CA1293917C - Laminated, thermal insulation panel - Google Patents
Laminated, thermal insulation panelInfo
- Publication number
- CA1293917C CA1293917C CA000566493A CA566493A CA1293917C CA 1293917 C CA1293917 C CA 1293917C CA 000566493 A CA000566493 A CA 000566493A CA 566493 A CA566493 A CA 566493A CA 1293917 C CA1293917 C CA 1293917C
- Authority
- CA
- Canada
- Prior art keywords
- membrane
- board
- adhesive
- polystyrene
- insulation panel
- 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.)
- Expired - Lifetime
Links
- 238000009413 insulation Methods 0.000 title claims abstract description 45
- 239000012528 membrane Substances 0.000 claims abstract description 86
- 239000000853 adhesive Substances 0.000 claims abstract description 48
- 230000001070 adhesive effect Effects 0.000 claims abstract description 48
- 239000004793 Polystyrene Substances 0.000 claims abstract description 37
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 33
- 229920002223 polystyrene Polymers 0.000 claims abstract description 32
- 239000000463 material Substances 0.000 claims abstract description 17
- 230000035699 permeability Effects 0.000 claims abstract description 14
- 239000002390 adhesive tape Substances 0.000 claims abstract description 6
- 238000000034 method Methods 0.000 claims description 10
- 239000000203 mixture Substances 0.000 claims description 9
- 238000010276 construction Methods 0.000 claims description 5
- 239000004794 expanded polystyrene Substances 0.000 claims description 5
- 238000010030 laminating Methods 0.000 claims description 5
- 238000004519 manufacturing process Methods 0.000 claims description 4
- 238000007789 sealing Methods 0.000 claims description 4
- 239000013032 Hydrocarbon resin Substances 0.000 claims description 3
- 239000004820 Pressure-sensitive adhesive Substances 0.000 claims description 3
- 239000003522 acrylic cement Substances 0.000 claims description 3
- 150000001336 alkenes Chemical class 0.000 claims description 3
- 150000002148 esters Chemical class 0.000 claims description 3
- 229920006270 hydrocarbon resin Polymers 0.000 claims description 3
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 claims description 3
- 239000005026 oriented polypropylene Substances 0.000 claims description 3
- 229920001083 polybutene Polymers 0.000 claims description 3
- 229920000346 polystyrene-polyisoprene block-polystyrene Polymers 0.000 claims description 3
- 239000011347 resin Substances 0.000 claims description 3
- 229920005989 resin Polymers 0.000 claims description 3
- RSWGJHLUYNHPMX-UHFFFAOYSA-N Abietic-Saeure Natural products C12CCC(C(C)C)=CC2=CCC2C1(C)CCCC2(C)C(O)=O RSWGJHLUYNHPMX-UHFFFAOYSA-N 0.000 claims description 2
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 claims description 2
- 244000043261 Hevea brasiliensis Species 0.000 claims description 2
- KHPCPRHQVVSZAH-HUOMCSJISA-N Rosin Natural products O(C/C=C/c1ccccc1)[C@H]1[C@H](O)[C@@H](O)[C@@H](O)[C@@H](CO)O1 KHPCPRHQVVSZAH-HUOMCSJISA-N 0.000 claims description 2
- 150000001338 aliphatic hydrocarbons Chemical class 0.000 claims description 2
- 150000004945 aromatic hydrocarbons Chemical class 0.000 claims description 2
- 229920003052 natural elastomer Polymers 0.000 claims description 2
- 229920001194 natural rubber Polymers 0.000 claims description 2
- 239000002904 solvent Substances 0.000 claims description 2
- 229920003051 synthetic elastomer Polymers 0.000 claims description 2
- 239000012209 synthetic fiber Substances 0.000 claims description 2
- 229920002994 synthetic fiber Polymers 0.000 claims description 2
- 239000005061 synthetic rubber Substances 0.000 claims description 2
- KHPCPRHQVVSZAH-UHFFFAOYSA-N trans-cinnamyl beta-D-glucopyranoside Natural products OC1C(O)C(O)C(CO)OC1OCC=CC1=CC=CC=C1 KHPCPRHQVVSZAH-UHFFFAOYSA-N 0.000 claims description 2
- 210000004379 membrane Anatomy 0.000 description 58
- 239000004775 Tyvek Substances 0.000 description 12
- 229920000690 Tyvek Polymers 0.000 description 12
- 238000012360 testing method Methods 0.000 description 8
- 230000004888 barrier function Effects 0.000 description 3
- 230000008901 benefit Effects 0.000 description 3
- 230000005494 condensation Effects 0.000 description 3
- 238000009833 condensation Methods 0.000 description 3
- 230000008595 infiltration Effects 0.000 description 3
- 238000001764 infiltration Methods 0.000 description 3
- 230000009467 reduction Effects 0.000 description 3
- 238000006722 reduction reaction Methods 0.000 description 3
- 230000005540 biological transmission Effects 0.000 description 2
- 230000032798 delamination Effects 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000012467 final product Substances 0.000 description 2
- 239000012774 insulation material Substances 0.000 description 2
- 238000003475 lamination Methods 0.000 description 2
- 238000009436 residential construction Methods 0.000 description 2
- YASAKCUCGLMORW-UHFFFAOYSA-N Rosiglitazone Chemical compound C=1C=CC=NC=1N(C)CCOC(C=C1)=CC=C1CC1SC(=O)NC1=O YASAKCUCGLMORW-UHFFFAOYSA-N 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 230000001413 cellular effect Effects 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000009792 diffusion process Methods 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 238000009432 framing Methods 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 239000003292 glue Substances 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
Classifications
-
- 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
- F16L59/021—Shape or form of insulating materials, with or without coverings integral with the insulating materials comprising a single piece or sleeve, e.g. split sleeve, two half sleeves
-
- 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
- B32B7/14—Interconnection of layers using interposed adhesives or interposed materials with bonding properties applied in spaced arrangements, e.g. in stripes
-
- 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
- E04B1/82—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 sound only
- E04B1/84—Sound-absorbing elements
- E04B1/86—Sound-absorbing elements slab-shaped
-
- 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
- E04B1/82—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 sound only
- E04B1/84—Sound-absorbing elements
- E04B2001/8457—Solid slabs or blocks
- E04B2001/8461—Solid slabs or blocks layered
Landscapes
- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Acoustics & Sound (AREA)
- General Engineering & Computer Science (AREA)
- Architecture (AREA)
- Mechanical Engineering (AREA)
- Electromagnetism (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Laminated Bodies (AREA)
- Building Environments (AREA)
Abstract
ABSTRACT
A laminated, thermal insulation panel comprises a board made of expanded, molded polystyrene, and a membrane laminated on one side of the polystyrene board by means of an adhesive. The board and membrane are both permeable to water vapor, but the membrane is also impervious to air and moisture. The adhesive is applied under the form of strips and presents permeability to water vapor while being compatible with both the board polystyrene and the membrane material. Accordingly, the adhesive does not chemically attack the polystyrene and membrane material, whereby the wa-ter vapor permeability and air/moisture imperviousness of the latter are not affected. It can be appreciated that the resulting insulation panel is impervious to air and moisture from the outside but is permeable to water vapor from the inside. The joints between adjacent, laminated insulation panels are sealed by means of an adhesive tape applied on the membranes of the adjacent panels.
A laminated, thermal insulation panel comprises a board made of expanded, molded polystyrene, and a membrane laminated on one side of the polystyrene board by means of an adhesive. The board and membrane are both permeable to water vapor, but the membrane is also impervious to air and moisture. The adhesive is applied under the form of strips and presents permeability to water vapor while being compatible with both the board polystyrene and the membrane material. Accordingly, the adhesive does not chemically attack the polystyrene and membrane material, whereby the wa-ter vapor permeability and air/moisture imperviousness of the latter are not affected. It can be appreciated that the resulting insulation panel is impervious to air and moisture from the outside but is permeable to water vapor from the inside. The joints between adjacent, laminated insulation panels are sealed by means of an adhesive tape applied on the membranes of the adjacent panels.
Description
1~3~
LAMINATED, THERMAL INSULATION PANEL
BACKGROUND OF THE INVENTION
1. Field of the invention:
The present invention relates to a laminated, thermal insulation panel for outside covering of a cons-truction, such as a residential house, which insulation panel is impervious to air and moisture from the outside but is permeable to water vapor from the inside.
LAMINATED, THERMAL INSULATION PANEL
BACKGROUND OF THE INVENTION
1. Field of the invention:
The present invention relates to a laminated, thermal insulation panel for outside covering of a cons-truction, such as a residential house, which insulation panel is impervious to air and moisture from the outside but is permeable to water vapor from the inside.
2. Brief description of the prior art:
Rigid polystyrene insulation material is pre-sently widely used in residential construction for exterior wall insulation. Such insulation material is commonly available under the Eorm expanded,molded polystyrene boards.
These boards are mounted adjacent -to each other to cover the entire, exterior wall surface of the residential cons-truction.
~3~ 7 In order to prevent air and moisture Erom the outside to penetrate into the walls, a membrane permeahle to water vapor but impervious to air and moisture is applied externally on the polystyrene boards. This membrane must totally and adequately cover the exterior surface to give proper protection. In particular, it must seal a]l cracks, fissures and joints in the wall s-tructure to prevent air and moisture penetration. Accordingly, a problem is -to adequately and suitably attach the membrane -to the exterior wall assembly.
One can appreciate that it is not possible to staple the membrane to the soft, pliable cellular plastic polystyrene for adequate interface contact. Consequently, the membrane is conventionally attached to the wood stud framing of the wall substrate by stapling through the membrane, in particular through the lapped joints thereof.
Decision as to the proper lapping over of the membrane, the proper laps and the number of staple fixation points is left to the specialized on-site workmen. This often results into unappropriate fixation of the membrane and/or in unadequate covering of the exterior wall surface by the membrane.
As the polystyrene boards and the membrane are both breathable to the diffusion of water vapor conveyed from the inside to the outside, condensation within the wall structure is thereby prevented. However, when the membrane is not adequately applied on the exterior wall surface for any of the above reasons, air and moisture can penetrate into the wall to cause condensation and/or air infiltration inside of the wall and eventually inside of the house.
As the membrane is commonly available under the form of rolls, another problem is that application of this membrane on the exterior wall surface becomes very difficult 3~
in presence of h:ig~l winds. Moreover, hiyh wlnds can cause tearing of the lapped joints of the membrane during cons-truction.
OBJECT OF THE INVENTION
An object of the present invention is therefore to provide a laminated, thermal insulation panel and a thermal, wall insulation method which eliminate all of the above discussed drawbacks of the prior art.
SUMMARY OF THE INVENTION
More specifically, according to the present invention, there is provided a laminated, thermal insula-tion panel comprising:
a board made of expanded polystyrene permeable to water vapor;
a membrane laminated over one side of the poly-styrene board, which membrane presents imperviousness to air and moisture and permeability to water vapor; and an adhesive applied between the membrane and board for laminating the membrane on said one side of the polystyrene board, said adhesive being applied in a pattern to ensure permeability to water vapor and being compatible with both the polys-ty-rene of the board and the material constituting the membrane, so that the adhesive does not chemically attack the board polystyrene and the membrane material whereby the water vapor permeability of the board polystyrene and the membrane material as well as the air/moisture imperviousness of the membrane material are not affected by the adhesive.
Pre~erably, the membrane is made of non-woven, spunbonded olefin, and the board of expanded, molded poly-styrene.
9~7 In accordance with a preferred embod.iment of the laminated, insulation panel oE the inven-ti.on, the pattern is fo.nm~d by a plurality o:E s-trips o:E an adhesive co~lprising as elastomeri.c base a blend of polybutene and styrene-isoprene-styrene block copolymer, and as tackifying resins a blend of syn-thetic hydrocarbon resins and rosin esters.
In accordance with the present invention, there is further provided a method of thermally insulating the exterior walls of a construction, such as a residential house, comprising the steps of:
in-plant manufacturing laminated, thermal insu-lation panels each obtained by laminating a membrane over one side of a board made of expanded polystyrene, which board and membrane are both permeable to water vapor and which membrane is further impervious to air and moisture;
covering the outside of said walls with a plurality of said insulation panels with the membrane thereof at the exterior; and sealing the joints between adjacen-t ones of the panels with-an adhesive tape impervious to air and moisture, which tape comprising an adhesive surface applied on the membranes of the adjacent pa-nels.
Preferably, the tape comprises permanent acrylic adhesive with an oriented polypropylene backing.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects, advan-tages and other features of the present invention will become more apparent upon reading of the following non restrictive description of a preferred embodiment thereof, given in conjunction with the accompa-nying drawings in which:
Figure 1 illustrates the structure of a laminated, - 5 ~ 339~7 thermal insulation panel in accordance with the preserlt invention; and Figure 2 shows a method oE sealing ~he join-t between two adjacent insula-tion panels both having a struc-ture similar to that illustrated in Figure 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As illustrated in Figure 1, the laminated, thermal insulation panel comprises (a) a board 1 made of expanded, molded polystyrene of varying thickness which is permeable to water vapor, and ~b) a membrane 2 which is impervious to air and moisture, while being also permeable to water vapor. The membrane 2 is laminated over one side of the board 1 by means oE a suitable adhesive applied in a pattern, for example longi-tudinal strips 3 as shown in Figure 1, to ensure permeability to water vapor. The adhesive should of course be compatible with both the membrane 2 and the board 1, i.e. it does not attack chemi-cally these board and membrane whereby the water vapor permeability and the air/moisture imperviousness of the same are not affected by the adhesive.
Each of the board 1, the membrane 2 and the adhesive forming the strips 3 will now be described sepa-rately by means of their characteristics and/or composition.
Of course, the different elements forming the insulation panel have been selected for the best results, which selec-tion results from a wide experimentation.
The board 1 is advantageously composed of an expanded, molded polystyrene board. An example is the board of Type-l manufactured and commerciallzed under the trademark ISOLOFOAM
by the Applicant company " LES PRODUITS ISOLOFOAM INC." .
The board 1 can vary in thickness depending on the desired level of thermal insulation. Of course, the ISOLOFOAM board is permeable to water vapor.
Tests on a specimen oE ISOLOE'OAM expanded poly-styrelle board oE Type-l have ~iven the following results:
Average thickness: 36~8 mm Bulk density: 15.5 kg/m' Hot surEace temperature: 3~ 8 C
Cold surface temperature: 13.7 C
Temperature difference: 21.1 K
Mean temperature of test: 24.3 C
Heat f],ux (through the thickness): 21.52 W/m2 Thermal conductance: 1.020 W/(m2 K) Thermal resistance: 0.9~0 m2 K/W
Thermal conductivity: 0.0375 W/(m K) Thermal resistance by unit thickness: 26.6 m K/W
These tests were performed with the specimen placed horizontally in a 610 mm2 Heat Flow Meter Apparatus.
Heat flowed upwards through the specimen during testing.
Paper-backed glass fiber insulation was placed around the perimeter of the plates of the Heat Flow Meter Apparatus and of the specimen to reduce edge heat losses.
Additional tests carried out on a plurality of specimen 25 mm thick of ISOLOFOAM expanded, molded polysty-rene board of Type-l indicated the following results:
Average compressive strength: 80 kPa Average Flexural strength: 193 kPa 0 The membrane 2 is advantageously that manufac-tured andcommercialized by the company DUPONT CANADA under the trademark TYVEK. The TYVEK membrane is a sheet of Eine synthetic fibers. More specifically, it is composed of ~3~ ~7 non-woven, spunbonded olefill. As it i.s -totally synthetic, it does not shrink nor ro-t. :[t resis-ts to tear and puncture, it is permeable to water vapor but is impervious to air and mois-ture. It therefore constitutes an air/moisture barrier and accordingly an energy saving air barrier.
Some data given by the manufacturer concerning the TYVEK membrane are the following:
Water vapor transmission rate (g/100 in2 _ 24 hours~:51.30 Weight (lb/1000 ft2): 8.81 Rupture resistance (lb/in2): 105.00 Tearing resistance (lb) (lengthwise): 32.50 (transversal): 24.80 Porosity to the air - seconds: 7.60 Resistance to water (cm of water pressure): 99.30 Thickness (mils): 6.10 The adhesive pattern is formed, in the example of Figure 1, by a plurality of longitudinal strips 3 of the adhesive SWIFT # 68468 manufactured and commercialized by the company SWIFT adhesives, division of Reichhold Limited.
Some of its physical properties are the following:
ELASTOMERIC BASE: Blend of Polybutene and Styrene-Isoprene-Styrene block copolymer TACKIFYING RESINS: Blend of synthetic hydrocarbon resin and rosi.n esters VISCOSITY: 12 - 15 poise SOLIDS: 48 - 50~
FLASH POINT: - 18C (T.C.C.*) SPECIFIC GRAVITY: 0.84 g/cc * Abbreviation for Tag (actually Tagliabue) closed cup, ~g3~7 a type of flash point tes-t.
The SWIFT # 68468 adhesive is a solvent-base pressure-sensitive adhesive of the permanent type including a blend of synthetic rubber and of aliphatic/aromatic hydro-carbons in a solvent. It has been formulated expressly for applications requiring high peel strength and holding power. The adhesive exhibits high shear strength over a broad range of service temperatures as well as an aggressive tack to a wide variety of surfaces.
In order to laminate the TYVEK membrane 2 on the ISOLOFOAM polystyrene board of Type-l, it is not sufficient to think to use an adhesive to glue the mem-brane 2 on the board 1. Indeed, the following requirements must be taken into consideration:
- the adhesive must not attack chemically neither the membrane 2 nor the board 1 whereby these board and membrane keep their physical characteristics, i.e. the adhesive must be compatible with both the board 1 and mem-brane 2;
- the adhesive must be applied in a pattern to ensure permeability to water vapor in order to cause no reduc-tion in water vapor permeability of-the overall insulation panel; and - the adhesive must produce a suitable bond between the membrane 2 and board 1.
2S Accordingly, one can appreciate that the selec-tion of the adhesive cannot be effected without a great quantity of tests and experimentations. Laminating the membrane 2 on the board l is not an evident matter when it is desired to obtain an insulation panel having the appro-priate, desired characteristics.
The adhesive SWIFT # 68468 meets with these requirements as it is non chemically aggressive when con-fronted with the materials forming the board 1 and membrane 2 at temperatures under 70C. Accordingly, it bonds the 3~ 317 _ 9 _ two materials without altering their chemical or perEormance charac-teristics.
Moreover, the adhesive SWIFT # 68~6~ dries quickly. ~ccordingly, in the manufacture process, it is not required to speed up cure by subjecting it to -tempera-tures above 70C at which the adhesive attacks chemically the polystyrene of the board 1.
The selected adhesive provides a bond between the board 1 and membrane 2 strong enough that when the TYVEK
membrane is removed, it tends to remove the surface of the polystyrene of the board 1. This results into stability of laminate while slippage is not a problem. However, due to the strong adhesion, re-adhesion properties are poor.
It has been experimented that strips 3 of a width a = 12.7 mm lengthwise of the insulation panel at a distance b = 100 mm between the centers of each pair of adjacent strips 3 provide for good bond between the TYVEK
membrane 2 and the ISOLOFOAM board 1. Such a bond is strong enough to prevent delamination problems or flapping situa-tions.
A distance c = 3.2 mm is maintained between the ends of the strips 3 and the corresponding edge of the board 1, as well as between the outer strips 3 and the respective board edges.
Total covering of the surEace oE the board 1 with adhesive is not desirable due to potential negative effects on the water vapor transmission rate through the insulation panel.
It should also be pointed out that o-ther types of adhesive having similar characteristics can even-tually be used, for example pressure-sensitive adhesives including natural rubber, or moisture cured urethane, etc.
Figure 2 illustra-tes a method of sealing the joint 7 between two adjacent insulation panels 4 and 5 simi-33~7 lar to that of Figure l.
When the two panels 4 and S have been mounted side by side as illustrated in Figure 2 Eor coveri.ng the outside of an external wall o:E for example a residential house, a self-adhesive tape 6 is applied on the outer sur-face of -the two adjacent membranes 2 in order to seal the joint 7 between the panels 4 and 5. As the TYVEK membranes 2 and the tape 6 form a system permeable to water vapor but impervious to air and moisture, a surface presenting uniform characteristics results from the latter operation.
A self-adhesive tape suitable for the above purpose is that manufactured and commercialized under No.
Y 8086 by the company 3M CANADA INC. Such a tape is constituted of permanent acrylic adhesive with an oriented polypropylene backing.
Use of the laminated, thermal insulation panel in accordance with the present invention for externally covering the walls of for example a residential house results in the following advantages:
- the TYVEK membrane can be in-plant laminated mechanically and automatically. Before lamination, the strips 3 of adhesive is applied on the ISOLOFOAM board surface;
- the in-plant lamination of the insulation panel results in savings in labor costs;
- the TYVEK membrane 2 constitutes a durable exterior layer for the ISOLOFOAM board which improves the puncture resistance and the durability of the expanded po-lystyrene. The membrane also protects the polystyrene board against direct exposure to the elements during cons-truction. This enhances the quality of the final product;
- the TYVEK membrane greatly reduces air infil-tration through the wall structure from the outside and accordingly causes reduction in heating and cooling costs;
~293~17 - the TYVEK membrane additionally protects the inside of the walls and -the polystyrene board against wind--driven moisture from the outside. This, in particular, maintalns -the high thermal resistance value oE the polysty-rene whereby an energy eEficien-t insulation board is obtained;
- when boards as shown in Figure 1 are installed to cover the outside of for example a residential house, and using a self-adhesive tape 6 to seal the joints between these boards, an air and moisture tight overall envelope results as all the cracks and fissures are sealed; and - the use of a laminated, thermal insulation panel as illustrated in Figure 1 eliminates material losses due to wind damage and wide lapped joints (commonly 4 to 12 inches wide), eliminates any development of loose flaps being beaten and damaged by the action of strong winds, and eli-minates all the guesswork on the on-site membrane applica-tion and fixation by the workers. This of course results in an enhanced quality of the final product.
During tests carried out on an insulation panel as that shown in Figure 1 at pressure differences varying from 25 Pa to 250 Pa, no delamination of the membrane 2 was produced, and a reduction of 41~ of air leakage compared with a polystyrene board with no laminated membrane was observed.
During other tests on a specimen of insulation panel similar to that of Figure l, comprising a polystyrene board 1 50 mm thick, it was observed that both the adhesive and TYVEK membrane had no significant effect on the permea-bility of the Type-l ISOLOFOAM polystyrene board to water vapor.
By way of example, with a board 1 of 33 mm thick, and 47 mm thick, the thermal insulation provided by the laminated panel is respectively R 4.7 and R 7Ø
Last of all, it should be pointed out that the 1;2~3~17 mos-t important advantage oE the laminated, -thermal klsula-tion panel,according to the present lnvention,is that it constitutes a barrier to air and moisture Erom the outside to the inside, while it allows passage of water vapor from the inside to the outside, to thereby prevent any condensa-tion, moisture and air infiltration within or through the wall assembly.
Although the present invention has been des-cribed herein above by way of a preferred embodimen-t thereof, it should be pointed out that any modification to this pre-ferred embodiment, within the scope of the appended claims, is not deemed to change or alter the nature and scope of the present invention.
Rigid polystyrene insulation material is pre-sently widely used in residential construction for exterior wall insulation. Such insulation material is commonly available under the Eorm expanded,molded polystyrene boards.
These boards are mounted adjacent -to each other to cover the entire, exterior wall surface of the residential cons-truction.
~3~ 7 In order to prevent air and moisture Erom the outside to penetrate into the walls, a membrane permeahle to water vapor but impervious to air and moisture is applied externally on the polystyrene boards. This membrane must totally and adequately cover the exterior surface to give proper protection. In particular, it must seal a]l cracks, fissures and joints in the wall s-tructure to prevent air and moisture penetration. Accordingly, a problem is -to adequately and suitably attach the membrane -to the exterior wall assembly.
One can appreciate that it is not possible to staple the membrane to the soft, pliable cellular plastic polystyrene for adequate interface contact. Consequently, the membrane is conventionally attached to the wood stud framing of the wall substrate by stapling through the membrane, in particular through the lapped joints thereof.
Decision as to the proper lapping over of the membrane, the proper laps and the number of staple fixation points is left to the specialized on-site workmen. This often results into unappropriate fixation of the membrane and/or in unadequate covering of the exterior wall surface by the membrane.
As the polystyrene boards and the membrane are both breathable to the diffusion of water vapor conveyed from the inside to the outside, condensation within the wall structure is thereby prevented. However, when the membrane is not adequately applied on the exterior wall surface for any of the above reasons, air and moisture can penetrate into the wall to cause condensation and/or air infiltration inside of the wall and eventually inside of the house.
As the membrane is commonly available under the form of rolls, another problem is that application of this membrane on the exterior wall surface becomes very difficult 3~
in presence of h:ig~l winds. Moreover, hiyh wlnds can cause tearing of the lapped joints of the membrane during cons-truction.
OBJECT OF THE INVENTION
An object of the present invention is therefore to provide a laminated, thermal insulation panel and a thermal, wall insulation method which eliminate all of the above discussed drawbacks of the prior art.
SUMMARY OF THE INVENTION
More specifically, according to the present invention, there is provided a laminated, thermal insula-tion panel comprising:
a board made of expanded polystyrene permeable to water vapor;
a membrane laminated over one side of the poly-styrene board, which membrane presents imperviousness to air and moisture and permeability to water vapor; and an adhesive applied between the membrane and board for laminating the membrane on said one side of the polystyrene board, said adhesive being applied in a pattern to ensure permeability to water vapor and being compatible with both the polys-ty-rene of the board and the material constituting the membrane, so that the adhesive does not chemically attack the board polystyrene and the membrane material whereby the water vapor permeability of the board polystyrene and the membrane material as well as the air/moisture imperviousness of the membrane material are not affected by the adhesive.
Pre~erably, the membrane is made of non-woven, spunbonded olefin, and the board of expanded, molded poly-styrene.
9~7 In accordance with a preferred embod.iment of the laminated, insulation panel oE the inven-ti.on, the pattern is fo.nm~d by a plurality o:E s-trips o:E an adhesive co~lprising as elastomeri.c base a blend of polybutene and styrene-isoprene-styrene block copolymer, and as tackifying resins a blend of syn-thetic hydrocarbon resins and rosin esters.
In accordance with the present invention, there is further provided a method of thermally insulating the exterior walls of a construction, such as a residential house, comprising the steps of:
in-plant manufacturing laminated, thermal insu-lation panels each obtained by laminating a membrane over one side of a board made of expanded polystyrene, which board and membrane are both permeable to water vapor and which membrane is further impervious to air and moisture;
covering the outside of said walls with a plurality of said insulation panels with the membrane thereof at the exterior; and sealing the joints between adjacen-t ones of the panels with-an adhesive tape impervious to air and moisture, which tape comprising an adhesive surface applied on the membranes of the adjacent pa-nels.
Preferably, the tape comprises permanent acrylic adhesive with an oriented polypropylene backing.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects, advan-tages and other features of the present invention will become more apparent upon reading of the following non restrictive description of a preferred embodiment thereof, given in conjunction with the accompa-nying drawings in which:
Figure 1 illustrates the structure of a laminated, - 5 ~ 339~7 thermal insulation panel in accordance with the preserlt invention; and Figure 2 shows a method oE sealing ~he join-t between two adjacent insula-tion panels both having a struc-ture similar to that illustrated in Figure 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As illustrated in Figure 1, the laminated, thermal insulation panel comprises (a) a board 1 made of expanded, molded polystyrene of varying thickness which is permeable to water vapor, and ~b) a membrane 2 which is impervious to air and moisture, while being also permeable to water vapor. The membrane 2 is laminated over one side of the board 1 by means oE a suitable adhesive applied in a pattern, for example longi-tudinal strips 3 as shown in Figure 1, to ensure permeability to water vapor. The adhesive should of course be compatible with both the membrane 2 and the board 1, i.e. it does not attack chemi-cally these board and membrane whereby the water vapor permeability and the air/moisture imperviousness of the same are not affected by the adhesive.
Each of the board 1, the membrane 2 and the adhesive forming the strips 3 will now be described sepa-rately by means of their characteristics and/or composition.
Of course, the different elements forming the insulation panel have been selected for the best results, which selec-tion results from a wide experimentation.
The board 1 is advantageously composed of an expanded, molded polystyrene board. An example is the board of Type-l manufactured and commerciallzed under the trademark ISOLOFOAM
by the Applicant company " LES PRODUITS ISOLOFOAM INC." .
The board 1 can vary in thickness depending on the desired level of thermal insulation. Of course, the ISOLOFOAM board is permeable to water vapor.
Tests on a specimen oE ISOLOE'OAM expanded poly-styrelle board oE Type-l have ~iven the following results:
Average thickness: 36~8 mm Bulk density: 15.5 kg/m' Hot surEace temperature: 3~ 8 C
Cold surface temperature: 13.7 C
Temperature difference: 21.1 K
Mean temperature of test: 24.3 C
Heat f],ux (through the thickness): 21.52 W/m2 Thermal conductance: 1.020 W/(m2 K) Thermal resistance: 0.9~0 m2 K/W
Thermal conductivity: 0.0375 W/(m K) Thermal resistance by unit thickness: 26.6 m K/W
These tests were performed with the specimen placed horizontally in a 610 mm2 Heat Flow Meter Apparatus.
Heat flowed upwards through the specimen during testing.
Paper-backed glass fiber insulation was placed around the perimeter of the plates of the Heat Flow Meter Apparatus and of the specimen to reduce edge heat losses.
Additional tests carried out on a plurality of specimen 25 mm thick of ISOLOFOAM expanded, molded polysty-rene board of Type-l indicated the following results:
Average compressive strength: 80 kPa Average Flexural strength: 193 kPa 0 The membrane 2 is advantageously that manufac-tured andcommercialized by the company DUPONT CANADA under the trademark TYVEK. The TYVEK membrane is a sheet of Eine synthetic fibers. More specifically, it is composed of ~3~ ~7 non-woven, spunbonded olefill. As it i.s -totally synthetic, it does not shrink nor ro-t. :[t resis-ts to tear and puncture, it is permeable to water vapor but is impervious to air and mois-ture. It therefore constitutes an air/moisture barrier and accordingly an energy saving air barrier.
Some data given by the manufacturer concerning the TYVEK membrane are the following:
Water vapor transmission rate (g/100 in2 _ 24 hours~:51.30 Weight (lb/1000 ft2): 8.81 Rupture resistance (lb/in2): 105.00 Tearing resistance (lb) (lengthwise): 32.50 (transversal): 24.80 Porosity to the air - seconds: 7.60 Resistance to water (cm of water pressure): 99.30 Thickness (mils): 6.10 The adhesive pattern is formed, in the example of Figure 1, by a plurality of longitudinal strips 3 of the adhesive SWIFT # 68468 manufactured and commercialized by the company SWIFT adhesives, division of Reichhold Limited.
Some of its physical properties are the following:
ELASTOMERIC BASE: Blend of Polybutene and Styrene-Isoprene-Styrene block copolymer TACKIFYING RESINS: Blend of synthetic hydrocarbon resin and rosi.n esters VISCOSITY: 12 - 15 poise SOLIDS: 48 - 50~
FLASH POINT: - 18C (T.C.C.*) SPECIFIC GRAVITY: 0.84 g/cc * Abbreviation for Tag (actually Tagliabue) closed cup, ~g3~7 a type of flash point tes-t.
The SWIFT # 68468 adhesive is a solvent-base pressure-sensitive adhesive of the permanent type including a blend of synthetic rubber and of aliphatic/aromatic hydro-carbons in a solvent. It has been formulated expressly for applications requiring high peel strength and holding power. The adhesive exhibits high shear strength over a broad range of service temperatures as well as an aggressive tack to a wide variety of surfaces.
In order to laminate the TYVEK membrane 2 on the ISOLOFOAM polystyrene board of Type-l, it is not sufficient to think to use an adhesive to glue the mem-brane 2 on the board 1. Indeed, the following requirements must be taken into consideration:
- the adhesive must not attack chemically neither the membrane 2 nor the board 1 whereby these board and membrane keep their physical characteristics, i.e. the adhesive must be compatible with both the board 1 and mem-brane 2;
- the adhesive must be applied in a pattern to ensure permeability to water vapor in order to cause no reduc-tion in water vapor permeability of-the overall insulation panel; and - the adhesive must produce a suitable bond between the membrane 2 and board 1.
2S Accordingly, one can appreciate that the selec-tion of the adhesive cannot be effected without a great quantity of tests and experimentations. Laminating the membrane 2 on the board l is not an evident matter when it is desired to obtain an insulation panel having the appro-priate, desired characteristics.
The adhesive SWIFT # 68468 meets with these requirements as it is non chemically aggressive when con-fronted with the materials forming the board 1 and membrane 2 at temperatures under 70C. Accordingly, it bonds the 3~ 317 _ 9 _ two materials without altering their chemical or perEormance charac-teristics.
Moreover, the adhesive SWIFT # 68~6~ dries quickly. ~ccordingly, in the manufacture process, it is not required to speed up cure by subjecting it to -tempera-tures above 70C at which the adhesive attacks chemically the polystyrene of the board 1.
The selected adhesive provides a bond between the board 1 and membrane 2 strong enough that when the TYVEK
membrane is removed, it tends to remove the surface of the polystyrene of the board 1. This results into stability of laminate while slippage is not a problem. However, due to the strong adhesion, re-adhesion properties are poor.
It has been experimented that strips 3 of a width a = 12.7 mm lengthwise of the insulation panel at a distance b = 100 mm between the centers of each pair of adjacent strips 3 provide for good bond between the TYVEK
membrane 2 and the ISOLOFOAM board 1. Such a bond is strong enough to prevent delamination problems or flapping situa-tions.
A distance c = 3.2 mm is maintained between the ends of the strips 3 and the corresponding edge of the board 1, as well as between the outer strips 3 and the respective board edges.
Total covering of the surEace oE the board 1 with adhesive is not desirable due to potential negative effects on the water vapor transmission rate through the insulation panel.
It should also be pointed out that o-ther types of adhesive having similar characteristics can even-tually be used, for example pressure-sensitive adhesives including natural rubber, or moisture cured urethane, etc.
Figure 2 illustra-tes a method of sealing the joint 7 between two adjacent insulation panels 4 and 5 simi-33~7 lar to that of Figure l.
When the two panels 4 and S have been mounted side by side as illustrated in Figure 2 Eor coveri.ng the outside of an external wall o:E for example a residential house, a self-adhesive tape 6 is applied on the outer sur-face of -the two adjacent membranes 2 in order to seal the joint 7 between the panels 4 and 5. As the TYVEK membranes 2 and the tape 6 form a system permeable to water vapor but impervious to air and moisture, a surface presenting uniform characteristics results from the latter operation.
A self-adhesive tape suitable for the above purpose is that manufactured and commercialized under No.
Y 8086 by the company 3M CANADA INC. Such a tape is constituted of permanent acrylic adhesive with an oriented polypropylene backing.
Use of the laminated, thermal insulation panel in accordance with the present invention for externally covering the walls of for example a residential house results in the following advantages:
- the TYVEK membrane can be in-plant laminated mechanically and automatically. Before lamination, the strips 3 of adhesive is applied on the ISOLOFOAM board surface;
- the in-plant lamination of the insulation panel results in savings in labor costs;
- the TYVEK membrane 2 constitutes a durable exterior layer for the ISOLOFOAM board which improves the puncture resistance and the durability of the expanded po-lystyrene. The membrane also protects the polystyrene board against direct exposure to the elements during cons-truction. This enhances the quality of the final product;
- the TYVEK membrane greatly reduces air infil-tration through the wall structure from the outside and accordingly causes reduction in heating and cooling costs;
~293~17 - the TYVEK membrane additionally protects the inside of the walls and -the polystyrene board against wind--driven moisture from the outside. This, in particular, maintalns -the high thermal resistance value oE the polysty-rene whereby an energy eEficien-t insulation board is obtained;
- when boards as shown in Figure 1 are installed to cover the outside of for example a residential house, and using a self-adhesive tape 6 to seal the joints between these boards, an air and moisture tight overall envelope results as all the cracks and fissures are sealed; and - the use of a laminated, thermal insulation panel as illustrated in Figure 1 eliminates material losses due to wind damage and wide lapped joints (commonly 4 to 12 inches wide), eliminates any development of loose flaps being beaten and damaged by the action of strong winds, and eli-minates all the guesswork on the on-site membrane applica-tion and fixation by the workers. This of course results in an enhanced quality of the final product.
During tests carried out on an insulation panel as that shown in Figure 1 at pressure differences varying from 25 Pa to 250 Pa, no delamination of the membrane 2 was produced, and a reduction of 41~ of air leakage compared with a polystyrene board with no laminated membrane was observed.
During other tests on a specimen of insulation panel similar to that of Figure l, comprising a polystyrene board 1 50 mm thick, it was observed that both the adhesive and TYVEK membrane had no significant effect on the permea-bility of the Type-l ISOLOFOAM polystyrene board to water vapor.
By way of example, with a board 1 of 33 mm thick, and 47 mm thick, the thermal insulation provided by the laminated panel is respectively R 4.7 and R 7Ø
Last of all, it should be pointed out that the 1;2~3~17 mos-t important advantage oE the laminated, -thermal klsula-tion panel,according to the present lnvention,is that it constitutes a barrier to air and moisture Erom the outside to the inside, while it allows passage of water vapor from the inside to the outside, to thereby prevent any condensa-tion, moisture and air infiltration within or through the wall assembly.
Although the present invention has been des-cribed herein above by way of a preferred embodimen-t thereof, it should be pointed out that any modification to this pre-ferred embodiment, within the scope of the appended claims, is not deemed to change or alter the nature and scope of the present invention.
Claims (16)
1. A laminated, thermal insulation panel com-prising:
a board made of expanded polystyrene permeable to water vapor;
a membrane laminated over one side of the polystyrene board, said membrane presenting imperviousness to air and moisture and being permeable to water vapor; and an adhesive applied between said membrane and board for laminating said membrane on said one side of the polystyrene board, said adhesive being applied in a pattern to ensure permeability to water vapor and being compatible with both the poly-styrene of the board and the material constituting the membrane, so that the adhesive does not chemically attack the board polystyrene and the membrane material whereby the water vapor permeability of the board polystyrene and of the membrane material as well as the air/moisture imper-viousness of the membrane material are not affected by the adhesive.
a board made of expanded polystyrene permeable to water vapor;
a membrane laminated over one side of the polystyrene board, said membrane presenting imperviousness to air and moisture and being permeable to water vapor; and an adhesive applied between said membrane and board for laminating said membrane on said one side of the polystyrene board, said adhesive being applied in a pattern to ensure permeability to water vapor and being compatible with both the poly-styrene of the board and the material constituting the membrane, so that the adhesive does not chemically attack the board polystyrene and the membrane material whereby the water vapor permeability of the board polystyrene and of the membrane material as well as the air/moisture imper-viousness of the membrane material are not affected by the adhesive.
2. An insulation panel according to claim 1, wherein said membrane is composed of fine synthetic fibers.
3. An insulation panel according to claim 2, in which said membrane is made of non-woven, spunbonded olefin.
4. An insulation panel according to claim 1, wherein said board is made of expanded,molded polystyrene.
5. An insulation panel according to claim 1, wherein said adhesive is a pressure-sensitive adhesive.
6. An insulation panel according to claim 5, wherein said adhesive comprises a blend of synthetic rubber and of aliphatic/aromatic hydrocarbons in a solvent.
7. An insulation panel according to claim 5, in which said adhesive comprises natural rubber.
8. An insulation panel according to claim 5, wherein said adhesive comprises moisture cured urethane.
9. An insulation panel according to claim 1, wherein said pattern comprises a plurality of strips of said adhesive applied between the said membrane and polystyrene board.
10. An insulation panel according to claim 3, wherein said adhesive comprises as elastomeric base a blend of polybutene and styrene-isoprene-styrene block copolymer, and as tackifying resins, a blend of synthetic hydrocarbon resins and rosin esters.
11. An insulation panel according to claim 4, wherein the expanded polystyrene of said board has a bulk density of 15.5 kg/ml and a thermal resistance of 26.6 m °K/W.
12. A method of thermally insulating the ex-terior walls of a construction, such as a residential house, comprising the steps of:
in-plant manufacturing laminated, thermal insu-lation panels each obtained by laminating a membrane over one side of a board made of expanded polystyrene, said board and membrane being both permeable to water vapor and said membrane being further impervious to air and moisture;
covering the outside of said walls with a plu-rality of said insulation panels with the membrane thereof at the exterior; and sealing the joints between adjacent ones of said covering panels with an adhesive tape impervious to air and moisture, said tape comprising an adhesive surface applied on the membranes of said adjacent panels.
in-plant manufacturing laminated, thermal insu-lation panels each obtained by laminating a membrane over one side of a board made of expanded polystyrene, said board and membrane being both permeable to water vapor and said membrane being further impervious to air and moisture;
covering the outside of said walls with a plu-rality of said insulation panels with the membrane thereof at the exterior; and sealing the joints between adjacent ones of said covering panels with an adhesive tape impervious to air and moisture, said tape comprising an adhesive surface applied on the membranes of said adjacent panels.
13. An insulating method according to claim 12, wherein said tape comprises permanent acrylic adhesive with an oriented polypropylene backing.
14. An insulating method according to claim 12, wherein said membrane is composed of non-woven, spun-bonded olefin.
15. An insulating method according to claim 12, wherein said in-plant manufacturing step comprises applying between the membrane and the polystyrene board an adhesive, which adhesive is applied in a pattern to ensure permeability to water vapor and is compatible with both the polystyrene of the board and material of the membrane, so that the adhesive does not chemically attack the polystyrene of said board and the material of said membrane whereby the water vapor permeability of the board polystyrene and of the membrane material as well as the air/moisture impervious-ness of the membrane material are not affected by the adhe-sive.
16. An insulating method according to claim 15, wherein said pattern comprises a plurality of strips of said adhesive.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000566493A CA1293917C (en) | 1988-05-11 | 1988-05-11 | Laminated, thermal insulation panel |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000566493A CA1293917C (en) | 1988-05-11 | 1988-05-11 | Laminated, thermal insulation panel |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1293917C true CA1293917C (en) | 1992-01-07 |
Family
ID=4138007
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000566493A Expired - Lifetime CA1293917C (en) | 1988-05-11 | 1988-05-11 | Laminated, thermal insulation panel |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1293917C (en) |
-
1988
- 1988-05-11 CA CA000566493A patent/CA1293917C/en not_active Expired - Lifetime
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