EP0627984A1 - Mousse polymere souple destinee a etre utilisee comme isolant et comme retardateur d'humidite, et son procede de production - Google Patents
Mousse polymere souple destinee a etre utilisee comme isolant et comme retardateur d'humidite, et son procede de productionInfo
- Publication number
- EP0627984A1 EP0627984A1 EP93902833A EP93902833A EP0627984A1 EP 0627984 A1 EP0627984 A1 EP 0627984A1 EP 93902833 A EP93902833 A EP 93902833A EP 93902833 A EP93902833 A EP 93902833A EP 0627984 A1 EP0627984 A1 EP 0627984A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- foam
- foam sheet
- sheet
- resin
- mixture
- 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.)
- Withdrawn
Links
- 239000006260 foam Substances 0.000 title claims abstract description 115
- 238000000034 method Methods 0.000 title claims description 26
- 239000012212 insulator Substances 0.000 title description 3
- 239000004604 Blowing Agent Substances 0.000 claims abstract description 28
- 239000002952 polymeric resin Substances 0.000 claims abstract description 3
- 229920005989 resin Polymers 0.000 claims description 28
- 239000011347 resin Substances 0.000 claims description 28
- -1 polyethylene Polymers 0.000 claims description 21
- 239000000203 mixture Substances 0.000 claims description 20
- 239000004698 Polyethylene Substances 0.000 claims description 14
- 229920000573 polyethylene Polymers 0.000 claims description 14
- 229920000642 polymer Polymers 0.000 claims description 12
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 7
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 claims description 6
- 239000004793 Polystyrene Substances 0.000 claims description 4
- 229920002223 polystyrene Polymers 0.000 claims description 4
- LVGUZGTVOIAKKC-UHFFFAOYSA-N 1,1,1,2-tetrafluoroethane Chemical compound FCC(F)(F)F LVGUZGTVOIAKKC-UHFFFAOYSA-N 0.000 claims description 3
- NPNPZTNLOVBDOC-UHFFFAOYSA-N 1,1-difluoroethane Chemical compound CC(F)F NPNPZTNLOVBDOC-UHFFFAOYSA-N 0.000 claims description 3
- 229910002092 carbon dioxide Inorganic materials 0.000 claims description 3
- 238000010438 heat treatment Methods 0.000 claims description 3
- 239000004743 Polypropylene Substances 0.000 claims description 2
- 239000001569 carbon dioxide Substances 0.000 claims description 2
- 238000010030 laminating Methods 0.000 claims description 2
- 239000000463 material Substances 0.000 claims description 2
- 229920001155 polypropylene Polymers 0.000 claims description 2
- 229920003002 synthetic resin Polymers 0.000 claims description 2
- JCXJVPUVTGWSNB-UHFFFAOYSA-N nitrogen dioxide Inorganic materials O=[N]=O JCXJVPUVTGWSNB-UHFFFAOYSA-N 0.000 claims 1
- 238000007789 sealing Methods 0.000 claims 1
- 238000009413 insulation Methods 0.000 abstract description 11
- 229920001169 thermoplastic Polymers 0.000 abstract description 2
- 238000001125 extrusion Methods 0.000 description 19
- 238000012360 testing method Methods 0.000 description 13
- 238000005187 foaming Methods 0.000 description 7
- 238000010276 construction Methods 0.000 description 6
- 238000009434 installation Methods 0.000 description 6
- 230000004888 barrier function Effects 0.000 description 5
- 239000002023 wood Substances 0.000 description 5
- 210000004027 cell Anatomy 0.000 description 4
- 239000002667 nucleating agent Substances 0.000 description 4
- 239000000654 additive Substances 0.000 description 3
- KRKNYBCHXYNGOX-UHFFFAOYSA-N citric acid Chemical compound OC(=O)CC(O)(C(O)=O)CC(O)=O KRKNYBCHXYNGOX-UHFFFAOYSA-N 0.000 description 3
- 239000011152 fibreglass Substances 0.000 description 3
- 239000000155 melt Substances 0.000 description 3
- OFBQJSOFQDEBGM-UHFFFAOYSA-N n-pentane Natural products CCCCC OFBQJSOFQDEBGM-UHFFFAOYSA-N 0.000 description 3
- 229910052757 nitrogen Inorganic materials 0.000 description 3
- 239000011120 plywood Substances 0.000 description 3
- UJPMYEOUBPIPHQ-UHFFFAOYSA-N 1,1,1-trifluoroethane Chemical compound CC(F)(F)F UJPMYEOUBPIPHQ-UHFFFAOYSA-N 0.000 description 2
- WXGNWUVNYMJENI-UHFFFAOYSA-N 1,1,2,2-tetrafluoroethane Chemical compound FC(F)C(F)F WXGNWUVNYMJENI-UHFFFAOYSA-N 0.000 description 2
- AHFMSNDOYCFEPH-UHFFFAOYSA-N 1,2-difluoroethane Chemical compound FCCF AHFMSNDOYCFEPH-UHFFFAOYSA-N 0.000 description 2
- VOPWNXZWBYDODV-UHFFFAOYSA-N Chlorodifluoromethane Chemical compound FC(F)Cl VOPWNXZWBYDODV-UHFFFAOYSA-N 0.000 description 2
- LCGLNKUTAGEVQW-UHFFFAOYSA-N Dimethyl ether Chemical compound COC LCGLNKUTAGEVQW-UHFFFAOYSA-N 0.000 description 2
- 229920001890 Novodur Polymers 0.000 description 2
- UIIMBOGNXHQVGW-UHFFFAOYSA-M Sodium bicarbonate Chemical compound [Na+].OC([O-])=O UIIMBOGNXHQVGW-UHFFFAOYSA-M 0.000 description 2
- 230000001143 conditioned effect Effects 0.000 description 2
- 238000007796 conventional method Methods 0.000 description 2
- 229920003020 cross-linked polyethylene Polymers 0.000 description 2
- 239000004703 cross-linked polyethylene Substances 0.000 description 2
- 238000009408 flooring Methods 0.000 description 2
- 230000008595 infiltration Effects 0.000 description 2
- 238000001764 infiltration Methods 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- TZIHFWKZFHZASV-UHFFFAOYSA-N methyl formate Chemical compound COC=O TZIHFWKZFHZASV-UHFFFAOYSA-N 0.000 description 2
- 238000010422 painting Methods 0.000 description 2
- GTLACDSXYULKMZ-UHFFFAOYSA-N pentafluoroethane Chemical compound FC(F)C(F)(F)F GTLACDSXYULKMZ-UHFFFAOYSA-N 0.000 description 2
- 239000000454 talc Substances 0.000 description 2
- 229910052623 talc Inorganic materials 0.000 description 2
- WGZYQOSEVSXDNI-UHFFFAOYSA-N 1,1,2-trifluoroethane Chemical compound FCC(F)F WGZYQOSEVSXDNI-UHFFFAOYSA-N 0.000 description 1
- OIQOUHIUUREZOM-UHFFFAOYSA-N 1,1-dichloro-1,2-difluoroethane Chemical compound FCC(F)(Cl)Cl OIQOUHIUUREZOM-UHFFFAOYSA-N 0.000 description 1
- FRCHKSNAZZFGCA-UHFFFAOYSA-N 1,1-dichloro-1-fluoroethane Chemical compound CC(F)(Cl)Cl FRCHKSNAZZFGCA-UHFFFAOYSA-N 0.000 description 1
- BHNZEZWIUMJCGF-UHFFFAOYSA-N 1-chloro-1,1-difluoroethane Chemical compound CC(F)(F)Cl BHNZEZWIUMJCGF-UHFFFAOYSA-N 0.000 description 1
- ATEBGNALLCMSGS-UHFFFAOYSA-N 2-chloro-1,1-difluoroethane Chemical compound FC(F)CCl ATEBGNALLCMSGS-UHFFFAOYSA-N 0.000 description 1
- 239000004156 Azodicarbonamide Substances 0.000 description 1
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 1
- 229920000784 Nomex Polymers 0.000 description 1
- 229920001328 Polyvinylidene chloride Polymers 0.000 description 1
- 239000004775 Tyvek Substances 0.000 description 1
- 229920000690 Tyvek Polymers 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 150000001336 alkenes Chemical class 0.000 description 1
- 239000003963 antioxidant agent Substances 0.000 description 1
- 235000006708 antioxidants Nutrition 0.000 description 1
- XOZUGNYVDXMRKW-AATRIKPKSA-N azodicarbonamide Chemical compound NC(=O)\N=N\C(N)=O XOZUGNYVDXMRKW-AATRIKPKSA-N 0.000 description 1
- 235000019399 azodicarbonamide Nutrition 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000001273 butane Substances 0.000 description 1
- 239000000378 calcium silicate Substances 0.000 description 1
- 229910052918 calcium silicate Inorganic materials 0.000 description 1
- OYACROKNLOSFPA-UHFFFAOYSA-N calcium;dioxido(oxo)silane Chemical compound [Ca+2].[O-][Si]([O-])=O OYACROKNLOSFPA-UHFFFAOYSA-N 0.000 description 1
- 150000001732 carboxylic acid derivatives Chemical class 0.000 description 1
- 210000003850 cellular structure Anatomy 0.000 description 1
- 239000001913 cellulose Substances 0.000 description 1
- 229920002678 cellulose Polymers 0.000 description 1
- 239000002666 chemical blowing agent Substances 0.000 description 1
- 239000012141 concentrate Substances 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 229920001577 copolymer Polymers 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 230000002708 enhancing effect Effects 0.000 description 1
- 229920001038 ethylene copolymer Polymers 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- 230000010006 flight Effects 0.000 description 1
- 239000011888 foil Substances 0.000 description 1
- 238000009432 framing Methods 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- IJDNQMDRQITEOD-UHFFFAOYSA-N n-butane Chemical compound CCCC IJDNQMDRQITEOD-UHFFFAOYSA-N 0.000 description 1
- 239000004763 nomex Substances 0.000 description 1
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 description 1
- 238000004806 packaging method and process Methods 0.000 description 1
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 1
- 229920000058 polyacrylate Polymers 0.000 description 1
- 229920002239 polyacrylonitrile Polymers 0.000 description 1
- 229920001707 polybutylene terephthalate Polymers 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 229920006327 polystyrene foam Polymers 0.000 description 1
- 239000004800 polyvinyl chloride Substances 0.000 description 1
- 229920000915 polyvinyl chloride Polymers 0.000 description 1
- 229920002620 polyvinyl fluoride Polymers 0.000 description 1
- 239000005033 polyvinylidene chloride Substances 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 230000001737 promoting effect Effects 0.000 description 1
- 238000009418 renovation Methods 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 229910000030 sodium bicarbonate Inorganic materials 0.000 description 1
- 235000017557 sodium bicarbonate Nutrition 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000003381 stabilizer Substances 0.000 description 1
- 238000012956 testing procedure Methods 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
- C08J9/12—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent
- C08J9/122—Hydrogen, oxygen, CO2, nitrogen or noble gases
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/34—Auxiliary operations
- B29C44/36—Feeding the material to be shaped
- B29C44/46—Feeding the material to be shaped into an open space or onto moving surfaces, i.e. to make articles of indefinite length
- B29C44/50—Feeding the material to be shaped into an open space or onto moving surfaces, i.e. to make articles of indefinite length using pressure difference, e.g. by extrusion or by spraying
- B29C44/505—Feeding the material to be shaped into an open space or onto moving surfaces, i.e. to make articles of indefinite length using pressure difference, e.g. by extrusion or by spraying extruding the compound through a flat die
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
- C08J9/12—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent
- C08J9/14—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent organic
- C08J9/142—Compounds containing oxygen but no halogen atom
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
- C08J9/12—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent
- C08J9/14—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent organic
- C08J9/143—Halogen containing compounds
- C08J9/144—Halogen containing compounds containing carbon, halogen and hydrogen only
- C08J9/146—Halogen containing compounds containing carbon, halogen and hydrogen only only fluorine as halogen atoms
-
- 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
- E04B1/76—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 heat only
- E04B1/78—Heat insulating elements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/26—Scrap or recycled material
Definitions
- a flexible polymeric foam for use as an insulator and a moisture retardant and a process for producing it.
- the invention relates to a flexible polymeric foam sheet which is useful as an insulator and moisture vapor retardant.
- wood members comprise the wall studs, trimmers, nailers, headers, among others.
- the remainder of the cavity defined within the residential wall is generally filled with insulation.
- the R or insulation value of the cavity may range from 19 to 21, however, the R value of the wood is approximately 1 per inch.
- energy loss occurs across or through the wood members which have a relatively low insulation value.
- the wood members conduct energy from the interior of the home to the outdoors, or vice versa.
- a thin polyethylene sheet is installed directly over the wooden members, and drywall in affixed to the wooden members through the polyethylene sheet. While this sheet functions as a vapor moisture retardant, the sheet has a nominal R value, and accordingly, lacks i y significant affect on energy conduction through the wooden members.
- the present invention relates to a flexible foam sheet which improves the insulation characteristics of structures within a home having wooden members, and also functions as a moisture vapor retardant.
- the flexible foam sheet may be incorporated during construction of residential homes by installing the flexible foam sheet across or between the wooden members on the interior face or side of the wooden members, and thereafter affixing drywall through the foam and into the wooden members, e.g., a nail or screw is driven through the drywall and the foam sheet, and into the wooden members.
- the wooden members After having installed the foam sheet, the wooden members are insulated from the drywall or the interior of the home; thereby increasing the R value of the wall, reducing moisture vapor permeation, and exfiltration of conditioned interior air, e.g., heated or cooled air.
- the seams between the foam sheet may be sealed before installation of the drywall, thereby permitting the foam to function as a secondary air infiltration barrier.
- the flexible foam sheet is produced by extrusion using conventional foam systems such as tandem, screw, stretched single screw, among others.
- a plurality of resins, virgin or recycled, or blends thereof, may be used for producing the flexible foam sheet. These resins are extruded and foamed using one or more foam expansion or blowing agents.
- FIG. 1 is a cross-sectional view of a residential wall which may be formed in accordance with the invention that illustrates drywall installed over the flexible foam sheet.
- Figure 2-Fig. 2 is a cut-away sectional view of the residential wall shown in Fig. 1.
- the invention relates to a flexible foam sheet which is located within the structure of a home in a manner that allows the foam sheet to reduce moisture vapor permeation and thermal conduction.
- the foam sheet is incorporated into the home by being affixed between or across at least the structural members, e.g., wooden wall studs, and thereafter, covered by the interior surface of the home.
- a thin flexible extruded foam sheet is installed on at least one face of a wooden member such as a wall stud, in order to form a moisture vapor and thermal barrier within the wall.
- the interior surface such as drywall, ceiling components, flooring, among others, is installed over the foam sheet.
- the foam sheet is installed by being affixed to the wooden members by any conventional and expedient technique.
- Conventional techniques include nailing, tacking, stapling, among others.
- the foam sheet may be creased and folded during manufacture in order to enhance installation of the sheet foam.
- an edge of a creased and folded foam sheet may be affixed to an upper portion of a wooden member, e.g., wall stud.
- the remainder of the sheet is unfurled or unrolled down the length of the wooden member.
- the unattached portions of the unrolled sheet foam are then readily affixed, e.g., stapled, onto the wooden member.
- the seam which is formed between individual foam sheets may be sealed by any suitable technique.
- the seam may be sealed by being taped using construction grade tape, e.g., TYVEK tape. It is also desirable to close or seam any other openings which may be present in the sheet foam. Openings in the foam, e.g., which may be provided for an electrical outlet, should be caulked or taped in order to ensure continuity of the moisture vapor barrier which is created by installing the foam sheet.
- the continuity of the foam sheet also enables the sheet to function as a secondary air infiltration barrier and a barrier to exfiltration of conditioned interior air, e.g., heated or cooled air.
- the interior surface of the residence is installed over or upon the sheet foam.
- the interior surface is installed by any conventional means such as nails, screws, among others.
- the interior surface comprises drywall which is installed upon the foam sheet, i.e., the drywall is indirectly attached to the wall studs.
- the sheet foam may be located throughout the residence, including beneath interior surfaces such as ceilings and floors, thereby enhancing the insulation and moisture vapor retardance of the entire home.
- the foam sheet may be installed upon the wooden structural members of a home to provide a whole house liner or enclosure.
- the sheet foam functions as a gasket by promoting a more uniform contact between the drywall and the wall stud.
- the foam sheet which is directly affixed to the wall stud compensates for surface irregularities of the drywall and/or the wall stud.
- the resultant interior wall surface has an improved surface quality or appearance which is desirable should the drywall be finished by painting, wall-papering, among others.
- the flexible sheet foam of the invention typically has a thickness which ranges from about 1/16 to about 3/8 inches.
- the foam sheet may be extruded or formed into a virtually unlimited array of lengths and widths.
- the foam sheet which is packaged for residential installation will have dimensions such as 12 X 4, 12 X 6, 12 X 8, continuos lengths, among others.
- Figure 1 illustrates one manner in which the flexible foam sheet can be incorporated into a residential wall.
- Figure 2 is a cut-away sectional drawing of the wall illustrated in Fig. 1, showing the wall as it would appear from the interior of the home.
- the exterior surface JO of the home may be comprised of conventional exterior sheathing.
- Conventional exterior sheathing may comprise one or more of plywood, insulation such as rigid polystyrene, phenolic or urethane foam, siding, shakes, clap board, stucco, among others.
- a component of the exterior surface such as siding, shakes, clap board, among others, may be spaced apart from the sheathing by a fenestration system (not shown).
- the exterior surface JO is attached to wooden members Jl.
- the wooden members Jl may comprise one or more of wall studs, ceiling frame, sub-flooring, among others.
- the space between the wooden members VY typically defines a cavity J2 which is filled with insulation such as low density fiberglass batts, cellulose, blown-in-place insulation, among others.
- the flexible foam sheet J of the invention is installed, e.g., by stapling, directly upon the wooden members 11 and across cavity 12.
- the seams between individual sheets of foam J may be sealed, for example by being taped (not shown).
- the interior surface of the wall 14 is installed over foam sheet 13 and affixed to the wooden members Jl.
- the interior surface J-4 comprises drywall which is nailed or screwed through the sheet foam J-3, and into the wall studs JL1.
- the interior surface J4 may be finished by using any suitable conventional technique such as painting, wall papering, carpeting, among others.
- the flexible polymeric foam sheet discussed above may be obtained by foaming a suitable polymeric composition with a blowing agent comprising up to about 20 weight percent, based on the total weight of the composition, of at least one blowing agent selected from the group consisting of 1,1,-difluoroethane (HFC- 152a); 1,2-difluoroethane (HFC-152); 1,1,1,2-tetrafluoroethane (HFC- 134a); 1,1,2,2-tetrafluoroethane (HFC-134); 1,1,1-trifluoroethane (HFC-143a); and 1,1,2-trifluoroethane (HFC- 143); pentafluoroethane (HFC- 125), chlorodifluoro- ethane (HCFC-22), 1,1-dichlorodifluoroethane (HCFC-141b), 1-chloro 1,1- difluoroethane (HCFC-142b), among others.
- the blowing agent may also comprise one or more hydrocarbons such as butane, pentane and isomers thereof, among others, and/or atmospheric gases such as carbon dioxide and nitrogen.
- the blowing agent may further comprise methylformate, dimethylether and chemical blowing agents such as azodicarbonamide.
- Suitable polymeric compositions for foaming comprise one or more virgin and/or recycled resins such as at least one member from the group of consisting polyethylene, polystyrene, polypropylene, and thermoplastic polymers such as polyvinyl chloride, polyvinylidene chloride, polyacrylonitrile, polyethylene terephthate, polybutylene terephthalate, polyesters, polyvinyl fluoride, ethylene copolymers, polyacrylates, among others.
- a suitable polymeric resin may also comprise an ionomeric resin which is a partially neutralized copolymer of an olefin and a carboxylic acid, e.g., SURLIN 9450. While particular emphasis is placed on producing a foam sheet comprising an ethylenic and/or a styrenic resin, it is to be understood that the present invention may be practiced by employing one or more of the polymers listed above.
- HFC-134a and/or HFC- 152a are particularly desirable for use as a blowing agent when forming polystyrene and polyethylene foams.
- HFC- 134a enhances the insulating characteristics of the polystyrene foam because HFC- 134a has a relatively slow permeation rate through this foam, i.e., a greater quantity of HFC- 134a is retained within the foam which increases the R value of the foam.
- nucleating agent serves primarily to increase cell count and reduce the cell size in the foam, and are typically used in an amount of about 0.1 part by weight to about 4.0 parts by weight per one hundred parts resin.
- talc sodium bicarbonate/ citric acid, gaseous CO2, calcium silicate, among others, are suitable nucleating agents for reducing cell size.
- the extruded foam sheet has a density which ranges from about 2.0 through about 8.0 pounds per cubic foot (pcf), and an average cell size of about 0.005 to 0.125, and normally about 0.010 to 0.125 inches in diameter.
- compositions which may be used for producing foam in accordance with the present invention comprises from about 0 to 5% talc, about 70 to 80% polyethylene having a density of about 0.9 grams per cc and a melt index of about 2.0 grams per 10 min, about 20 to 30% recycled polyethylene having a density of about 0.96 grams per cc and a melt index of about 0.6 grams per 10 min, and about 10 to 20% of a blowing agent based upon the total amount of the foam.
- Various additives for example, fire retardant additives, color concentrates, stabilizers, anti-oxidants, lubricants, among others, may also be used depending upon the specific end use of the foam sheet.
- Another aspect of the invention comprises a method for foaming a mixture of a styrenic and/or an ethylenic resin(s) and a polyfluorocarbon blowing agent.
- the method comprises producing a styrenic and/or an ethylenic foam by heating a resin in an extruder to produce a molten resin; introducing into the molten resin a blowing agent comprising at least one blowing agent such as HFC- 152a and/or HFC- 134a to produce a plasticized extrusion mass under a pressure sufficient which prevents excessive foaming of the extrusion mass; and extruding the extrusion mass through a die into a zone having a temperature and pressure sufficient to permit complete foaming of the extrusion mass; thereby providing the foam sheet.
- the foam may be extruded using conventional foam extrusion systems such as tandem, twin screw, stretched single screw, among others.
- the resin e.g., styrenic resin
- a blowing agent e.g., styrenic resin
- the foaming is typically carried out with the use of an extruder, wherein the styrenic polymer is heated to about 400° -450° F to produce a molten polymer.
- the blowing agent is then introduced into the extruder wherein it is mixed with the molten polymer under pressures such that the resulting plasticized extrusion mass does not excessively foam, but its viscosity decreases.
- the extrusion mass is then cooled. Cooling increases the viscosity and the melt strength of the mass prior to extrusion.
- the mass is then extruded through a die of any desirable shape at a controlled temperature, usually about 300° F, wherein the reduced pressure outside the extruder permits the extruded mass to foam.
- the temperature and pressure conditions under which the resin and blowing agent mixture will not excessively foam will depend upon the particular resin being used and generally, will be a temperature which ranges between about 240° F and about 440° F, and a pressure above about 600 psig.
- the conditions of temperature and pressure under which the extrusion mass will complete foaming again will depend upon the particular resin used and generally, will be a temperature which ranges between about 240° F and 440° F but at a relatively low pressure. However, the more precisely the temperature is controlled throughout the extrusion process, the more uniform the resulting foam.
- the degree of melt plasticization is controlled by the choice of the particular blowing agent composition, the amount of and type of nucleating agent or other additive(s) present, the particular resin or mixture being used and the Tg or Tg's of the resin(s), and the temperature, pressure in the extruder and the extrusion rate.
- the shaping means used can also affect the orientation of the polymer.
- the blowing agent may be added to the resin by injecting a stream of the blowing agent composition directly into the molten resin in the extruder.
- the blowing agent should be mixed thoroughly with the resin which is contained before the blowing agent and resin mass are extruded from the die. Thoroughly mixing the blowing agent and resin is desirable for producing a foam which has a generally uniform density and cellular structure.
- the extrusion mass comprising the molten resin and the blowing agent is normally extruded into an expansion zone within which foam formation and expansion takes place.
- Any suitable extrusion equipment capable of processing polymeric compositions into a flexible foam sheet can be used for the extmsion, e.g., single or multiple-screw extruders.
- Softening of the polymer and mixing with the blowing agent normally occur while working the polymer between flights of the screw or screws, which also serves to convey the extrusion mass to the extruder die. Screw speed and extruder barrel temperature should be sufficient to achieve adequate mixing and softening but not so high as to degrade the composition being processed.
- the resultant foam can be used in the as-manufactured flexible sheet configuration, cut into other shapes, further shaped or processed.
- the flexible foam sheet may be creased in order to improve packaging of the foam as well as installation.
- a creased foam sheet is readily folded and prepared for shipment to the ultimate consumer. The consumer may then remove the folded foam sheet, affix one edge of the sheet to an upper end portion of a wooden member, and allow the folded foam sheet to unfurl or unroll. The remainder of the sheet is affixed to the wooden members in order to complete installation of the sheet.
- the foam may be used in any environment where properties such as moisture vapor retardance, insulating, and flame resistance, are desirable.
- the sheet foam may be useful for providing insulation in a structure having metallic or masonry members.
- installation of the foam sheet is not limited to new home construction because the foam sheet may be installed during a renovation and/or at any specific location which the properties of the foam sheet are desirable.
- Foam was extruded through an annular die, stretched over a mandrel about 4 times the die's diameter, and slit to produce a single sheet.
- the extrusion system was started using HCFC-22 as the blowing agent. After about 25 minutes, HFC-152a was introduced from cylinders pressurized with nitrogen.
- a polyethylene foam sheet was produced using HFC- 152a as the blowing agent in a commercial tandem extrusion system.
- Foam was extruded through an annular die, then stretched over a 20 mandrel with a diameter about 4 times that of the die to yield a foam tube which was then slit.
- the extruder and die operated at a pressure of about 750 psig, a resin melt temperature of about 210° F and a rate of about 300 lbs/hr.
- the HFC-152a blowing agent was injected at a rate of about 49.5-60 lbs/hr.
- EXAMPLE 3 A flexible polyethylene foam sheet was produced generally in accordance with the process of Examples 1 and 2, with the exception that nitrogen was used as the blowing agent.
- the resultant foam sheet comprised low density cross-linked polyethylene foam, was about 1/16 inches thick, and had a density of about 4 pcf.
- This foam sheet was installed into a test panel, and analyzed substantially in accordance with ASTM Testing Procedure No. C236-87 to determine the insulating value of the sheet foam.
- Two (2) test panels, each measuring about 4 X 6 feet, were constructed from 2 X 4 inch lumber, using a 16" center. Exterior grade plywood measuring about 1/2" thick was nailed to one side of the test panels to represent exterior sheathing. R-ll backed fiberglass insulation was placed into the cavity defined between the 2 X 4 lumber.
- One of the test panels was used as a control wall. In the control wall a
- the second test panel was used for testing the foam sheet of the invention.
- the foam sheet was installed in the same manner and location as the polyethylene sheet in the first test panel, and about 1/2 inch thick drywall was installed over the foam sheet.
- the ASTM test was performed on both panels. The results of the ASTM test are listed below.
- the results of the test demonstrate that the foam sheet of the invention is capable of increasing the R-value of a wall by at least about 14%.
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Health & Medical Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Organic Chemistry (AREA)
- Physics & Mathematics (AREA)
- Architecture (AREA)
- Acoustics & Sound (AREA)
- Electromagnetism (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Building Environments (AREA)
- Laminated Bodies (AREA)
- Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
Abstract
Cette invention concerne une mousse en feuille polymère souple possédant des propriétés d'isolation thermique et de protection contre la vapeur humide, qu'on installe sous le contre-mur en maçonnerie sèche des surfaces internes d'une maison. On peut placer la mousse en feuille souple sur les éléments en bois qui définissent la structure de la maison, ou bien entre ces derniers. La mousse en feuille réduit les pertes en énergie existant entre l'intérieur de la maison et l'extérieur qui résultent elles-mêmes de la conduction thermique à travers les éléments en bois de la maison. On peut fabriquer la mousse en feuille en extrudant une résine polymère thermoplastique qu'on transforme ensuite en mousse en la soumettant à expansion ou en lui ajoutant des agents gonflants.
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US82548192A | 1992-01-24 | 1992-01-24 | |
US825481 | 1992-01-24 | ||
PCT/US1992/011315 WO1993014923A1 (fr) | 1992-01-24 | 1992-12-30 | Mousse polymere souple destinee a etre utilisee comme isolant et comme retardateur d'humidite, et son procede de production |
Publications (1)
Publication Number | Publication Date |
---|---|
EP0627984A1 true EP0627984A1 (fr) | 1994-12-14 |
Family
ID=25244107
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP93902833A Withdrawn EP0627984A1 (fr) | 1992-01-24 | 1992-12-30 | Mousse polymere souple destinee a etre utilisee comme isolant et comme retardateur d'humidite, et son procede de production |
Country Status (5)
Country | Link |
---|---|
EP (1) | EP0627984A1 (fr) |
CA (1) | CA2128733A1 (fr) |
FI (1) | FI943444A (fr) |
NO (1) | NO942601L (fr) |
WO (1) | WO1993014923A1 (fr) |
Families Citing this family (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0749455A4 (fr) * | 1994-03-11 | 1998-02-11 | A C I Operations | Mousse en matiere plastique et son procede de fabrication |
US5753717A (en) * | 1994-03-30 | 1998-05-19 | Aci Operations Pty Ltd. | Plastics foam and method of manufacturing same |
DE19525861A1 (de) * | 1995-07-15 | 1997-01-16 | Huels Chemische Werke Ag | Isolierkörper |
GB9701291D0 (en) | 1997-01-22 | 1997-03-12 | Ici Plc | Closed cell polymer foam |
Family Cites Families (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3160688A (en) * | 1961-06-02 | 1964-12-08 | Monsanto Co | Extrusion process |
US3362120A (en) * | 1965-10-18 | 1968-01-09 | Holland Plastics Company | Dry wall construction and method of assembly |
US3638381A (en) * | 1968-10-11 | 1972-02-01 | Basf Corp | Insulated masonry building wall construction |
US4071993A (en) * | 1976-07-06 | 1978-02-07 | Grefco, Inc. | Construction material in sheet form and method of joining sheets edge-to-edge |
JPS58111834A (ja) * | 1981-12-25 | 1983-07-04 | Japan Styrene Paper Co Ltd | ポリスチレン板状押出発泡体の製造法 |
US4510268A (en) * | 1982-04-09 | 1985-04-09 | The Dow Chemical Company | Directional flexibilization of expanded thermoplastic foam sheet for low temperature insulation |
WO1988006216A1 (fr) * | 1987-02-12 | 1988-08-25 | Robert Kenneth Prudhoe | Ameliorations apportees a des batiments |
EP0445847A3 (en) * | 1987-04-15 | 1992-01-15 | The Dow Chemical Company | Preparation of polymer foam and product |
-
1992
- 1992-12-30 CA CA002128733A patent/CA2128733A1/fr not_active Abandoned
- 1992-12-30 EP EP93902833A patent/EP0627984A1/fr not_active Withdrawn
- 1992-12-30 WO PCT/US1992/011315 patent/WO1993014923A1/fr not_active Application Discontinuation
-
1994
- 1994-07-11 NO NO942601A patent/NO942601L/no unknown
- 1994-07-20 FI FI943444A patent/FI943444A/fi unknown
Non-Patent Citations (1)
Title |
---|
See references of WO9314923A1 * |
Also Published As
Publication number | Publication date |
---|---|
NO942601D0 (no) | 1994-07-11 |
WO1993014923A1 (fr) | 1993-08-05 |
FI943444A0 (fi) | 1994-07-20 |
NO942601L (no) | 1994-07-11 |
FI943444A (fi) | 1994-07-20 |
CA2128733A1 (fr) | 1993-08-05 |
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