FR2885987A1 - Multilayer reflective insulating material for e.g. house construction, has fibers covering partially metallized reflective film, and multilayer assembly constituted of batting film on metallized framed sealed film and polyethylene foam - Google Patents

Abstract

The material has hydrophobic and rot-proof fibers covering partially a metallized reflective film. A multilayer assembly assembled by seaming is constituted of an aluminized batting film on a non woven sheet (F), a metallized framed sealed film (4), a polyester wadding (1), a metallized double-faced film (2) and a polyethylene foam (3) with 3 millimeter thickness and with a density of 20 kilogram per meter cube.

Description

The present invention relates to a multilayer insulating complex reflective, waterproof and anti-condensation; used for building insulation; and its manufacturing peculiarities.
Thick insulators such as fibrous insulators have been known for a long time (for example, rock wool, glass wool, etc.) and cellular insulators (for example: polyurethane foam, expanded polystyrene, extruded, etc.).
In recent years have appeared so-called thin reflective insulation, distinguishable into 2 major categories:
SIMPLE INSULATORS generally composed of a material enclosed by gluing between two reflective films (generally of more or less thick aluminum).
MULTILAYER INSULATION: complexes composed of different layers of different materials (fibrous, cellular, reflective films ...) enclosed between 2 layers of reflective films.
The first: simple, have the disadvantage of having a very low thermal resistance to conduction phenomena by their small thickness but have the advantage of being waterproof and therefore easily used as insulation film under-roofing. But, this seal can become a major disadvantage in the case where there is water infiltration (for example: damaged roof covering). The product can then be filled with water (such as a pocket) which can not be evacuated and thus loses much of its thermal insulation qualities.
The second: multilayer, use in their composition a superposition of materials (5 to 15, see more) which together form an effective insulating product and thick enough to obtain good insulating characteristics in the field of conduction.
The complexing of many components requires the use of an economically viable assembly process. The different processes are as follows:
It is possible to laminate the materials between them (by foaming, cold gluing, flat gluing or hot melt), but this requires many passes in machines (usually 1 pass for the gluing of 2 products). This process therefore requires many manipulations, so expensive.
It is also possible to make a joint by welding (high frequency, ultrasonic, thermal), in this case there are certain limits of thickness, of composition of the materials used, and in the end each point of welding constitutes a thermal bridge in the as all the materials are melted together and thus finish in thickness 0.
It is still possible to make a sewing assembly on multi-needle machine that in one pass can assemble all the components. A good seam adjustment prevents too much seaming and thus reduces the risk of thermal bridging at this level.
However, at each stitch is created a perforation of the materials and the product loses its sealing capabilities, which is problematic if the product is used in insulating screen under-roofing. Conversely these holes will allow the water infiltrated accidentally to evacuate.
Another disadvantage of Thin-Walled Thin Insulation products is their thickness when used in under-roofing. Indeed, in order to ensure a good continuity of the insulation, it is advisable not to make joined connections, but by overlapping. These connections are then finalized by affixing a reflective adhesive film.
From a certain thickness (2 to 3 cm), overlapping already poses problem. Indeed, this extra thickness causes problems of alignment and continuity of the cover elements (rippling slates at the connections of the strips.).
This problem of overlap with some thin insulators limits the development of products that will be called semi-thick (3 to 5 cm, so more insulating).
For Thin Reflective Insulators, it appeared in use that condensation problems could occur under certain conditions of use and cause, in the worst case, serious alterations to buildings (rotting of wooden structures - framework for example ).
In the context of fibrous insulation materials, condensation takes place inside the insulation itself. The moisture then formed significantly reduces the insulating power of the product. This moisture is evacuated as soon as the temperatures rise (phenomenon of natural evaporation).
As part of Thin Reflective Insulators, these are usually water vapor proof, which prevents condensation inside the product itself. However this ambient humidity exists, and, depending on the climatic conditions and the insulating quality of the product, it can happen that is formed on the internal face (interior of the house) of condensation. If the conditions are sufficient (high temperature difference between the inside and the outside of the house, very humid indoor air, lack of ventilation ...), drops of water can then form and flow along the water. insulation; be deposited on the lumber that serve as a support for fixing the insulation and thus eventually cause serious damage to the construction.
The present invention therefore aims to overcome many disadvantages of the prior art by providing a semi-thick reflective multilayer insulating material offering good insulation in the three areas of heat transfer in buildings (conduction: semi-thick product; convection: a product that is impervious to wind and drafts, reflection: use of reflective films) and which mitigates the risk of condensation.
This object is achieved by the fact that the material according to the invention comprises at least one multilayer assembly assembled by stitching which comprises at least one component of density and sufficient thickness not to collapse at the seam (example: polyethylene foam 3 mm thick, density 20 kg / m3).
According to another feature, the multilayer assembly will have on one of its faces a metallized film reflecting frame that will ensure the mechanical strength of the system and the sealing of the inner face (house side) of the product.
According to another feature, this film will be covered with a second reflective metallized film which has been previously needled on a nonwoven of hydrophobic and rotproof fibers (polyester, polyamide, polypropylene, etc.).
This needle-punched metallized film will act as an anti-condenser insofar as, in the event of condensation, the fibers will prevent the creation of drops that would run off and seep into the lumber.
This film, being only partially fibrous, nevertheless retains a large part of its reflective advantages, and therefore its ability to play the role of a thermal insulator.
According to another particularity, the multilayer assembly thus produced economically will be protected on its outer face (cover side) by gluing a reflective metal foil reflective which will aim to completely seal the outer side of the seams and thus prevent all risks of accidental water infiltration and thus give the product thus formed, the real characteristics of an insulating under-roof film.
According to another feature, this bonded metallized metallized film will create an air mattress at the seams, which will largely avoid thermal bridges at this level.
According to another feature, the first components of the multilayer (outer face) and the adhesive bonded film will be wider (5 to 10 cm) than the rest of the product. This is to allow partial overlap of the two consecutive strips without generating extra thickness at the connections.
This overlapping system will thus avoid the risk of water infiltration or draft at this level, facilitate installation for the rest of the roof, simplify the installation of the reflective adhesive film that finalizes the assembly.
The features and advantages of the present invention will appear more clearly on reading the following description made with reference to the accompanying drawings; in which: Figure 1 shows the superposition of the materials before any assembly operation. Figure 2 schematically shows the same complex as Fig. 1 after sewing assembly. FIG. 3 represents the same complex as in FIG. 2 after bonding of the metallized armor film.
With reference to FIG. 1, the composite material according to the invention will consist of a needled aluminized film on a nonwoven web (F), a metallized waterproofed film (4), a thermally bonded polyester wadding of 120 g / m 2 (1), a two-sided metallized film (2), a closed cell polyethylene foam of 3mm density 20 kg / m3 (3), a two-sided metallized film (2), a wadding 120g / m2 (1) , a two-sided metallized film (2), a 3mm foam (3), a two-sided metallized film (2), a 120g / m2 wadding (1). Either a multilayer set of 11 components.
The number of components and their technical characteristics may vary depending on the thermal results sought.
Figure 2 schematically shows the complex of fig.l after assembly by stitching. It can be noted at the points (C) that the seams have flattened the complex. Crushing limited by the use of sufficiently thick and dense foams (3 figl.).
It can be noted in (A) that the first layers are wider than the others.
FIG. 3 diagrammatically represents the complex (12 components) after addition of the metallized metallized surface sheet (E) which has been bonded. At points (D), the air space created between the stitch and the glued film is noted. Air space playing the role of insulation and mitigating the problem of thermal bridges at this level.
The material thus formed according to the invention can be used as underlay screen during the renovation or construction of houses and buildings. It will also provide the role of thermal and sound insulation.
The nonwoven metallized anti-condensation sheet will be oriented towards the inside of the building and the sealed film will be oriented towards the outside.

CLAIMS.
1- reflective multilayer insulation materials characterized in that it comprises, on at least one of its faces, a reflective metallized film partly covered with hydrophobic and rot-proof fibers.

Claims (1)

2- reflective multilayer insulation materials according to claim 1, characterized in that it uses in the multilayer quilted a component sufficiently dense and thick to avoid crushing at the seams. 3- reflective multilayer insulation materials according to any one of the preceding claims, characterized in that it glues, on one side of the quilted multilayer complex, a sealed metallized reflective metallized film. 4- reflective multilayer insulation materials according to claim 3 and characterized in that the metallized film used is of greater width (5 to 10 cm) to the multilayer product which serves as a bonding medium.