WO2007022548A2 - Insulating product and method of manufacture - Google Patents

Insulating product and method of manufacture Download PDF

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Publication number
WO2007022548A2
WO2007022548A2 PCT/ZA2006/000101 ZA2006000101W WO2007022548A2 WO 2007022548 A2 WO2007022548 A2 WO 2007022548A2 ZA 2006000101 W ZA2006000101 W ZA 2006000101W WO 2007022548 A2 WO2007022548 A2 WO 2007022548A2
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WO
WIPO (PCT)
Prior art keywords
liquid
substance
product
product according
fibrous
Prior art date
Application number
PCT/ZA2006/000101
Other languages
French (fr)
Other versions
WO2007022548A3 (en
Inventor
Michael John Bywater
Brian Lupton-Smith
Original Assignee
Michael John Bywater
Brian Lupton-Smith
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 Michael John Bywater, Brian Lupton-Smith filed Critical Michael John Bywater
Publication of WO2007022548A2 publication Critical patent/WO2007022548A2/en
Publication of WO2007022548A3 publication Critical patent/WO2007022548A3/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
    • 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
    • B32B5/22—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0043—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by their foraminous structure; Characteristics of the foamed layer or of cellular layers
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0056—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the compounding ingredients of the macro-molecular coating
    • 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
    • E04B1/80—Heat insulating elements slab-shaped
    • E04B1/806—Heat insulating elements slab-shaped with air or gas pockets included in the slab
    • 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
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0253—Polyolefin fibres
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/06—Vegetal fibres
    • B32B2262/062—Cellulose fibres, e.g. cotton
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/06—Vegetal fibres
    • B32B2262/062—Cellulose fibres, e.g. cotton
    • B32B2262/065—Lignocellulosic fibres, e.g. jute, sisal, hemp, flax, bamboo
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • 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
    • B32B2307/304—Insulating
    • 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
    • B32B2307/306—Resistant to heat
    • B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
    • 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
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B2001/742—Use of special materials; Materials having special structures or shape
    • E04B2001/745—Vegetal products, e.g. plant stems, barks
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A30/00—Adapting or protecting infrastructure or their operation
    • Y02A30/24—Structural elements or technologies for improving thermal insulation
    • Y02A30/244—Structural elements or technologies for improving thermal insulation using natural or recycled building materials, e.g. straw, wool, clay or used tires

Definitions

  • This invention relates to an insulating product which is suitable for use as a roof insulating material.
  • the scope of the invention is however not limited to this particular application.
  • Typical roof insulating materials known to the applicants include a sheet material with one or more silvered or reflective surfaces which reflect heat from the material, and a lofted fibrous and plastics bubble product which limits heat transmission through the product. To the applicants' knowledge these products display only limited fire retardancy characteristics.
  • the invention is concerned with a product which is readily manufactured and which offers good thermal insulation and fire resistant qualities.
  • the invention provides an insulating product which includes a material which is at least partly impregnated with a substance which includes a plurality of encased gaseous voids.
  • the material may be of a nature which permits the material to expand to a limited extent under the action of the substance.
  • the material may thus have interstices, voids or cavities which the substance can occupy.
  • the material may be porous or fibrous.
  • the material should, itself, be a poor heat conductor i.e. offer good thermal insulation properties.
  • the material should inherently have a fire retardant characteristic or it should be treated with an appropriate fire retardant so as to exhibit this characteristic.
  • the material should also be able to bond or key to the substance, a requirement which can be met, for example, by the porous or fibrous nature of the material.
  • the weight or density of the material may vary according to requirement. Similarly its thickness may vary according to requirement. Merely by way of non- limiting examples the material may have a density of from 50g/m 2 to 200g/m 2 and a thickness of 2mm and upwards.
  • the material may be provided in sheet form and the substance may extend on one side of the sheet or on both sides.
  • use is made of at least two sheets or layers of material and the substance is positioned, at least, between the layers. With this variation the substance preferably also penetrates, at least partly, the layers.
  • the substance may be a gaseous synthetic chemical, for example of an expandable or pre-expandable thermoplastics material which may be blended with other materials or desired properties for example a flame retardant modifier and a synthetic binder.
  • the insulating product is preferably provided in sheet form but this is a non- limiting shape.
  • the invention also extends to a method of forming an insulating product which includes the steps of at least partly impregnating a porous or fibrous material with a liquid, causing a plurality of gaseous voids to be generated within the liquid and allowing the liquid to set with a plurality of entrapped gaseous voids within or on the material.
  • the volume of the porous fibrous material and the liquid may be increased.
  • the voids may be generated in any appropriate way, for example by exposing the liquid to an energy source which raises the temperature of the liquid.
  • the energy source may be a thermal oven, an infrared source or the like.
  • the temperature of the liquid may be raised for a controlled period. Merely by way of example the temperature of the liquid may be raised to a temperature of from 100 0 C to 160 0 C for a period of from 15s to 90s.
  • the liquid may be impregnated into the material in any appropriate way and the invention is not limited in this regard.
  • the material is immersed in a bath of the liquid.
  • the liquid is applied to one side of the material which acts as a substrate or underlying layer which receives the liquid.
  • the liquid is positioned in sandwich form between two opposing sheets of the material. This allows the liquid to penetrate each of the sheets.
  • the liquid may be impregnated into the material using spray, direct or indirect foam, printing or lick roller baths or similar application techniques.
  • the material and the liquid Prior to the generation of the voids the material and the liquid may be subjected to a roller or vacuuming process to extract excess liquid and to produce an intermediate product which is of a predetermined thickness before that intermediate product is subjected to the void-generating step.
  • the insulating product of the invention can be laminated or printed to meet specific market requirements.
  • a sheet can for example be laminated to an outer surface of the product after its manufacture, or as a final step in the manufacture of the finished product.
  • the invention is based on the provision of an insulating product which comprises a fibrous material impregnated with a gaseous or void forming synthetic chemical.
  • the fibrous material may be a synthetic fibre such as glass, polyester, nylon or polypropylene or a natural fibre such as cotton or coir.
  • the synthetic chemical may be an expandable or pre-expandable thermoplastics material which includes a large number of microspheres with gas-proof shells which contain a liquid hydrocarbon.
  • the chemical is blended with water, a synthetic binder, a filler, a flame retardant and a rot-proofing agent to enhance its end properties.
  • a suitable chemical is that sold under the name ExpancelTM by Akzo Nobel of Sweden.
  • the fibrous material should be an effective thermal insulator. If the fibrous material is not inherently fire resistant it should be treated to be flame retardant. Similar considerations apply to the substance which is impregnated into the fibrous material.
  • FIG. 1 of the accompanying drawings illustrates one way of making an insulating product 10 according to the invention.
  • a fibrous layer 14 of any of the indicated materials for example of polyester, which is loosely structured or air-layed using conventional techniques, and which has a weight of from 80 to 200 g/m 2 , acts as a substrate which is passed over a bed, not shown, and a chemical 16 is applied to an upper surface of the substrate.
  • thermoplastic substance 18 which is mixed by means of a blender 20 with a flame retardant 22, a binder 24 and other ingredients.
  • the chemical 16 is applied to the substrate in any appropriate way for example by using a spray or a direct or indirect foam applicator.
  • the thickness 28 of the substance, on the substrate is controlled by means of a skimmer 30 which scrapes excess material from the substrate.
  • a second layer 32 of the fibrous material is brought into close contact with an upper surface of the chemical and the two layers of fibrous material with the liquid sandwiched between them are passed through padded rollers 34 or are subjected to a slot vacuuming system (not shown) to remove excess chemical. This step also ensures that the chemical, in the illustrated example, is fully impregnated into the fibrous layers.
  • the product then passes to a drying and curing stage 38 where moisture is released from the chemical and expansion and film forming of the product take place.
  • the drying and curing stage can be carried out by direct heating in a hot air over or by infrared techniques.
  • the temperature in the oven is controlled in the range of from 120 0 C to 160 0 C.
  • the dwell time i.e. the time for which the product is exposed to the heating process, is subject to a number of variables but typically lies in the range of from 30s to 90s.
  • the thermoplastic substance 18 includes small particles 18A of liquid hydrocarbon which are thoroughly dispersed in the chemical 16. When exposed to heat these hydrocarbon particles gasify and expand, forming a large number of entrapped gaseous microspheres or voids 18B. This results in an expansion of the
  • the product 10 which emerges from the oven in this example, consists of the expanded thermoplastic material which includes a plurality of gaseous voids 18B sandwiched between opposed layers 14 and 32 of fibrous material into or onto which the thermoplastic material is adhered. At least to a limited extent the thickness of each fibrous layer is increased by the reaction of the chemical within the fibrous layer.
  • the product 10 can be processed into rolls or cut to size, according to requirement, and is ready for use. Optionally however it is possible to laminate the product onto carriers, not shown, or to print patterns or designs onto the product, using silk screening or other techniques, to meet customer requirements.
  • Figure 2 illustrates a process for making an insulating product 10A which bears many similarities to what has been described in connection with Figure 1 and, for this reason, like reference numerals are used to designate like components. Only the differences between the process of Figure 2 and the process of Figure 1 are described.
  • the chemical 16 is directly applied to a fibrous or porous substrate 14 using a spray device 40.
  • the thickness of the chemical on the substrate is controlled using a scraper, not shown, and the product is then subjected to a drying and curing process in an oven 38.
  • the product 10A which emerges from the oven includes a single layer of the substrate fibrous material with the expanded insulating substance 16A set and adhering thereto due to the at least partial impregnation of the fibrous material by the chemical.
  • Figure 3 shows a process wherein a substrate 14 of fibrous material is guided by means of a number of rollers 44 through a bath 46 which contains the chemical 16 in liquid form.
  • the material 14 is fully immersed in the chemical and then passes through padded rollers 34 before going to the oven 38.
  • the insulating product 10B emerging from the oven is generally similar to the product 10A shown in Figure 2 although the void-containing substance produced by the chemical 16 is present to a greater extent on an underside of the substrate compared to the Figure 2 case.

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Architecture (AREA)
  • Textile Engineering (AREA)
  • Acoustics & Sound (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
  • Insulating Bodies (AREA)

Abstract

An insulating product (10) which comprises a fibrous material (14) which is at least partly impregnated with a thermo-plastics substance (18) which, once heated, produces a plurality of encased gaseous voids (18B).

Description

INSULATING PRODUCT
BACKGROUND OF THE INVENTION
[0001] This invention relates to an insulating product which is suitable for use as a roof insulating material. The scope of the invention is however not limited to this particular application.
[0002] Typical roof insulating materials known to the applicants include a sheet material with one or more silvered or reflective surfaces which reflect heat from the material, and a lofted fibrous and plastics bubble product which limits heat transmission through the product. To the applicants' knowledge these products display only limited fire retardancy characteristics.
[0003] The invention is concerned with a product which is readily manufactured and which offers good thermal insulation and fire resistant qualities.
SUMMARY OF INVENTION
[0004] The invention provides an insulating product which includes a material which is at least partly impregnated with a substance which includes a plurality of encased gaseous voids.
[0005] The material may be of a nature which permits the material to expand to a limited extent under the action of the substance. The material may thus have interstices, voids or cavities which the substance can occupy. For example the material may be porous or fibrous. The material should, itself, be a poor heat conductor i.e. offer good thermal insulation properties. The material should inherently have a fire retardant characteristic or it should be treated with an appropriate fire retardant so as to exhibit this characteristic. The material, should also be able to bond or key to the substance, a requirement which can be met, for example, by the porous or fibrous nature of the material.
[0006] The weight or density of the material may vary according to requirement. Similarly its thickness may vary according to requirement. Merely by way of non- limiting examples the material may have a density of from 50g/m2 to 200g/m2 and a thickness of 2mm and upwards.
[0007] The material may be provided in sheet form and the substance may extend on one side of the sheet or on both sides. In a variation of the invention use is made of at least two sheets or layers of material and the substance is positioned, at least, between the layers. With this variation the substance preferably also penetrates, at least partly, the layers.
[0008] The substance may be a gaseous synthetic chemical, for example of an expandable or pre-expandable thermoplastics material which may be blended with other materials or desired properties for example a flame retardant modifier and a synthetic binder.
[0009] The insulating product is preferably provided in sheet form but this is a non- limiting shape.
[0010] The invention also extends to a method of forming an insulating product which includes the steps of at least partly impregnating a porous or fibrous material with a liquid, causing a plurality of gaseous voids to be generated within the liquid and allowing the liquid to set with a plurality of entrapped gaseous voids within or on the material.
[0011] When the voids are generated the volume of the porous fibrous material and the liquid may be increased.
[0012] The voids may be generated in any appropriate way, for example by exposing the liquid to an energy source which raises the temperature of the liquid. The energy source may be a thermal oven, an infrared source or the like. The temperature of the liquid may be raised for a controlled period. Merely by way of example the temperature of the liquid may be raised to a temperature of from 1000C to 1600C for a period of from 15s to 90s.
[0013] The liquid may be impregnated into the material in any appropriate way and the invention is not limited in this regard. In one form of the invention the material is immersed in a bath of the liquid. In second form of the invention the liquid is applied to one side of the material which acts as a substrate or underlying layer which receives the liquid. In another form of the invention the liquid is positioned in sandwich form between two opposing sheets of the material. This allows the liquid to penetrate each of the sheets.
[0014] The liquid may be impregnated into the material using spray, direct or indirect foam, printing or lick roller baths or similar application techniques.
[0015] Prior to the generation of the voids the material and the liquid may be subjected to a roller or vacuuming process to extract excess liquid and to produce an intermediate product which is of a predetermined thickness before that intermediate product is subjected to the void-generating step. [0016] The insulating product of the invention can be laminated or printed to meet specific market requirements. A sheet can for example be laminated to an outer surface of the product after its manufacture, or as a final step in the manufacture of the finished product.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The invention is further described by way of examples with reference to the accompanying drawings Figures 1 to 3 each of which illustrates a respective manner of making an insulating product according to the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0018] In broad terms the invention is based on the provision of an insulating product which comprises a fibrous material impregnated with a gaseous or void forming synthetic chemical.
[0019] The fibrous material may be a synthetic fibre such as glass, polyester, nylon or polypropylene or a natural fibre such as cotton or coir. The synthetic chemical may be an expandable or pre-expandable thermoplastics material which includes a large number of microspheres with gas-proof shells which contain a liquid hydrocarbon. The chemical is blended with water, a synthetic binder, a filler, a flame retardant and a rot-proofing agent to enhance its end properties. A suitable chemical is that sold under the name Expancel™ by Akzo Nobel of Sweden.
[0020] The fibrous material should be an effective thermal insulator. If the fibrous material is not inherently fire resistant it should be treated to be flame retardant. Similar considerations apply to the substance which is impregnated into the fibrous material.
[0021] Figure 1 of the accompanying drawings illustrates one way of making an insulating product 10 according to the invention.
[0022] A fibrous layer 14 of any of the indicated materials, for example of polyester, which is loosely structured or air-layed using conventional techniques, and which has a weight of from 80 to 200 g/m2, acts as a substrate which is passed over a bed, not shown, and a chemical 16 is applied to an upper surface of the substrate.
[0023] As is indicated somewhat symbolically the chemical is produced from a thermoplastic substance 18 which is mixed by means of a blender 20 with a flame retardant 22, a binder 24 and other ingredients.
[0024] The chemical 16 is applied to the substrate in any appropriate way for example by using a spray or a direct or indirect foam applicator. The thickness 28 of the substance, on the substrate, is controlled by means of a skimmer 30 which scrapes excess material from the substrate. Thereafter a second layer 32 of the fibrous material is brought into close contact with an upper surface of the chemical and the two layers of fibrous material with the liquid sandwiched between them are passed through padded rollers 34 or are subjected to a slot vacuuming system (not shown) to remove excess chemical. This step also ensures that the chemical, in the illustrated example, is fully impregnated into the fibrous layers.
[0025] The product then passes to a drying and curing stage 38 where moisture is released from the chemical and expansion and film forming of the product take place. The drying and curing stage can be carried out by direct heating in a hot air over or by infrared techniques. The temperature in the oven is controlled in the range of from 1200C to 1600C. The dwell time, i.e. the time for which the product is exposed to the heating process, is subject to a number of variables but typically lies in the range of from 30s to 90s.
[0026] The thermoplastic substance 18 includes small particles 18A of liquid hydrocarbon which are thoroughly dispersed in the chemical 16. When exposed to heat these hydrocarbon particles gasify and expand, forming a large number of entrapped gaseous microspheres or voids 18B. This results in an expansion of the
volume of the chemical which manifests itself in an increase in the thickness of the segment between the two fibrous layers.
[0027] The product 10 which emerges from the oven, in this example, consists of the expanded thermoplastic material which includes a plurality of gaseous voids 18B sandwiched between opposed layers 14 and 32 of fibrous material into or onto which the thermoplastic material is adhered. At least to a limited extent the thickness of each fibrous layer is increased by the reaction of the chemical within the fibrous layer.
[0028] The product 10 can be processed into rolls or cut to size, according to requirement, and is ready for use. Optionally however it is possible to laminate the product onto carriers, not shown, or to print patterns or designs onto the product, using silk screening or other techniques, to meet customer requirements.
[0029] Figure 2 illustrates a process for making an insulating product 10A which bears many similarities to what has been described in connection with Figure 1 and, for this reason, like reference numerals are used to designate like components. Only the differences between the process of Figure 2 and the process of Figure 1 are described.
[0030] The chemical 16 is directly applied to a fibrous or porous substrate 14 using a spray device 40. The thickness of the chemical on the substrate is controlled using a scraper, not shown, and the product is then subjected to a drying and curing process in an oven 38. The product 10A which emerges from the oven includes a single layer of the substrate fibrous material with the expanded insulating substance 16A set and adhering thereto due to the at least partial impregnation of the fibrous material by the chemical.
[0031] Figure 3 shows a process wherein a substrate 14 of fibrous material is guided by means of a number of rollers 44 through a bath 46 which contains the chemical 16 in liquid form. The material 14 is fully immersed in the chemical and then passes through padded rollers 34 before going to the oven 38. The insulating product 10B emerging from the oven is generally similar to the product 10A shown in Figure 2 although the void-containing substance produced by the chemical 16 is present to a greater extent on an underside of the substrate compared to the Figure 2 case.

Claims

1. An insulating product which includes a material which is at least partly impregnated with a substance which includes a plurality of encased gaseous voids.
2. A product according to claim 1 which is in sheet form.
3. A product according to claim 1 wherein the material is fibrous or porous.
4. A product according to claim 1 wherein the material is a fibrous material selected from glass, nylon, polypropylene, polyester, cotton and coir.
5. A product according to claim 1 wherein the material is a fibrous material which is loosely structured or air-layed or treated to permit penetration of the substance into at least part of the fibrous material.
6. A product according to claim 1 wherein the material has a density of from 50g/m2 to 200g/m2 and a thickness of at least 2mm.
7. A product according to claim 1 wherein the material is in sheet form and the substance is at least on one side of the sheet.
8. A product according to claim 1 wherein the material is in at least two layers and the substance is positioned, at least, between the layers.
9. A product according to claim 1 wherein the substance includes an expandable or pre-expandable thermoplastics material which is blended with a flame retardant modifier and a synthetic binder.
10. A method of forming an insulating product which includes the steps of at least partly impregnating a porous or fibrous material with a liquid, causing a plurality of gaseous voids to be generated within the liquid and allowing the liquid to set with a plurality of entrapped gaseous voids within or on the material.
11. A method according to claim 10 wherein the voids are generated by exposing the liquid to an energy source which raises the temperature of the liquid.
12. A method according to claim 10 wherein the liquid is impregnated into the material by one of the following: a) immersing the material into a bath of the liquid; b) applying the liquid to one side of the material; and
c) positioning the liquid between two opposing sheets of the material.
13. A method according to claim 10 which includes the steps of removing, excess liquid from the material before generating the voids.
PCT/ZA2006/000101 2005-08-15 2006-08-15 Insulating product and method of manufacture WO2007022548A2 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ZA2005/06736 2005-08-15
ZA200506736 2005-08-15

Publications (2)

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WO2007022548A3 WO2007022548A3 (en) 2007-05-31

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WO (1) WO2007022548A2 (en)
ZA (1) ZA200801214B (en)

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1995008661A1 (en) * 1993-09-21 1995-03-30 W.L. Gore & Associates, Inc. Puffed insulative material and methods for making such material
US20010038893A1 (en) * 2000-01-26 2001-11-08 Mohan Kosaraju Krishna Low density paperboard articles
US20020013389A1 (en) * 2000-02-02 2002-01-31 Taylor Donald W. Polymeric blends and composites and laminates thereof
US20030138594A1 (en) * 2002-01-18 2003-07-24 Honeywell International, Inc., Law Dept. Non-woven shaped fiber media loaded with expanded polymer microspheres
US20030198780A1 (en) * 2002-04-17 2003-10-23 Campese John A. Resin formulation
US20040229052A1 (en) * 2003-01-29 2004-11-18 Elkcorp Composite material

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1995008661A1 (en) * 1993-09-21 1995-03-30 W.L. Gore & Associates, Inc. Puffed insulative material and methods for making such material
US20010038893A1 (en) * 2000-01-26 2001-11-08 Mohan Kosaraju Krishna Low density paperboard articles
US20020013389A1 (en) * 2000-02-02 2002-01-31 Taylor Donald W. Polymeric blends and composites and laminates thereof
US20030138594A1 (en) * 2002-01-18 2003-07-24 Honeywell International, Inc., Law Dept. Non-woven shaped fiber media loaded with expanded polymer microspheres
US20030198780A1 (en) * 2002-04-17 2003-10-23 Campese John A. Resin formulation
US20040229052A1 (en) * 2003-01-29 2004-11-18 Elkcorp Composite material

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ZA200801214B (en) 2009-01-28

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