VAPOR AND RADIANT BARRIER
FIELD OF THE INVENTION
The present invention relates to a vapor and radiant barrier membrane used in insulation applications in the construction industry. More specifically, the vapor and radiant barrier membrane of the present invention relates to a laminate of an aluminum substrate and polyethylene layers.
BACKGROUND OF THE INVENTION
Vapor barriers have proven to be an effective means for improving the insulation properties of the walls of a building.
Many vapor barriers of the prior art use, alone or in combination, materials such as paper, metal foils, or specialized Kraft paper. Examples of such vapor barrier are shown in US patents nos. 4,625,486 and 5,750,225.
The choice of the materials used is often guided so as to provide a vapor barrier with specific desired physical characteristics. The most common characteristics sought-after are an improved rigidity, an improved surface abrasion resistance and an improved tensile strength. However, in general, the vapor barriers of the prior art, because of their construction, have been more expensive than desired.
There is thus still a need for an improved cost-effective vapor barrier.
SUMMARY OF THE INVENTION
An object of the present invention is to propose a vapor barrier that will satisfy the above-mentioned need.
Another object is to propose a cost-effective vapor and radiant barrier membrane having heat reflectivity and vapor protection capacities as well as high tensile strength and rigidity.
In accordance with the present invention, these objects are achieved with a vapor and radiant barrier membrane for covering a wall surface. The membrane comprises a facing layer which contains a radiant material, and a backing layer laminated to the facing layer. The backing layer is made of polyethylene and has a thickness that limits vapor permeability.
The present invention also provides a wall structure which comprises a wall body with an inner and an outer face, and a vapor and radiant barrier membrane as described above which covers either the inner face or the outer face of the wall body.
The vapor and radiant barrier membrane according to the present invention is lighter and thinner than the usual vapor barrier of the prior art and still provides a greater tensile strength, an improved rigidity and a smoother outer surface for better abrasion resistance.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention and its advantages will be more easily understood after reading the following non-restrictive
description of a preferred embodiment thereof, made with reference to the following drawings wherein:
Figure 1 is a perspective view of a vapor and radiant barrier membrane according to a preferred embodiment of the present invention, wherein a portion is shown in exploded.
Figure 2 is a perspective view of a wall structure comprising the vapor and radiant barrier membrane illustrated in Fig. 1.
Figure 3 is a flow sheet showing the steps involved in a process for making a vapor and radiant barrier membrane according to the present invention.
DESCRIPTION OF A PREFERRED EMBODIMENT
Referring to Figure 1, there is shown a vapor and radiant barrier membrane (10) according to a preferred embodiment of the invention for covering a wall surface. However, it has to be understood that Nwall surface" may represent a ceiling surface, a wall roof or any surfaces of a building that may need vapor impermeability and heat reflectivity.
The membrane (10) comprises a facing layer (12) which contains a radiant material. As its radiant material, aluminum foil is preferred, or any other metal foil that will provide efficient heat reflectivity to the facing layer (12) .
The inventive membrane (10) further comprises a backing layer
(14) made of polyethylene, and which has a thickness that limits vapor permeability. The membrane (10) preferably has a total thickness of at least 1 mil, and most preferably of
3 mils. As will be more fully described hereinbelow, the
backing layer (14) is laminated, preferably heat laminated, to the facing layer (12) .
The backing layer (14) preferably comprises a first sheet (16) and a second sheet (18) of polyethylene. In this case, the first sheet (16) of polyethylene is preferably sandwiched between the facing layer (12) and the second sheet of polyethylene (18) of the backing layer (14) .
The polyethylene of the first sheet (16) is preferably a virgin low density polyethylene whereas the second sheet (18) of the backing layer (14) is preferably a combination of virgin low density and linear low density polyethylene.
The facing layer (12) preferably consists of a radiant aluminum foil of about 0.275 mil thick, the first sheet of polyethylene (16) of the backing layer (14) preferably has a thickness of about 0.5 mil and the second sheet of polyethylene (18) of the backing layer (14) preferably has a thickness of about 2.5 mils.
Referring now to Figure 2, the present invention also relates to a wall structure (20) comprising a wall body (22) with an inner face (24) and an outer face (26) and a vapor and radiant barrier membrane (20) according to the present invention. The latter (20) covers either one of the inner face (24) and outer face (26) of the wall body (22) . The inner face '(24) and the outer face (26) are both preferably and respectively covered with an interior finish (30) such as plastered sheeting (for example Gyprox*) and an exterior finish (31) made of a brick wall, a wood plank, plastic or aluminum, as apparent to a person in the art. It will be
* Trademark
understood that the wall structure (20) refers to any type of wall that is commonly known to a person skilled in the field of construction, for example, it could be a concrete wall, a wall constructed with wood or metal studs or any other type of construction.
In a preferred aspect, the membrane (10) is sandwiched between the inner face (24) and the interior finish (30) . A plurality of spaced-apart holding strips (28) are used to secure the membrane (10) to the inner face (24) of the wall body (22) . The interior finish (30) is then secured to the holding strips (28) and covers the membrane (10) . Air spaces
(32) are defined between the membrane (10) and the interior finish (30) so as to provide an efficient factor R. An efficient factor R can be obtained with an air space of H of an inch.
Figure 3 is a flow sheet showing the steps of a process for a vapor and radiant barrier membrane (10) according to the present invention. Other embodiments and variations thereof within the scope or teaching of this invention will be apparent to one skilled in the art. In the particular embodiment illustrated in Figure 3, the aluminum foil (12) is fed from roll 50 along with the first sheet of polyethylene (16) from roll 52 and the second sheet of polyethylene (18) from roll 54. Then, the aluminum foil (12), the first and the second sheets (14, 16) are all fed to laminating rolls 56 and 58 which press and laminate the foil (12) and the polyethylene sheets (14, 16) together so as to create the vapor and radiant barrier membrane (10) of the present invention which is finally wrapped on the roll 60.
The first sheet of polyethylene (16) is preferably provided in a semi-fluid form which is preferably obtained by heating
the first sheet (16) at about 600°F. The semi-fluid polyethylene of the first sheet (16) acts as an adhesive which falls between the aluminum foil (12) and the second sheet of polyethylene (18) . The first (16) and the second (18) sheets of polyethylene are then bonded or melted altogether so as to form the backing layer (14). The sandwich construction is preferably the result of a mechanical and heated laminated bond between the facing layer (12) and the backing layer (14) of the membrane (10) of the present invention.
Physical properties of a vapor barrier according to the present invention
Weight: approximately 18 lbs/Mpi2 (88 g/m2)
Tensile resistance: Minimum of 23.9 Mpa (longitudinal) Minimum of 19.5 Mpa (transversal)
Saturated vapor pressure : (ASTM-E96 Process "A")
Before ageing, lng/Pa. S. m.2 (0.01147 perms)
After ageing, 4 ng/Pa. S. m2 (0.04588 perms)
Reflection: 97%
Emission: 3%
Flexibility: at -10°C (excellent)
Factor R: as calculated according to the Ashrea Handbook of Insulation, the vapor barrier of the present invention offers a factor R in the order of 2.9 - 3.8. Horizontal heat movement (walls) . In order to obtain this factor R, you must allow a " air-space (20 mm) facing
the radiant surface of the vapor barrier of the present invention.
Evaluation of technical requirements of the vapor barrier of the present invention according to the Canadian Construction Materials Center (CCMC) .
A sample of the present invention was tested in accordance with the CCMC Technical Guide for "Vapor Barrier" Masterformat Section 07261 for the following tests:
Sheet width - Sheet length - Pliability
Tensile strength and elongation
Water vapor permenance (before and after ageing)
The results of the analysis are summarized in Table 1. The sample of the vapor barrier of the present invention has passed the requirements outlined in the CCMC Technical Guide for "Vapor Barrier" Masterformat Section 07261.