WO2004054799A1 - Vapour permeable heat-reflective membranes - Google Patents

Vapour permeable heat-reflective membranes Download PDF

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Publication number
WO2004054799A1
WO2004054799A1 PCT/GB2003/005471 GB0305471W WO2004054799A1 WO 2004054799 A1 WO2004054799 A1 WO 2004054799A1 GB 0305471 W GB0305471 W GB 0305471W WO 2004054799 A1 WO2004054799 A1 WO 2004054799A1
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WO
WIPO (PCT)
Prior art keywords
film
membrane
supporting material
stress
building structure
Prior art date
Application number
PCT/GB2003/005471
Other languages
French (fr)
Inventor
Neil Murray Rideout
Robert Patmore
Original Assignee
Building Product Design Limited
Spunchem Africa (Pty) Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Building Product Design Limited, Spunchem Africa (Pty) Ltd filed Critical Building Product Design Limited
Priority to AU2003290266A priority Critical patent/AU2003290266A1/en
Publication of WO2004054799A1 publication Critical patent/WO2004054799A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B32B15/085—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/14—Layered products comprising a layer of metal next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D12/00—Non-structural supports for roofing materials, e.g. battens, boards
    • E04D12/002—Sheets of flexible material, e.g. roofing tile underlay
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/10—Fibres of continuous length
    • B32B2305/20—Fibres of continuous length in the form of a non-woven mat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/724—Permeability to gases, adsorption
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2311/00—Metals, their alloys or their compounds
    • B32B2311/24—Aluminium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2323/00—Polyalkenes
    • B32B2323/04—Polyethylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2323/00—Polyalkenes
    • B32B2323/10—Polypropylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00—Buildings or parts thereof
    • B32B2419/06—Roofs, roof membranes
    • 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
    • E04B1/625—Sheets or foils allowing passage of water vapor but impervious to liquid water; house wraps
    • 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
    • E04B2001/7691—Heat reflecting layers or coatings

Definitions

  • VAPOUR PERMEABLE HEAT-REFLECTIVE MEMBRANES This invention relates to vapour permeable heat-reflective membranes.
  • Vapour permeable heat-reflective membranes are used for a range of applications.
  • permeable membranes comprising a vacuum aluminised polyethylene substrate.
  • the aluminised surface typically has a dull appearance and therefore has reduced heat reflectivity.
  • a microperforated reflective foil applied to a vapour permeable substrate.
  • microperforation can be an expensive procedure and the perforations can detract from the heat reflectivity of the foil and may not provide sufficient permeability.
  • An object of the present invention is to provide a vapour permeable membrane with good heat reflectivity which is simple and inexpensive to manufacture.
  • a method of forming a vapour permeable heat reflective membrane wherein a pre-formed heat reflective film is applied to at least one face of a vapour permeable supporting material, and the film is made porous by application of stress thereto such as to produce ruptures at multiple locations therein.
  • the pre-formed film can have good heat reflective properties and the stress ruptures need not appreciably disturb such properties.
  • stress rupturing is a process which can be applied in a simple and inexpensive manner e.g. simply by stretching the film.
  • the film may be fixed to the supporting material in any suitable manner e.g. by means of adhesive interposed between the film and the supporting material.
  • This adhesive may be in the form of discrete areas such as dots or lines or stripes or the like. This adhesive may be applied to the supporting material prior to contact with the film.
  • an adhesive-backed film may be used.
  • the adhesive may be a contact adhesive or it may require further treatment or processing such as exposure to heat or radiation or the air to effect bonding.
  • a separate adhesive material for attachment of the film to the supporting material other attachment techniques may be used.
  • the surface of the supporting material may be heated at least in selected areas to achieve melt-bonding to the film.
  • the film is preferably a coherent self-supporting flexible foil with low elongation, such as aluminium foil, having requisite physical properties such as to permit formation of multiple ruptures when stressed, that is the foil may be of a tearable or crackable nature.
  • the supporting material may be of any suitable structure and may be formed from any suitable material or combination of materials.
  • the supporting material is a fabric and this may be a non-woven structure, such as a spun-bonded or flash-bonded structure formed from synthetic strands or fibres such as polypropylene polyester or polyethylene, although any other suitable structure and material or combination of materials may be used.
  • a non-woven structure such as a spun-bonded or flash-bonded structure formed from synthetic strands or fibres such as polypropylene polyester or polyethylene, although any other suitable structure and material or combination of materials may be used.
  • the stress rupturing is applied such as to produce multiple apertures, particularly of the nature of irregular cracks, which are discrete and which provide openings which collectively make up a minor proportion of the surface area of the film, whereby the film, after stress rupturing, remains as a continuous, coherent film.
  • the stress rupturing is carried out after application of the film to the supporting material.
  • the structure of the supporting material is such that it can be stretched without significant disruption thereto and is preferably resiliently or elastically extensible, at least in a direction of stress application, so that after rupturing the supporting material can relax and allow or cause the film to regain substantially its dimensions prior to stressing.
  • Stress may be applied to the film in any suitable manner, particularly in the plane of the film.
  • stress is applied on a continuous or continual basis as the film, preferably united with the fabric, is advanced or fed from a supply device to a take up or storage device.
  • the stress may be applied as the film is fed from a movable supply device such as a feed roller or nip to a movable take up device such as a take up roller or nip with the relative movements of such devices, e.g. the relative rotations of the rollers or nips, selected to cause the film to be stretched in the direction of feed.
  • the membrane of the invention may have the ruptured film on one or both faces of the supporting material. It can be advantageous to have the film on both faces to improve emissivity characteristics.
  • the membrane may be used for any suitable purpose in any suitable context.
  • the membrane may be used in building structures, particularly in external walls and roofs of houses to allow escape of water vapour whilst preventing ingress of liquid water.
  • non-heat reflective vapour permeable membranes comprising non-woven sheets of polypropylene strands are used for this purpose.
  • One example is a timber-frame structure having an inner wall made of timber uprights with insulating material inbetween the uprights, and external brickwork providing an aesthetic rain screen.
  • the external brickwork is built up outside the timber-frame wall on-site.
  • the timber-frame wall is protected from the weather by application of the vapour permeable membrane to its outer surface.
  • the vapour permeable membrane it is possible to utilise a vapour permeable membrane to substantially improve thermal resistance by providing the membrane with heat reflecting properties thereby to impart low emissivity to air cavities within constructional material to which the membrane is applied.
  • the membrane of the invention may be applied to a building structure, particularly a wall or roof structure, which contains one or more cavities, particularly one or more cavities in an insulated structure defined by spaces between structural elements and/or spaces within a body of fibrous or reticulated or other air-containing insulating material, the membrane preferably being fixed with the (or one) said heat reflective film facing the cavity or cavities.
  • the invention may find particular application in the context of a timber-frame structure as described above.
  • the membrane of the present invention may be used for any suitable purpose and in any suitable context not necessarily related to the building industry.
  • the membrane of the invention may be used as an interlining in clothing or for duvets, thermal covers and the like.
  • FIG. 1 is a diagrammatic representation of one apparatus used to make one form of a heat reflective vapour permeable membrane in accordance with the method of the invention
  • FIG. 2 is an enlarged diagrammatic perspective view of an edge region of the membrane.
  • Figure 3 is a perspective view showing the membrane in use in a timber-frame building structure.
  • a sheet 1 of non-woven fabric made from polypropylene strands is fed from a supply roller 2 through a driven roller nip 3.
  • the fabric 1 is spun-bonded and is water-resistant but breathable. That is the strands are sufficiently closely randomly tangled to produce a structure which resists penetration of liquid water and particles e.g. such as rain, dust but which permits escape of water vapour.
  • the fabric is strong, flexible and elastically extensible at least in its longitudinal direction. A top face of the fabric has heat-activated adhesive applied thereto.
  • a sheet 4 of aluminium foil is fed from a second supply roller 5 to the nip 3 over the adhesive-coated top face of the fabric 1 .
  • the aluminium foil 4 is thin and flexible and has a bright highly reflective surface at its top face.
  • the foil 4 is in the form of a coherent continuous imperforate sheet.
  • the adhesive coated face of the fabric 1 and the foil 4 are pressed together and fed through a heater 6 and a further nip 7.
  • the heater 6 activates the adhesive, and the foil 4 and the fabric 1 are bonded together.
  • the adhesive forms a vapour permeable layer between the foil 4 and the fabric 1 .
  • the resulting laminate 8 is fed to a take up roll 9.
  • Laminate 8 is taken off this roll 9 and fed from a further feed roll 1 0 to a further take-up roll 1 1 .
  • This roll 1 1 is driven slightly faster than the roll 1 0 so that the run between the two rolls 10, 1 1 is stretched along the length of the run in the plane of the aluminium foil 4. This causes the foil 4 to rupture producing multiple irregular discrete cracks 1 2 ( Figure 2) distributed over the surface of the foil.
  • the construction of the fabric 1 is such as to permit stretching without significant disruption of the fabric.
  • the stressed laminate 8 is wound onto the take-up roll 1 1 and relaxed the elasticity of the fabric 1 causes the stretched foil 4 to return to its original dimension so that the cracks 1 2 close up sufficiently to give an essentially continuous reflective surface whilst retaining vapour permeable apertures.
  • the resulting laminate 8 is vapour permeable by virtue of the properties of the fabric 1 and the stress rupturing of the foil 4.
  • the ruptured foil retains its bright heat reflective surface.
  • a timber-frame building structure has an inner structural wall 1 3 made from timber uprights 1 4 with thermal insulation 1 5 between the uprights. At its outer face the wall 1 3 is completed with plywood sheeting 1 6. The laminate 8 described above is applied over the uprights 1 4 and the plywood sheeting 1 6 with the foil 4 facing outwardly away from the insulation 1 5. A brick wall 1 7 is constructed in front of the timber wall 1 3 leaving a vented cavity between the bricks and the laminate 8.
  • the insulation material 1 2 contains air-filled pockets and gaps.
  • the invention is not restricted to timber frame walls but may be used in relation to any other kind of wall or roof structure or indeed any other appropriate structure or application including clothing interlining, duvets, thermal covers and the like.
  • the laminate 8 is applied with the foil 4 facing outwardly (into the cavity between the timber frame 1 0 and the brick wall 17) it is also possible to have the foil facing inwardly and advantageously from a low emissivity point of view the foil 4 may be applied to both faces of the fabric 1 .

Abstract

A vapour permeable heat reflective membrane has a heat reflective film (4), such as aluminium foil, applied to the surface of a vapour permeable substrate (1), such as a non-woven fabric. The film (4) is made porous by application of stress to the film to cause it to rupture by stretching between roller nips (3, 7) producing multiple discrete cracks (12). The membrane may be used in a timber-frame house wall between an inner wall (13) made from timber uprights (14) with thermal insulation (15) covered with plywood sheeting (16) and an outer brick wall (17), the membrane (8) being applied to the plywood sheeting (16) with the heat reflective film (4) facing an air cavity between the brick wall (17) and the membrane (8).

Description

VAPOUR PERMEABLE HEAT-REFLECTIVE MEMBRANES This invention relates to vapour permeable heat-reflective membranes.
Vapour permeable heat-reflective membranes are used for a range of applications.
There is however the problem of how to attain good heat reflectivity without unduly adversely affecting the vapour permeability of the membrane, with a construction that is practical to manufacture.
Thus, permeable membranes are known comprising a vacuum aluminised polyethylene substrate. However the aluminised surface typically has a dull appearance and therefore has reduced heat reflectivity. It would also be possible to use a microperforated reflective foil applied to a vapour permeable substrate. However, microperforation can be an expensive procedure and the perforations can detract from the heat reflectivity of the foil and may not provide sufficient permeability.
An object of the present invention is to provide a vapour permeable membrane with good heat reflectivity which is simple and inexpensive to manufacture.
According to the invention therefore there is provided a method of forming a vapour permeable heat reflective membrane wherein a pre-formed heat reflective film is applied to at least one face of a vapour permeable supporting material, and the film is made porous by application of stress thereto such as to produce ruptures at multiple locations therein.
With this arrangement, the pre-formed film can have good heat reflective properties and the stress ruptures need not appreciably disturb such properties. Moreover, stress rupturing is a process which can be applied in a simple and inexpensive manner e.g. simply by stretching the film.
The film may be fixed to the supporting material in any suitable manner e.g. by means of adhesive interposed between the film and the supporting material. This adhesive may be in the form of discrete areas such as dots or lines or stripes or the like. This adhesive may be applied to the supporting material prior to contact with the film. Alternatively an adhesive-backed film may be used. The adhesive may be a contact adhesive or it may require further treatment or processing such as exposure to heat or radiation or the air to effect bonding. Instead of or additionally to the use of a separate adhesive material for attachment of the film to the supporting material other attachment techniques may be used. Thus, for example, in the case of a supporting material which is meltable the surface of the supporting material may be heated at least in selected areas to achieve melt-bonding to the film. The film is preferably a coherent self-supporting flexible foil with low elongation, such as aluminium foil, having requisite physical properties such as to permit formation of multiple ruptures when stressed, that is the foil may be of a tearable or crackable nature.
The supporting material may be of any suitable structure and may be formed from any suitable material or combination of materials.
Preferably the supporting material is a fabric and this may be a non-woven structure, such as a spun-bonded or flash-bonded structure formed from synthetic strands or fibres such as polypropylene polyester or polyethylene, although any other suitable structure and material or combination of materials may be used.
Preferably the stress rupturing is applied such as to produce multiple apertures, particularly of the nature of irregular cracks, which are discrete and which provide openings which collectively make up a minor proportion of the surface area of the film, whereby the film, after stress rupturing, remains as a continuous, coherent film.
Preferably the stress rupturing is carried out after application of the film to the supporting material. In this case desirably the structure of the supporting material is such that it can be stretched without significant disruption thereto and is preferably resiliently or elastically extensible, at least in a direction of stress application, so that after rupturing the supporting material can relax and allow or cause the film to regain substantially its dimensions prior to stressing.
Stress may be applied to the film in any suitable manner, particularly in the plane of the film. Preferably stress is applied on a continuous or continual basis as the film, preferably united with the fabric, is advanced or fed from a supply device to a take up or storage device. Thus, the stress may be applied as the film is fed from a movable supply device such as a feed roller or nip to a movable take up device such as a take up roller or nip with the relative movements of such devices, e.g. the relative rotations of the rollers or nips, selected to cause the film to be stretched in the direction of feed. The membrane of the invention may have the ruptured film on one or both faces of the supporting material. It can be advantageous to have the film on both faces to improve emissivity characteristics.
The membrane may be used for any suitable purpose in any suitable context. Advantageously the membrane may be used in building structures, particularly in external walls and roofs of houses to allow escape of water vapour whilst preventing ingress of liquid water. Typically, non-heat reflective vapour permeable membranes comprising non-woven sheets of polypropylene strands are used for this purpose.
One example is a timber-frame structure having an inner wall made of timber uprights with insulating material inbetween the uprights, and external brickwork providing an aesthetic rain screen.
The external brickwork is built up outside the timber-frame wall on-site. During construction of the brickwork the timber-frame wall is protected from the weather by application of the vapour permeable membrane to its outer surface. As requirements for insulation levels become more demanding it is necessary to enhance the insulation properties of constructional materials of building structures, but, for reasons of economy and convenience, it is desirable to be able to do this without unduly increasing constructional thickness or quality of material. With the present invention it is possible to utilise a vapour permeable membrane to substantially improve thermal resistance by providing the membrane with heat reflecting properties thereby to impart low emissivity to air cavities within constructional material to which the membrane is applied. Thus, the membrane of the invention may be applied to a building structure, particularly a wall or roof structure, which contains one or more cavities, particularly one or more cavities in an insulated structure defined by spaces between structural elements and/or spaces within a body of fibrous or reticulated or other air-containing insulating material, the membrane preferably being fixed with the (or one) said heat reflective film facing the cavity or cavities.
The invention may find particular application in the context of a timber-frame structure as described above.
It is however to be understood that the membrane of the present invention may be used for any suitable purpose and in any suitable context not necessarily related to the building industry. For example the membrane of the invention may be used as an interlining in clothing or for duvets, thermal covers and the like.
The invention will now be described further by way of example only and with reference to the accompanying drawings in which:- Figure 1 is a diagrammatic representation of one apparatus used to make one form of a heat reflective vapour permeable membrane in accordance with the method of the invention;
/ Figure 2 is an enlarged diagrammatic perspective view of an edge region of the membrane; and
Figure 3 is a perspective view showing the membrane in use in a timber-frame building structure.
Referring to Figure 1 a sheet 1 of non-woven fabric made from polypropylene strands is fed from a supply roller 2 through a driven roller nip 3.
The fabric 1 is spun-bonded and is water-resistant but breathable. That is the strands are sufficiently closely randomly tangled to produce a structure which resists penetration of liquid water and particles e.g. such as rain, dust but which permits escape of water vapour. The fabric is strong, flexible and elastically extensible at least in its longitudinal direction. A top face of the fabric has heat-activated adhesive applied thereto.
A sheet 4 of aluminium foil is fed from a second supply roller 5 to the nip 3 over the adhesive-coated top face of the fabric 1 . The aluminium foil 4 is thin and flexible and has a bright highly reflective surface at its top face. The foil 4 is in the form of a coherent continuous imperforate sheet. At the nip 3 the adhesive coated face of the fabric 1 and the foil 4 are pressed together and fed through a heater 6 and a further nip 7. The heater 6 activates the adhesive, and the foil 4 and the fabric 1 are bonded together. The adhesive forms a vapour permeable layer between the foil 4 and the fabric 1 . The resulting laminate 8 is fed to a take up roll 9. Laminate 8 is taken off this roll 9 and fed from a further feed roll 1 0 to a further take-up roll 1 1 .
This roll 1 1 is driven slightly faster than the roll 1 0 so that the run between the two rolls 10, 1 1 is stretched along the length of the run in the plane of the aluminium foil 4. This causes the foil 4 to rupture producing multiple irregular discrete cracks 1 2 (Figure 2) distributed over the surface of the foil. The construction of the fabric 1 is such as to permit stretching without significant disruption of the fabric. As the stressed laminate 8 is wound onto the take-up roll 1 1 and relaxed the elasticity of the fabric 1 causes the stretched foil 4 to return to its original dimension so that the cracks 1 2 close up sufficiently to give an essentially continuous reflective surface whilst retaining vapour permeable apertures.
The resulting laminate 8 is vapour permeable by virtue of the properties of the fabric 1 and the stress rupturing of the foil 4. The ruptured foil retains its bright heat reflective surface.
As shown in Figure 3, a timber-frame building structure has an inner structural wall 1 3 made from timber uprights 1 4 with thermal insulation 1 5 between the uprights. At its outer face the wall 1 3 is completed with plywood sheeting 1 6. The laminate 8 described above is applied over the uprights 1 4 and the plywood sheeting 1 6 with the foil 4 facing outwardly away from the insulation 1 5. A brick wall 1 7 is constructed in front of the timber wall 1 3 leaving a vented cavity between the bricks and the laminate 8.
The insulation material 1 2 contains air-filled pockets and gaps.
Heat from the insulation material 1 5 and from these pockets and gaps which reaches the laminate 8 escapes slowly due to the low thermal emissivity of the foil 4-. This provides or enhances low emissivity properties for the pockets and gaps and the insulation material itself.
High thermal resistance can therefore be achieved in a convenient and cost effective manner.
It is of course to be understood that the invention is not intended to be restricted to the details of the above embodiment which are described by way of example only.
Thus, the invention is not restricted to timber frame walls but may be used in relation to any other kind of wall or roof structure or indeed any other appropriate structure or application including clothing interlining, duvets, thermal covers and the like.
Also, whilst as described the laminate 8 is applied with the foil 4 facing outwardly (into the cavity between the timber frame 1 0 and the brick wall 17) it is also possible to have the foil facing inwardly and advantageously from a low emissivity point of view the foil 4 may be applied to both faces of the fabric 1 .

Claims

1 . A method of forming a vapour permeable heat reflective membrane wherein a pre-formed heat reflective film is applied to at least one face of a vapour permeable supporting material, and the film is made porous by application of stress thereto such as to produce ruptures at multiple locations therein.
2. A method according to claim 1 wherein the film is attached to the supporting material by means of adhesive.
3. A method according to claim 1 wherein the supporting material is meltable and the film is attached to the supporting material by heating the supporting material to achieve melt-bonding to the film.
4. A method according to any one of claims 1 to 3 wherein the film is a coherent, self-supporting flexible foil which is of a tearable or crackable nature.
5. A method according to claim 4 wherein the foil is aluminium foil.
6. A method according to any one of claims 1 to 5 wherein the supporting material is a fabric.
7. A method according to claim 6 wherein the fabric is a non-woven structure.
8. A method according to any one of claims 1 to 7 wherein the stress rupturing is applied to produce discrete said ruptures.
9. A method according to claim 8 wherein the ruptures provide openings which collectively make up a minor proportion of the surface area of the film.
1 0. A method according to any one of claims 1 to 9 wherein the stress rupturing is carried out after application of the film to the supporting material.
1 1 . A method accordingly to claim 10 wherein the supporting material is elastically extensible at least in a direction of stress application.
1 2. A method according to claim 1 1 wherein after rupturing the support material is allowed to relax to allow or cause the film to regain substantially its dimensions prior to stressing.
1 3. A method according to any one of claims 1 to 1 2 wherein stress is applied on a continuous or continual basis as the film is advanced from a supply device to a take up or storage device.
14. A method according to claim 1 3 wherein the stress is applied as the film is fed from a movable supply device to a movable take up device with the relative movements of such devices selected to cause the film to be stretched in the direction of feed.
1 5. A method according to claim 1 4 wherein the movable devices comprise rotatable rollers or roller nips.
1 6. A method according to any one of claims 1 to 1 5 wherein said ruptured film is applied to opposite faces of the supporting material.
1 7. A membrane when made by the method of any one of claims 1 to 1 6.
1 8. A building structure incorporating a membrane according to claim 1 7.
1 9. A building structure according to claim 1 8 which is a wall of a house.
20. A building structure according to claim 1 8 which is a roof of a house.
21 . A building structure according to any one of claims 1 8-20 which contains at least one cavity, the membrane being fixed with the (or one) said heat reflective film facing the cavity.
22. A building structure according to claim 21 when dependent on claim 1 9 which is an insulated wall structure and wherein the cavity is defined by a space between inner and outer structural elements.
23. A building structure according to claim 22 which is a timber-frame structure having an inner structural element made of timber uprights with insulating material therebetween and an external brickwork structural element.
24. A membrane according to claim 1 substantially as hereinbefore described with reference to and as illustrated in the accompanying drawings.
25. A building structure according to claim 1 8 substantially as hereinbefore described with reference to and as illustrated in the accompanying drawings.
PCT/GB2003/005471 2002-12-17 2003-12-16 Vapour permeable heat-reflective membranes WO2004054799A1 (en)

Priority Applications (1)

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AU2003290266A AU2003290266A1 (en) 2002-12-17 2003-12-16 Vapour permeable heat-reflective membranes

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GB0229411.4 2002-12-17
GBGB0229411.4A GB0229411D0 (en) 2002-12-17 2002-12-17 Vapour permeable heat-reflective membranes

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GB2451183A (en) * 2007-07-17 2009-01-21 Thermal Economics Ltd Improved thermal insulation
WO2009039557A1 (en) * 2007-09-25 2009-04-02 2020 Constructions Systems Pty Ltd Wall and method of forming a wall
WO2013059240A1 (en) * 2011-10-17 2013-04-25 Aspenson Mark A Building insulation system
DE102016118484A1 (en) 2015-11-10 2017-05-11 WIDO–PROFIL – Spółka z ograniczoną odpowiedzialnością Insulating composite panel
WO2021206572A1 (en) 2020-04-06 2021-10-14 Wido-Profil - Sp. Z O. O. Method of manufacturing vapor-permeable insulating panel and vapor-permeable insulating panel
US11958308B1 (en) 2023-05-31 2024-04-16 G13 Innovation In Production Ltd Thermal paper, and methods and systems for forming the same

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Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2451183A (en) * 2007-07-17 2009-01-21 Thermal Economics Ltd Improved thermal insulation
GB2451183B (en) * 2007-07-17 2010-07-07 Thermal Economics Ltd Improved thermal Insulation
WO2009039557A1 (en) * 2007-09-25 2009-04-02 2020 Constructions Systems Pty Ltd Wall and method of forming a wall
WO2013059240A1 (en) * 2011-10-17 2013-04-25 Aspenson Mark A Building insulation system
DE102016118484A1 (en) 2015-11-10 2017-05-11 WIDO–PROFIL – Spółka z ograniczoną odpowiedzialnością Insulating composite panel
WO2021206572A1 (en) 2020-04-06 2021-10-14 Wido-Profil - Sp. Z O. O. Method of manufacturing vapor-permeable insulating panel and vapor-permeable insulating panel
US11958308B1 (en) 2023-05-31 2024-04-16 G13 Innovation In Production Ltd Thermal paper, and methods and systems for forming the same

Also Published As

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AU2003290266A8 (en) 2004-07-09
GB0229411D0 (en) 2003-01-22

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