Multilayer densified surface to improve air flow resistance and structural properties

• US 20050136235A1
• Filed: 02/03/2005
• Published: 06/23/2005
• Est. Priority Date: 06/30/2003
• Status: Active Grant

• Current Assignee: Owens Corning Intellectual Capital, LLC (Owens Corning)
• Original Assignee: Owens Corning Intellectual Capital, LLC (Owens Corning)
• Inventors: Rockwell, Anthony L.
• Granted Patent: US 7,357,974 B2
• Time in Patent Office: Days
• US Class Current: 428/218
• CPC Class Codes: B29C 2043/483 cooperating with a second endless belt, i.e. double band presses
• CPC Class Codes: B29C 43/228 using endless belts feeding the material between non-rotating pressure members, e.g. vibrating pressure members
• CPC Class Codes: D04H 13/00 Other non-woven fabrics
• CPC Class Codes: E04B 1/7662 comprising fiber blankets or batts
• CPC Class Codes: Y10T 428/24942 including components having same physical characteristic in differing degree
• CPC Class Codes: Y10T 428/2495 Thickness [relative or absolute]
• CPC Class Codes: Y10T 428/24992 Density or compression of components
• CPC Class Codes: Y10T 428/249933 Fiber embedded in or on the surface of a natural or synthetic rubber matrix

Abstract

A thermoplastic blanket includes multiple layers of thermoplastic material. The first such layer has a first surface zone, a second, optional surface zone and a first base zone between the first and second surface zones. The second layer of thermoplastic material includes a third surface zone, a fourth optional surface zone and a second base zone between the third and fourth surface zones. At least one surface zone of each layer is densified to a density of between about 1.5 to about 30.0 pcf while each base zone has a density of between about 0.5 to about 10.0 pcf.

Claims

1. A thermoplastic blanket, comprising:

a first layer of thermoplastic material including a first surface zone and a first base zone, said first surface zone being densified and having a density of between about 1.5 to about 30.0 pcf and a thickness of between about 0.01 to about 0.1 inches and said first base zone having a density of between about 0.5 to about 10.0 pcf and a thickness of between about 0.25 to about 4.0 inches; and

a second layer of thermoplastic material including a third surface zone and a second base zone, said third surface zone being densified and having a density of between about 1.5 to about 30.0 pcf and a thickness of between about 0.01 to about 0.1 inches and said second base zone having a density of between about 0.5 to about 10.0 pcf and a thickness of between about 0.25 to about 4.0 inches.

2. The thermoplastic blanket of claim 1 wherein said thermoplastic blanket is formed from a polymer based thermoplastic material.

3. The thermoplastic blanket of claim 2, wherein said polymer based thermoplastic material is selected from a group consisting of polyester, polyethylene, polypropylene, polyethylene terephthalate, rayon, nylon, and any mixtures thereof.

4. The thermoplastic blanket of claim 3, wherein said polymer based thermoplastic material includes fibers selected from a group consisting of glass fibers, natural fibers and mixtures thereof.

5. The thermoplastic blanket of claim 1, further including a facing layer on said thermoplastic blanket.

6. The thermoplastic blanket of claim 5, wherein said facing layer is selected from a group consisting of polyester, rayon, metallic foil and mixtures thereof.

7. The thermoplastic blanket of claim 1, wherein said first layer includes a second densified surface zone and said second densified surface zone abuts said third densified surface zone.

8. The thermoplastic blanket of claim 7, further including a first facing layer on said first densified surface zone of said thermoplastic blanket and a second facing layer on said second base zone of said thermoplastic blanket.

9. The thermoplastic blanket of claim 8, wherein said first and second facing layers are selected from a group consisting of polyester, rayon, metallic foil and mixtures thereof.

10. The thermoplastic blanket of claim 1, wherein said first and second base zones are at least partially constructed from material selected from a group consisting of thermoset polymer material, fiber glass, foam, mineral fiber, cardboard and mixtures thereof.

11. The thermoplastic blanket of claim 8, wherein said second densified surface zone has a density of between about 1.5 to about 30.0 pcf and a thickness of between about 0.01 to about 0.1 inches.

12. The thermoplastic blanket of claim 11, wherein a fourth densified surface zone having a density of between about 1.5 to about 30.0 pcf and a thickness of between about 0.01 to about 0.1 inches is provided between said second base zone and said second facing layer.

13. The thermoplastic blanket of claim 1, further including a third layer of thermoplastic material having a fifth surface zone and a third base zone, said fifth surface zone being densified and having a density of between about 1.5 to about 30.0 pcf and a thickness of between about 0.01 to about 0.1 inches and said third base zone having a density of between about 0.5 to about 10.0 pcf and a thickness of between about 0.25 to about 4.0 inches.

14. The thermoplastic blanket of claim 13, wherein said fifth surface zone abuts said second base zone.

15. The thermoplastic material of claim 13 wherein said fifth surface zone abuts said third surface zone.

16. The thermoplastic material of claim 13, wherein said third layer includes a sixth densified surface zone having a density of between about 1.5 to about 30.0 pcf and a thickness of between about 0.01 to about 0.1 inches.

17. The thermoplastic blanket of claim 11, further including a third layer of thermoplastic material having a fifth surface zone and a third base zone, said fifth surface zone being densified and having a density of between about 1.5 to about 30.0 pcf and a thickness of between about 0.01 to about 0.1 inches and said third base zone having a density of between about 0.5 to about 10.0 pcf and a thickness of between about 0.25 to about 4.0 inches.

18. The thermoplastic blanket of claim 17, wherein said fourth surface zone abuts said fifth surface zone.

19. The thermoplastic material of claim 18, wherein said fourth surface zone abuts said third base zone.

20. The thermoplastic blanket of claim 12, further including a third layer of thermoplastic material having a fifth surface zone and a third base zone, said fifth surface zone being densified and having a density of between about 1.5 to about 30.0 pcf and a thickness of between about 0.01 to about 0.1 inches and said third base zone having a density of between about 0.5 to about 10.0 pcf and a thickness of between about 0.25 to about 4.0 inches.

21. The thermoplastic blanket of claim 20, wherein said fourth surface zone abuts said fifth surface zone.

22. The thermoplastic material of claim 21, wherein said fourth surface zone abuts said third base zone.

23. A thermoplastic blanket, comprising:

a first layer of thermoplastic material including a first densified surface zone, a second densified surface zone and a first base zone between said first densified surface zone and said second densified surface zone, said first layer being characterized by said first and second densified surface zones having a density between about 1.5 to about 30.0 pcf and said first base layer having a density of between about 0.5 to about 10.0 pcf; and

a second layer of thermoplastic material including a third densified surface zone and a second base zone, said third surface zone being densified and having a density of between about 1.5 to about 30.0 pcf and said second base zone having a density of between about 0.5 to about 10.0 pcf.