The present invention relates to insulation layers, and more particularly, to a system and method for providing reflective insulation layers.
Thermal insulation is an important characteristic of most residential, commercial, agricultural, and industrial building structures, including residences. Conventional thermal insulation systems include reflective insulation technology, which attempts to reflect heat energy back to the atmosphere and/or not emit heat energy into a structure during the summer. Additionally, this conventional reflective insulation technology attempts to reflect heat energy back into the structure and/or not emit heat energy into the atmosphere during the winter. For example, the assignee of the present application designed a reflective insulation layer including a metallic foil layer, a paper layer, and a paper expander integral with the paper layer, which couples the metallic foil layer and the paper layer.
However, conventional reflective insulation systems have several shortcomings. For example, conventional reflective insulation systems include cellulose, a material which, in the presence of moisture, can facilitate the growth of mold. Additionally, the layers of conventional reflective insulation systems do not structurally accommodate vapor transmission, without perforations through all the layers.
Accordingly, it would be advantageous to provide a system for providing a reflective insulation system which does not facilitate the growth of mold and further provides vapor transmission to all of the layers of the reflective insulation system.
In one embodiment of the present invention, a reflective insulation layer is provided for a structure. The structure includes a wall and spaced-apart strips which extend along the wall from a top portion of the wall to a bottom portion of the wall. The reflective insulation layer includes a low emittance layer having first perforations, and a synthetic polymer layer having second perforations. Additionally, the reflective insulation layer includes an expander spaced between the low emittance layer and the synthetic polymer layer. The expander couples the low emittance layer to the synthetic polymer layer to form a first air space between the low emittance layer and the synthetic polymer layer.
In another embodiment of the present invention, a reflective insulation layer is provided for a structure. The structure includes a wall and spaced-apart strips which extend along the wall from a top portion of the wall to a bottom portion of the wall. The reflective insulation layer includes a low emittance layer, an intermediate low emittance layer, and an outer synthetic polymer layer. A first expander is spaced between the low emittance layer and the intermediate low emittance layer, to form a first air space between the low emittance layer and the intermediate low emittance layer. Additionally, a second expander is spaced between the intermediate low emittance layer and the outer synthetic polymer layer, to form a second air space between the intermediate low emittance layer and the outer synthetic polymer layer.
In another embodiment of the present invention, a method is provided for providing reflective insulation for a structure. The structure has a wall and spaced-apart strips extending along the wall from a top portion of the wall to a bottom portion of the wall. The method includes forming a reflective insulation layer. The step of forming the reflective insulation layer includes forming a first plurality of perforations in a low emittance layer, and forming a second plurality of perforations in a synthetic polymer layer. Additionally, the step of forming the reflective insulation layer includes spacing an expander between the low emittance layer and the synthetic polymer layer, where the expander couples the low emittance layer to the synthetic polymer layer, to form a first air space between the low emittance layer and the synthetic polymer layer.
A more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the embodiments of the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
In describing particular features of different embodiments of the present invention, number references will be utilized in relation to the figures accompanying the specification. Similar or identical number references in different figures may be utilized to indicate similar or identical components among different embodiments of the present invention.
Additionally, the reflective insulation layer 10 includes an expander 36 which is spaced between the low emittance layer 28 and the synthetic polymer layer 32, and is configured to couple the low emittance layer 28 to the synthetic polymer layer 32 to form a first reflective air space 38 between the low emittance layer 28 and the synthetic polymer layer 32. The expander 36 is coupled to respective inner surfaces 40,42 of the low emittance layer 28 and the synthetic polymer layer 32. Although
The first perforations 30 in the low emittance layer 28 and the second perforations 34 in the synthetic polymer layer 32 are configured to permit vapor transmission through the respective low emittance layer 28 and synthetic polymer layer 32. The synthetic polymer layer 32 is formed from a mold-resistant material, such as a material excluding cellulose to enhance a resistance to of the growth of mold. In an exemplary embodiment of the present invention, a reflective insulation layer 10 may achieve one or more of the following performance characteristics: no growth of mold & mildew in accordance with ASTM C1338, an approximate 7.46 water vapor permeance in accordance with ASTM E96, an approximate <25 flame spread rating, an approximate <50 smoke developed rating, a class A interior wall and ceiling finish classification in accordance with ASTM E84; no corrosivity, no bleeding, and no delamination, in accordance with ASTM D3310; and an approximate 0.034 foil emittance in accordance with ASTM C1371, for example. The numeric performance characteristics listed above are merely exemplary, and the synthetic polymer layer of the present invention may be formed from a mold-resistant material which deviates from these numeric performance characteristics, yet still achieves an acceptable level of mold resistance.
As illustrated in
In securing the first and second side 44,46 of the reflective insulation layer 10 to the respective first and second strip 16,18, the reflective insulation layer 10 is oriented with the synthetic polymer layer 32 facing an opposite direction to the wall 14 and the low emittance layer 28 facing the wall 14. The first side 44 is attached along the first strip 16 from the top portion 24 to the bottom portion 26 of the wall 14. The reflective insulation layer 10 is severed across the width 33 adjacent to the bottom portion 26 of the wall 14. The reflective insulation layer 10 is stretched across the width 33 between the first and second strip 16,18, upon which the second side 46 is attached along the second strip 18 from the top portion 24 to the bottom portion 26. Additionally, a top end 54 and a bottom end 56 of the reflective insulation layer 10 opposite to the top end of the reflective insulation layer are respectively attached, such as with staples, screws, or an adhesive, to a top strip and a bottom strip, the top strip and bottom strips are configured to intersect the spaced apart strips respectively adjacent to the top portion and the bottom portion of the wall.
The reflective insulation layer 10′ includes a first expander 36′ spaced between the low emittance layer 28′ and the intermediate low emittance layer 29′ to form a first reflective air space 38′ between the low emittance layer 28′ and the intermediate low emittance layer 29′. In an exemplary embodiment of the present invention, the first expander 36′ with a 48 gauge (0.00001″ units) may have one or more of the following performance characteristics: an approximate nominal yield of 41,200 in2/lb, approximate MD and TD F-5 respective values of 15,900 lb/in2, and 14,600 lb/in2, approximate MD and TD tensile strengths at break of 39,800 lb/in2 and 36,300 lb/in2, approximate MD and TD elongation at break values of 120% and 129%, approximate MD and TD heat shrinkage at 190° C. of 3.7% and 0.4%, approximate A-side and B-side coefficient of friction values of 0.40 and 0.30 and an approximate haze value of 2.1%. As with the previously discussed numerical performance characteristics, the first expander 36′ may have a performance characteristic which deviates from the numerical performance characteristics listed above.
Additionally, the reflective insulation layer 10′ includes a second expander 37′ between the intermediate low emittance layer 29′ and the outer synthetic polymer layer 32′ to form a second reflective air space 53′ between the intermediate low emittance layer 29′ and the outer synthetic polymer layer 32′. Upon securing the respective reflective insulation layer 10′ to the first and second strips 16′,18′, the first expander 36′ forms the first reflective air space 38′ and a third reflective air space 52′ between the wall 14′ and the low emittance layer 28′. Additionally, the second expander 37′ forms the second reflective air space 53′ upon securing the reflective insulation layer 10′ to the first and second strips 16′,18′. In an exemplary embodiment of the present invention, a reflective insulation layer 10′ may achieve one or more of the following performance characteristics: no growth of mold & mildew in accordance with ASTM C1338, an approximate 7.46 water vapor permeance in accordance with ASTM E96, an approximate <25 flame spread rating, an approximate <50 smoke developed rating, a class A interior wall and ceiling finish classification in accordance with ASTM E84; no corrosivity, no bleeding, and no delamination, in accordance with ASTM D3310; and an approximate 0.034 foil emittance in accordance with ASTM C1371, for example. Those elements of
This written description uses examples to disclose embodiments of the invention, including the best mode, and also to enable any person skilled in the art to make and use the embodiments of the invention. The patentable scope of the embodiments of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
This application claims the benefit of U.S. Provisional Patent Application No. 61/080,719, filed Jul. 15, 2008, which is incorporated herein by reference.
Number | Date | Country | |
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61080719 | Jul 2008 | US |