CA2147443A1 - Duct liner with pre-applied adhesive and the method of making the same - Google Patents
Duct liner with pre-applied adhesive and the method of making the sameInfo
- Publication number
- CA2147443A1 CA2147443A1 CA 2147443 CA2147443A CA2147443A1 CA 2147443 A1 CA2147443 A1 CA 2147443A1 CA 2147443 CA2147443 CA 2147443 CA 2147443 A CA2147443 A CA 2147443A CA 2147443 A1 CA2147443 A1 CA 2147443A1
- Authority
- CA
- Canada
- Prior art keywords
- major surface
- adhesive
- fibrous insulation
- wrap
- duct
- 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.)
- Abandoned
Links
- 239000000853 adhesive Substances 0.000 title claims abstract description 77
- 230000001070 adhesive effect Effects 0.000 title claims abstract description 77
- 238000004519 manufacturing process Methods 0.000 title claims description 12
- 239000002184 metal Substances 0.000 claims abstract description 40
- 238000009413 insulation Methods 0.000 claims abstract description 35
- 239000011248 coating agent Substances 0.000 claims abstract description 21
- 238000000576 coating method Methods 0.000 claims abstract description 21
- 239000000428 dust Substances 0.000 claims abstract description 10
- 239000000835 fiber Substances 0.000 claims abstract description 9
- 230000004888 barrier function Effects 0.000 claims abstract description 7
- 239000003365 glass fiber Substances 0.000 claims description 34
- 238000000034 method Methods 0.000 claims description 11
- 239000004820 Pressure-sensitive adhesive Substances 0.000 claims description 5
- 239000002655 kraft paper Substances 0.000 claims description 2
- 238000009833 condensation Methods 0.000 claims 2
- 230000005494 condensation Effects 0.000 claims 2
- 239000010410 layer Substances 0.000 description 9
- 230000006835 compression Effects 0.000 description 7
- 238000007906 compression Methods 0.000 description 7
- 239000000123 paper Substances 0.000 description 6
- 238000004378 air conditioning Methods 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- 239000002085 irritant Substances 0.000 description 3
- 231100000021 irritant Toxicity 0.000 description 3
- 239000012790 adhesive layer Substances 0.000 description 2
- 241000252203 Clupea harengus Species 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 210000000988 bone and bone Anatomy 0.000 description 1
- 238000000151 deposition Methods 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 235000019514 herring Nutrition 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 239000004816 latex Substances 0.000 description 1
- 229920000126 latex Polymers 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- JTJMJGYZQZDUJJ-UHFFFAOYSA-N phencyclidine Chemical compound C1CCCCN1C1(C=2C=CC=CC=2)CCCCC1 JTJMJGYZQZDUJJ-UHFFFAOYSA-N 0.000 description 1
- 229920001084 poly(chloroprene) Polymers 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 229920001296 polysiloxane Polymers 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 239000004575 stone Substances 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
- F24F13/00—Details common to, or for air-conditioning, air-humidification, ventilation or use of air currents for screening
- F24F13/02—Ducting arrangements
- F24F13/0263—Insulation for air ducts
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
- F24F13/00—Details common to, or for air-conditioning, air-humidification, ventilation or use of air currents for screening
- F24F13/02—Ducting arrangements
- F24F13/0245—Manufacturing or assembly of air ducts; Methods therefor
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
- F24F13/00—Details common to, or for air-conditioning, air-humidification, ventilation or use of air currents for screening
- F24F13/02—Ducting arrangements
- F24F13/0281—Multilayer duct
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Combustion & Propulsion (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Duct Arrangements (AREA)
- Laminated Bodies (AREA)
Abstract
A fibrous insulation duct wrap for application to an exterior surface of a sheet metal air duct or to a sheet metal strip that is formed into a sheet metal air duct comprises first and second major surfaces. The first major surface of the duct wrap has a vapor impermeable facing adhered thereto to provide a vapor barrier to prevent moisture from condensing on the air duct. The second major surface has an adhesive coating for adhering the duct wrap to the air duct. and to encapsulate loose fibers and dust within said second major surface. The adhesive coating is covered by a separable release sheet which, in conjunction with the adhesive, encapsulates fibers and dust within the second major surface. The release sheet is removed immediately prior to applying the duct wrap to the sheet metal.
The adhesive coating is applied to the second major surface of the duct wrap by applying the release sheet, already coated with the adhesive, to the surface.
The adhesive coating is applied to the second major surface of the duct wrap by applying the release sheet, already coated with the adhesive, to the surface.
Description
21~7~43 DUCT ~RAP ~IT~ PRB-APPLIED ADaE8IVE
AND T~E MBT~OD OF MARIN~ T B SAX~
R~ UND OF T~B INVENTION
The present invention is directed to a fibrous insulation duct wrap for sheet metal air ducts and, in particular, to a fibrous insulation duct wrap with a pre-applied adhesive on one major surface which provides a means for adhering the duct wrap to the exterior surface of a sheet metal air duct.
A relatively low density (e.g. 3/4 pound/cubic foot) layer of glass fiber insulation is commonly used as a duct wrap to insulate sheet metal ductwork in heating, ventilating and air conditioning systems. The duct wrap insulates the ductwork to conserve energy and to maintain the air within the ductwork within a desired temperature range. In addition the duct wrap is typically provided with a vapor impermeable exterior facing sheet which functions as a vapor barrier to prevent moisture from condensing on the surface of the sheet metal air duct.
The glass fiber insulation duct wrap is normally sold in roll form to both heating, ventilating and air conditioning contractors and insulation contractors who fabricate and install 2S the ductwork. The glass fiber insulation duct wrap in these rolls is typically about 100 feet in length and come in st~n~rd widths ranging from 2 to 4 feet. The contractors presently fabricate the sheet metal ductwork and then, apply the duct wrap to the exterior surface of the ductwork. The glass fiber duct wrap is applied to the exterior surface of the ductwork by wrapping the duct wrap around the ductwork and then pinnin~ the duct wrap onto the exterior surface of the ductwork at the job site. Sections of the glass fiber duct wrap are then stapled to adjacent sections of the duct wrap and the resultant seam is taped to maintain a vapor barrier.
This method of applying the duct wrap to the sheet metal ductwork requires the contractor to have an inventory of pins and staples at the job site. In addition, this method of applying the duct wrap at the job site adds to the ductwork fabrication and installation procedures required at the job site and requires the contractor to incur labor costs associated with the wrapping, pinning, stapling and taping of the duct wrap at the job site.
Thus, there has been a need to simplify the contractor's fabricating operations at the job site, and to reduce the contractor's fabrication costs.
8~MNARY OF THE I~VE~TIO~
The present invention provides a glass fiber insulation duct wrap, with a pre-applied adhesive, which solves the problems of the prior art. The glass fiber insulation duct wrap of the present invention insulates the sheet metal ductwork to con~rve energy and to maintain the temperature of the air stream within the ductwork within a desired temperature range.
The duct wrap has a first major surface that is preferably covered with a vapor impermeable facing sheet that provides a vapor barrier to prevent moisture from condensing on the surface of the sheet metal ductwork. The vapor impermeable facing sheet also encapsulates loose fibers and dust, which can be an irritant, within the first major surface of the duct wrap.
The second major surface of the glass fiber insulation duct wrap has a pre-applied adhesive coating thereon which provides a means for bonding the duct wrap to the exterior surface of the sheet metal duct work at the job site or to a sheet metal strip that is formed by the ductwork fabricating contractor into the air duct at a fabrication job shop.
In the preferred method of the present invention, the duct wrap is applied and bonded to a sheet metal strip at the fabrication job shop. The sheet metal strip, with the duct wrap already adhered thereto, is then formed into the ductwork at the fabrication job shop.
The adhesive coating on the second major surface of the duct wrap is covered by a release sheet until immediately prior to the application of the duct liner to the sheet metal strip or the _ 2147443 exterior surface of the ductwork. Accordingly, the adhesive coating and the release sheet also function to encapsulate loose fibers and dust, which can be an irritant, within the second major surface of the duct wrap during handling, shipping and application of the duct wrap. Once the release sheet is removed from the second major surface of the duct wrap, the duct wrap is laid on and pressed against the sheet metal strip or the exterior surface of the ductwork to bond the duct wrap to the sheet metal.
Since the surface of the glass fiber insulation duct wrap is very permeable, spray coating the second major surface with adhesive would waste considerable amounts of adhesive that would pass on down into the duct wrap. Accordingly, in the present invention, the coating of adhesive is applied to the second major surface of the duct wrap by applying the release sheet, already coated with the adhesive, to the second major surface of the duct wrap in an on-line operation during the manufacture of the duct wrap. After the adhesive coated release sheet is applied to the duct wrap, the duct wrap is wound into a roll for shipment to either the heating, ventilating and air conditioning contractor or the insulation contractor.
BRIEF D~8rPTPTION OF THE DRA~ING8 FIG. 1 is a schematic side elevation of a duct wrap facing application station, an adhesive application station and a wind-up station of the duct wrap manufacturing line of the present invention.
FIG. 2 is a schematic side elevation of a second embodiment of the adhesive application station of the present invention.
FIG. 3 is a schematic side elevation of an automated duct wrap application station of the present invention.
FIG. 4 is a transverse cross section of the glass fiber insulation duct wrap of the present invention.
FIG. 5 is a transverse cross section of a sheet metal air duct wrapped with the glass fiber insulation duct wrap of the present invention.
21~7443 DB8CRIPTION OF T~ PREFI~RRED E:~SBODl~S~
FIG. 1 illustrates an on-line method of and apparatus for applying a facing sheet to a first major surface 22 of a glass fiber blanket 20 and for applying an adhesive coating with a release sheet to a second major surface 24 of the glass fiber blanket to form a duct wrap 26. The glass fiber blanket 20 is fed from a fiberizing and blanket forming and curing station (not shown) of the production line into a facing application station 28 of the production line.
In the facing application station 28 a facing sheet 30 is adhesively bonded to the first major surface 22 of the glass fiber blanket 20. The facing sheet 30 is typically a vapor impermeable, foil-scrim-kraft laminate, such as, the facing disclosed in U.S. patent no. 3,318,063; issued May 9, 1967; to Stone et al; the disclosure of which is hereby incorporated herein in its entirety by reference; a foil-scrim facing, such as, the facing disclosed in U.S. patent no. 3,837,992; issued September 24, 1974; to Sherman et al; the disclosure of which is hereby incorporated herein in its entirety by reference, or a similar, commercially available, vapor impermeable facing. The facing sheet 30 is fed from a supply roll 32 past adhesive application nozzles 34 which apply an adhesive 36 to the entire surface 38 of the facing sheet. After the adhesive 36 is applied to the facing sheet 30, the facing sheet passes under roll 40 and between compression rolls 42 and 44 where it is pressed against and bonded to the upper major surface 22 of the glass fiber blanket 20 which is also fed between the compression rolls. From the facing application station 28, the glass fiber blanket, with the facing sheet 30 laminated thereto, passes through a conventional adhesive drying oven 45 and into the adhesive application station 46 where adhesive is applied to the F~conA
major surface 24 of the glass fiber blanket to complete the manufacture of the duct wrap 26.
In the adhesive application station 46, a sheet of release paper 48, such as, a silicone treated paper, is fed from a release paper supply roll 50 past adhesive application nozzles 21~7~43 52. As shown in FIG. 1, the adhesive application nozzles 52, which in one embodiment extend across the entire width of the release paper, apply the adhesive 54 onto one major surface 56 of the release sheet thereby coating the entire surface 56 with adhesive. Thus, when the release sheet is laminated to the surface 24 of the glass fiber blanket 20, the adhesive 56 will be applied to the entire surface. In another embodiment of the invention, the nozzles can be shut off or eliminated at certain locations across the width of the release sheet 48 to form longitudinally extending areas on the release sheet that have no adhesive. For example, longitudinally ext~A;ng areas or strips of adhesive can be applied on the central portion and adjacent the lateral edges of the surface 56 by shutting off certain nozzles 52 in the areas where no adhesive is desired. Thus, when the release sheet is laminated to the surface 24 of the glass fiber blanket 20, the adhesive will only be applied to the surface 24 in a longitudinally extending central region and along the lateral edges. The adhesive can be a commercially available, pressure sensitive, water based, latex polymer adhesive, such as an acrylic or neoprene adhesive.
The sheet of release paper 48 with the surface 56 coated with adhesive, as described above, and the glass fiber blanket 20 are brought into contact with each other by passing the release sheet and the glass fiber blanket between compression rolls 58 and 60. As the adhesive coated release sheet 48 passes over roll 58, the release sheet is pressed against the second major surface 24 of the glass fiber blanket 20 laminating the adhesive coated release sheet to the glass fiber blanket, depositing the adhesive on the second major surface 24 and completing the formation of the duct wrap 26. The width of the release sheet 48 Gorresponds to the width of the glass fiber blanket 20. Accordingly, the release sheet completely covers the surface 24 of the glass fiber blanket and applies a layer or coating 62 of the adhesive to the entire surface 24 of the glass fiber blanket, when fully coated with the adhesive, or in spaced longitudinally ext~n~ing strips, when coated in spaced longitudinally extending areas with the adhesive. The release 21~7143 -sheet 48 and the adhesive coating or layer 62 encapsulate fibers and dust within the surface 24 and, when the release sheet 48 is removed, provide a means to adhere the duct wrap 26 to sheet metal. The duct wrap 26, with the release sheet 48 laminated thereto, is wound onto a take-up roll 64 in stAn~rd lengths of typically 100 feet and is ready for shipment to the ductwork fabricating contractor. When needed, an infrared heater 66 can be used to drive off excess moisture from the adhesive layer 62 before the duct wrap 26 is wound into the roll.
FIG. 2 shows an alternative embodiment of the method and apparatus of the present invention for applying the adhesive 54 to the surface 56 of the release sheet 48. Instead of the nozzles 52, an application roll 68, having the same width as the release sheet, is used in conjunction with a backing roll to apply a layer or coating 62 of adhesive on the surface 56 of the release sheet 48. The application roll 68 is coated with the adhesive 54 from an adhesive reservoir 70 by means of a transfer roll 72 which is partially immersed in the adhesive within the reservoir 70. The application roll 68 can have a smooth cylindrical application surface for its entire width; several raised cylindrical application surfaces across its width, e.g.
a raised central portion and two raised lateral edge portions;
or raised portions having specific patterns, such as, a herring bone pattern. Once the adhesive 54 is applied to the surface 56 of the release sheet 48, the adhesive is transferred to the major surface 24 of the glass fiber blanket 20 in the same manner discussed above in connection with the embodiment illustrated in FIG. 1.
Under certain circumstances, rather than applying the adhesive to the release sheet in an on-line operation, as described above, it is contemplated that the release sheet could be coated with an adhesive in an off-line operation or purchA~^~
already coated with adhesive from a supplier.
As shown in FIG. 4, the duct wrap 26 comprises a layer of glass fiber insulation 20 with one major surface 22 completely covered by a vapor impermeable facing sheet 30 which functions as a vapor barrier and to encapsulate glass fibers and/or dust 21~7~43 within the surface 22. The other major surface 24 is completely or partially coated with an adhesive coating or layer 62 which is used to adhere the duct wrap to a sheet metal duct. A sheet of release paper 48 overlays the adhesive layer 62 and covers the entire major surface 24 of the duct wrap 26. The adhesive coating 62 and the release sheet 48 also function to encapsulate loose fibers and dust, which can be irritants, within the surface 24 prior to the bonding of the duct wrap 26 to the sheet metal strip or the exterior surface of the air duct.
When the ductwork fabricating contractor fabricates an externally insulated air duct 74, the contractor merely strips the release sheet from the duct wrap 26, leaving the adhesive coating or layer 62 on the surface of the duct wrap, and applies the duct wrap to the sheet metal strip 76 or to the exterior surface of the ductwork or air duct 74. The layer 62 of adhesive bonds the duct wrap 26 to the sheet metal strip 76 which can then be formed into the air duct 74 or to the exterior surface of the previously fabricated ductwork.
FIG. 3 illustrates a method and apparatus for applying the duct wrap 26 of the present invention to the sheet metal strip 76. The sheet metal strip 76 is fed between a pair of compression rolls 78 and 80 from a supply roll 82. The duct wrap 26 is also fed between the compression rolls 78 and 80 from a supply roll 84. The release sheet 48 is stripped from the surface 24 of the duct wrap 26 and wound onto a roll 86, exposing the layer of adhesive 62, immediately before the duct wrap pA~
between the compression rolls 78 and 80. As the duct wrap 26 and the sheet metal strip 76 pass between the compression rolls 78 and 80, the duct wrap and sheet metal strip are pressed together causing the pressure sensitive adhesive to adhere the duct wrap to the sheet metal strip. After the duct wrap is bonded to the sheet metal strip, the sheet metal strip can be fabricated into the ductwork or air duct 74 by conventional fabricating apparatus (not shown).
In describing the invention, certain embodiments have been used to illustrate the invention and the practices thereof.
However, the invention is not limited to these specific 21~7443 embodiments as other embodiments and modifications within the spirit of the invention will readily occur to those skilled in the art on reading this specification. Thus, the invention is not intended to be limited to the specific embodiments disclosed, S but is to be limited only by the claims appended hereto.
AND T~E MBT~OD OF MARIN~ T B SAX~
R~ UND OF T~B INVENTION
The present invention is directed to a fibrous insulation duct wrap for sheet metal air ducts and, in particular, to a fibrous insulation duct wrap with a pre-applied adhesive on one major surface which provides a means for adhering the duct wrap to the exterior surface of a sheet metal air duct.
A relatively low density (e.g. 3/4 pound/cubic foot) layer of glass fiber insulation is commonly used as a duct wrap to insulate sheet metal ductwork in heating, ventilating and air conditioning systems. The duct wrap insulates the ductwork to conserve energy and to maintain the air within the ductwork within a desired temperature range. In addition the duct wrap is typically provided with a vapor impermeable exterior facing sheet which functions as a vapor barrier to prevent moisture from condensing on the surface of the sheet metal air duct.
The glass fiber insulation duct wrap is normally sold in roll form to both heating, ventilating and air conditioning contractors and insulation contractors who fabricate and install 2S the ductwork. The glass fiber insulation duct wrap in these rolls is typically about 100 feet in length and come in st~n~rd widths ranging from 2 to 4 feet. The contractors presently fabricate the sheet metal ductwork and then, apply the duct wrap to the exterior surface of the ductwork. The glass fiber duct wrap is applied to the exterior surface of the ductwork by wrapping the duct wrap around the ductwork and then pinnin~ the duct wrap onto the exterior surface of the ductwork at the job site. Sections of the glass fiber duct wrap are then stapled to adjacent sections of the duct wrap and the resultant seam is taped to maintain a vapor barrier.
This method of applying the duct wrap to the sheet metal ductwork requires the contractor to have an inventory of pins and staples at the job site. In addition, this method of applying the duct wrap at the job site adds to the ductwork fabrication and installation procedures required at the job site and requires the contractor to incur labor costs associated with the wrapping, pinning, stapling and taping of the duct wrap at the job site.
Thus, there has been a need to simplify the contractor's fabricating operations at the job site, and to reduce the contractor's fabrication costs.
8~MNARY OF THE I~VE~TIO~
The present invention provides a glass fiber insulation duct wrap, with a pre-applied adhesive, which solves the problems of the prior art. The glass fiber insulation duct wrap of the present invention insulates the sheet metal ductwork to con~rve energy and to maintain the temperature of the air stream within the ductwork within a desired temperature range.
The duct wrap has a first major surface that is preferably covered with a vapor impermeable facing sheet that provides a vapor barrier to prevent moisture from condensing on the surface of the sheet metal ductwork. The vapor impermeable facing sheet also encapsulates loose fibers and dust, which can be an irritant, within the first major surface of the duct wrap.
The second major surface of the glass fiber insulation duct wrap has a pre-applied adhesive coating thereon which provides a means for bonding the duct wrap to the exterior surface of the sheet metal duct work at the job site or to a sheet metal strip that is formed by the ductwork fabricating contractor into the air duct at a fabrication job shop.
In the preferred method of the present invention, the duct wrap is applied and bonded to a sheet metal strip at the fabrication job shop. The sheet metal strip, with the duct wrap already adhered thereto, is then formed into the ductwork at the fabrication job shop.
The adhesive coating on the second major surface of the duct wrap is covered by a release sheet until immediately prior to the application of the duct liner to the sheet metal strip or the _ 2147443 exterior surface of the ductwork. Accordingly, the adhesive coating and the release sheet also function to encapsulate loose fibers and dust, which can be an irritant, within the second major surface of the duct wrap during handling, shipping and application of the duct wrap. Once the release sheet is removed from the second major surface of the duct wrap, the duct wrap is laid on and pressed against the sheet metal strip or the exterior surface of the ductwork to bond the duct wrap to the sheet metal.
Since the surface of the glass fiber insulation duct wrap is very permeable, spray coating the second major surface with adhesive would waste considerable amounts of adhesive that would pass on down into the duct wrap. Accordingly, in the present invention, the coating of adhesive is applied to the second major surface of the duct wrap by applying the release sheet, already coated with the adhesive, to the second major surface of the duct wrap in an on-line operation during the manufacture of the duct wrap. After the adhesive coated release sheet is applied to the duct wrap, the duct wrap is wound into a roll for shipment to either the heating, ventilating and air conditioning contractor or the insulation contractor.
BRIEF D~8rPTPTION OF THE DRA~ING8 FIG. 1 is a schematic side elevation of a duct wrap facing application station, an adhesive application station and a wind-up station of the duct wrap manufacturing line of the present invention.
FIG. 2 is a schematic side elevation of a second embodiment of the adhesive application station of the present invention.
FIG. 3 is a schematic side elevation of an automated duct wrap application station of the present invention.
FIG. 4 is a transverse cross section of the glass fiber insulation duct wrap of the present invention.
FIG. 5 is a transverse cross section of a sheet metal air duct wrapped with the glass fiber insulation duct wrap of the present invention.
21~7443 DB8CRIPTION OF T~ PREFI~RRED E:~SBODl~S~
FIG. 1 illustrates an on-line method of and apparatus for applying a facing sheet to a first major surface 22 of a glass fiber blanket 20 and for applying an adhesive coating with a release sheet to a second major surface 24 of the glass fiber blanket to form a duct wrap 26. The glass fiber blanket 20 is fed from a fiberizing and blanket forming and curing station (not shown) of the production line into a facing application station 28 of the production line.
In the facing application station 28 a facing sheet 30 is adhesively bonded to the first major surface 22 of the glass fiber blanket 20. The facing sheet 30 is typically a vapor impermeable, foil-scrim-kraft laminate, such as, the facing disclosed in U.S. patent no. 3,318,063; issued May 9, 1967; to Stone et al; the disclosure of which is hereby incorporated herein in its entirety by reference; a foil-scrim facing, such as, the facing disclosed in U.S. patent no. 3,837,992; issued September 24, 1974; to Sherman et al; the disclosure of which is hereby incorporated herein in its entirety by reference, or a similar, commercially available, vapor impermeable facing. The facing sheet 30 is fed from a supply roll 32 past adhesive application nozzles 34 which apply an adhesive 36 to the entire surface 38 of the facing sheet. After the adhesive 36 is applied to the facing sheet 30, the facing sheet passes under roll 40 and between compression rolls 42 and 44 where it is pressed against and bonded to the upper major surface 22 of the glass fiber blanket 20 which is also fed between the compression rolls. From the facing application station 28, the glass fiber blanket, with the facing sheet 30 laminated thereto, passes through a conventional adhesive drying oven 45 and into the adhesive application station 46 where adhesive is applied to the F~conA
major surface 24 of the glass fiber blanket to complete the manufacture of the duct wrap 26.
In the adhesive application station 46, a sheet of release paper 48, such as, a silicone treated paper, is fed from a release paper supply roll 50 past adhesive application nozzles 21~7~43 52. As shown in FIG. 1, the adhesive application nozzles 52, which in one embodiment extend across the entire width of the release paper, apply the adhesive 54 onto one major surface 56 of the release sheet thereby coating the entire surface 56 with adhesive. Thus, when the release sheet is laminated to the surface 24 of the glass fiber blanket 20, the adhesive 56 will be applied to the entire surface. In another embodiment of the invention, the nozzles can be shut off or eliminated at certain locations across the width of the release sheet 48 to form longitudinally extending areas on the release sheet that have no adhesive. For example, longitudinally ext~A;ng areas or strips of adhesive can be applied on the central portion and adjacent the lateral edges of the surface 56 by shutting off certain nozzles 52 in the areas where no adhesive is desired. Thus, when the release sheet is laminated to the surface 24 of the glass fiber blanket 20, the adhesive will only be applied to the surface 24 in a longitudinally extending central region and along the lateral edges. The adhesive can be a commercially available, pressure sensitive, water based, latex polymer adhesive, such as an acrylic or neoprene adhesive.
The sheet of release paper 48 with the surface 56 coated with adhesive, as described above, and the glass fiber blanket 20 are brought into contact with each other by passing the release sheet and the glass fiber blanket between compression rolls 58 and 60. As the adhesive coated release sheet 48 passes over roll 58, the release sheet is pressed against the second major surface 24 of the glass fiber blanket 20 laminating the adhesive coated release sheet to the glass fiber blanket, depositing the adhesive on the second major surface 24 and completing the formation of the duct wrap 26. The width of the release sheet 48 Gorresponds to the width of the glass fiber blanket 20. Accordingly, the release sheet completely covers the surface 24 of the glass fiber blanket and applies a layer or coating 62 of the adhesive to the entire surface 24 of the glass fiber blanket, when fully coated with the adhesive, or in spaced longitudinally ext~n~ing strips, when coated in spaced longitudinally extending areas with the adhesive. The release 21~7143 -sheet 48 and the adhesive coating or layer 62 encapsulate fibers and dust within the surface 24 and, when the release sheet 48 is removed, provide a means to adhere the duct wrap 26 to sheet metal. The duct wrap 26, with the release sheet 48 laminated thereto, is wound onto a take-up roll 64 in stAn~rd lengths of typically 100 feet and is ready for shipment to the ductwork fabricating contractor. When needed, an infrared heater 66 can be used to drive off excess moisture from the adhesive layer 62 before the duct wrap 26 is wound into the roll.
FIG. 2 shows an alternative embodiment of the method and apparatus of the present invention for applying the adhesive 54 to the surface 56 of the release sheet 48. Instead of the nozzles 52, an application roll 68, having the same width as the release sheet, is used in conjunction with a backing roll to apply a layer or coating 62 of adhesive on the surface 56 of the release sheet 48. The application roll 68 is coated with the adhesive 54 from an adhesive reservoir 70 by means of a transfer roll 72 which is partially immersed in the adhesive within the reservoir 70. The application roll 68 can have a smooth cylindrical application surface for its entire width; several raised cylindrical application surfaces across its width, e.g.
a raised central portion and two raised lateral edge portions;
or raised portions having specific patterns, such as, a herring bone pattern. Once the adhesive 54 is applied to the surface 56 of the release sheet 48, the adhesive is transferred to the major surface 24 of the glass fiber blanket 20 in the same manner discussed above in connection with the embodiment illustrated in FIG. 1.
Under certain circumstances, rather than applying the adhesive to the release sheet in an on-line operation, as described above, it is contemplated that the release sheet could be coated with an adhesive in an off-line operation or purchA~^~
already coated with adhesive from a supplier.
As shown in FIG. 4, the duct wrap 26 comprises a layer of glass fiber insulation 20 with one major surface 22 completely covered by a vapor impermeable facing sheet 30 which functions as a vapor barrier and to encapsulate glass fibers and/or dust 21~7~43 within the surface 22. The other major surface 24 is completely or partially coated with an adhesive coating or layer 62 which is used to adhere the duct wrap to a sheet metal duct. A sheet of release paper 48 overlays the adhesive layer 62 and covers the entire major surface 24 of the duct wrap 26. The adhesive coating 62 and the release sheet 48 also function to encapsulate loose fibers and dust, which can be irritants, within the surface 24 prior to the bonding of the duct wrap 26 to the sheet metal strip or the exterior surface of the air duct.
When the ductwork fabricating contractor fabricates an externally insulated air duct 74, the contractor merely strips the release sheet from the duct wrap 26, leaving the adhesive coating or layer 62 on the surface of the duct wrap, and applies the duct wrap to the sheet metal strip 76 or to the exterior surface of the ductwork or air duct 74. The layer 62 of adhesive bonds the duct wrap 26 to the sheet metal strip 76 which can then be formed into the air duct 74 or to the exterior surface of the previously fabricated ductwork.
FIG. 3 illustrates a method and apparatus for applying the duct wrap 26 of the present invention to the sheet metal strip 76. The sheet metal strip 76 is fed between a pair of compression rolls 78 and 80 from a supply roll 82. The duct wrap 26 is also fed between the compression rolls 78 and 80 from a supply roll 84. The release sheet 48 is stripped from the surface 24 of the duct wrap 26 and wound onto a roll 86, exposing the layer of adhesive 62, immediately before the duct wrap pA~
between the compression rolls 78 and 80. As the duct wrap 26 and the sheet metal strip 76 pass between the compression rolls 78 and 80, the duct wrap and sheet metal strip are pressed together causing the pressure sensitive adhesive to adhere the duct wrap to the sheet metal strip. After the duct wrap is bonded to the sheet metal strip, the sheet metal strip can be fabricated into the ductwork or air duct 74 by conventional fabricating apparatus (not shown).
In describing the invention, certain embodiments have been used to illustrate the invention and the practices thereof.
However, the invention is not limited to these specific 21~7443 embodiments as other embodiments and modifications within the spirit of the invention will readily occur to those skilled in the art on reading this specification. Thus, the invention is not intended to be limited to the specific embodiments disclosed, S but is to be limited only by the claims appended hereto.
Claims (17)
1. A fibrous insulation duct wrap for application on an exterior surface of a sheet metal air duct comprising:
a blanket of fibrous insulation having a first substantially planar major surface and a second substantially planar major surface; said first major surface having a vapor impermeable facing sheet adhesively bonded thereto which functions as a vapor barrier to prevent the condensation of vapor on an exterior surface of a sheet metal air duct and encapsulates fibers and dust within said first major surface; said second major surface having an adhesive coating thereon for adhering said fibrous insulation duct wrap to an exterior surface of a sheet metal air duct; and a release sheet covering and separable from said adhesive coating which in conjunction with the adhesive coating encapsulates fibers and dust within said second major surface and is removed immediately prior to application of the fibrous insulation duct wrap to an exterior surface of a sheet metal air duct.
a blanket of fibrous insulation having a first substantially planar major surface and a second substantially planar major surface; said first major surface having a vapor impermeable facing sheet adhesively bonded thereto which functions as a vapor barrier to prevent the condensation of vapor on an exterior surface of a sheet metal air duct and encapsulates fibers and dust within said first major surface; said second major surface having an adhesive coating thereon for adhering said fibrous insulation duct wrap to an exterior surface of a sheet metal air duct; and a release sheet covering and separable from said adhesive coating which in conjunction with the adhesive coating encapsulates fibers and dust within said second major surface and is removed immediately prior to application of the fibrous insulation duct wrap to an exterior surface of a sheet metal air duct.
2. The fibrous insulation duct wrap of claim 1, wherein:
said adhesive coating and said release sheet are substantially coextensive with said second major surface.
said adhesive coating and said release sheet are substantially coextensive with said second major surface.
3. The fibrous insulation duct wrap of claim 2, wherein:
said adhesive is a pressure sensitive adhesive.
said adhesive is a pressure sensitive adhesive.
4. The fibrous insulation duct wrap of claim 3, wherein:
said blanket of fibrous insulation is a glass fiber blanket.
said blanket of fibrous insulation is a glass fiber blanket.
5. The fibrous insulation duct wrap of claim 1, wherein:
portions of said second major surface are free of said adhesive coating and said release sheet is substantially coextensive with said second major surface.
portions of said second major surface are free of said adhesive coating and said release sheet is substantially coextensive with said second major surface.
6. The fibrous insulation duct wrap of claim 5, wherein:
said adhesive is a pressure sensitive adhesive.
said adhesive is a pressure sensitive adhesive.
7. The fibrous insulation duct wrap of claim 6, wherein:
said blanket of fibrous insulation is a glass fiber blanket.
said blanket of fibrous insulation is a glass fiber blanket.
8. The fibrous insulation duct wrap of claim 1, wherein:
said adhesive coating covers a longitudinally extending central portion and lateral edge portions of said second major surface;
and said release sheet is substantially coextensive with said second major surface.
said adhesive coating covers a longitudinally extending central portion and lateral edge portions of said second major surface;
and said release sheet is substantially coextensive with said second major surface.
9. The fibrous insulation duct wrap of claim 8, wherein:
said adhesive ia a pressure sensitive adhesive.
said adhesive ia a pressure sensitive adhesive.
10. The fibrous insulation duct wrap of claim 9, wherein:
said blanket of fibrous insulation is a glass fiber blanket.
said blanket of fibrous insulation is a glass fiber blanket.
11. The fibrous insulation duct wrap of claim 1, wherein:
said vapor impermeable facing is a foil-scrim-kraft facing.
said vapor impermeable facing is a foil-scrim-kraft facing.
12. A method of making a fibrous insulation duct wrap for the exterior surface of a sheet metal air duct comprising:
providing a blanket of fibrous insulation having a first major surface and a second major surface; adhesively bonding a vapor impermeable facing sheet to said first major surface to encapsulate fibers and dust within said first major surface and provide a vapor barrier to prevent the condensation of moisture on a sheet metal air duct; and applying an adhesive to said second major surface by applying a release sheet coated on one major surface with the adhesive to said second major surface to provide a means for adhering said fibrous insulation duct wrap to a sheet metal air duct by removing said release sheet from said second major surface, exposing said adhesive on said second major surface and laying said second major surface on the sheet metal air duct.
providing a blanket of fibrous insulation having a first major surface and a second major surface; adhesively bonding a vapor impermeable facing sheet to said first major surface to encapsulate fibers and dust within said first major surface and provide a vapor barrier to prevent the condensation of moisture on a sheet metal air duct; and applying an adhesive to said second major surface by applying a release sheet coated on one major surface with the adhesive to said second major surface to provide a means for adhering said fibrous insulation duct wrap to a sheet metal air duct by removing said release sheet from said second major surface, exposing said adhesive on said second major surface and laying said second major surface on the sheet metal air duct.
13. The method of claim 12, including: applying said adhesive to said major surface of said release sheet immediately prior to applying said release sheet to said second major surface.
14. The method of claim 13, including: applying said adhesive to cover substantially all of said major surface of said release sheet.
15. The method of claim 14, wherein: said adhesive is a pressure sensitive adhesive.
16. The method of claim 15, wherein: said fibrous blanket is a glass fiber blanket.
17. The method of claim 13, including: applying said adhesive to cover a central longitudinally extending portion and lateral edge portions of said major surface of said release sheet.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US23293194A | 1994-04-22 | 1994-04-22 | |
| US08/232,931 | 1994-04-22 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2147443A1 true CA2147443A1 (en) | 1995-10-23 |
Family
ID=22875169
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2147443 Abandoned CA2147443A1 (en) | 1994-04-22 | 1995-04-20 | Duct liner with pre-applied adhesive and the method of making the same |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2147443A1 (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| NL1011603C2 (en) * | 1999-03-19 | 2000-09-27 | Rockwool Lapinus Bv | Self-adhesive insulation blanket. |
| WO2001016534A1 (en) * | 1999-08-31 | 2001-03-08 | Owens Corning | Perforated faced insulation assembly and method of making the same |
-
1995
- 1995-04-20 CA CA 2147443 patent/CA2147443A1/en not_active Abandoned
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| NL1011603C2 (en) * | 1999-03-19 | 2000-09-27 | Rockwool Lapinus Bv | Self-adhesive insulation blanket. |
| WO2000057101A1 (en) * | 1999-03-19 | 2000-09-28 | Rockwool Lapinus B.V. | Self-adhesive insulation blanket |
| WO2001016534A1 (en) * | 1999-08-31 | 2001-03-08 | Owens Corning | Perforated faced insulation assembly and method of making the same |
| US6444289B1 (en) | 1999-08-31 | 2002-09-03 | Owens Corning Fiberglas Technology, Inc. | Perforated faced insulation assembly |
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