed description of the embodiments An insulation product 10 is shown in Figures 1 and 2 having a core foam layer 20 of rebonded foam, such as polyurethane crumbs bound with a urethane adhesive. Typically the core foam layer would be produced in two different densities, such as 69kgs/m 3 and 120kgs/m 3 and would be sliced from a foam block, typically measuring 15 1900mm wide x 780mm high x 10000mm long. Three different thickness of the foam core 20 are typically provided, being 5mm, 7mm and 9mm, for the 69kgs/m 3 density foam and typically one thickness of 7mm is provided for the 120kgs/m 3 density foam. The foam core 20 is then fed through a lamination process with first and second outer layers 30, 40 on either side. The stack is fed through a top and bottom heated roller, 20 applying the appropriate pressure to ensure a destructive bond between the outer layers 30, 40 and the foam core 20. The insulation product is then able to be rolled up and wrapped in plastic sheet ready for delivery. The outer layers 30, 40 are foil laminates comprising an aluminium foil sheet, a polypropylene layer, a weave layer and an adhesive layer, providing superior tensile 25 strength. One outer layer 30 uses a high reflective aluminium foil sheet, whereas the other outer layer 40 uses a low reflective aluminium foil sheet. The foil sheets and 5 polyurethane core layer together assist in reducing radiant heat transfer, reducing the conductive/convective heat transfer and provide a rigid and strong construction. The insulation product 10 has a high moisture resistance, as well as providing a high R value, being the standard measure of thermal resistance. The greater the R value the 5 thinner the layer of foam that can be used to obtain the same thermal resistance. Advantageously, the product also includes an anti-glare backing on one surface making it safer and easier to install. The use of rebonded foam means that the density of the foam core 20 can be controlled. The greater the density, the thinner the foam core 20 can be to provide the 10 required properties. Producing a product from recycled content has many advantages, including the fact that the cost of rebonded foam is significantly less than virgin foam and therefore a more cost effective insulation product can be produced. Polyurethane foam provides a fibre free construction, making it easier to install. The combination of the rebonded foam core and the foil laminates increases the tensile strength of the 15 insulation product. It will be understood that the invention disclosed and defined in this specification extends to all alternative combinations of two or more of the individual features mentioned or evident from the text or drawings. All of these different combinations constitute various alternative aspects of the invention.

Claims

1. An insulation product, including a core layer of rebonded foam laminated with at least one outer layer.

2. An insulation product according to claim 1, wherein the core layer is laminated 5 between a first and second outer layer.

3. An insulation product according to claim 1 or 2, wherein the outer layer(s) include a foil sheet.

4. An insulation product according to claim 3, wherein the outer layer(s) are foil laminates, comprising an aluminium foil sheet, a polypropylene layer, a weave layer 0 and an adhesive layer.

5. An insulation product according to any one of the preceding claims, wherein the rebonded foam is polyurethane.