LOW-EMISSIVITY STRUCTURES

• US 20110262699A1
• Filed: 07/03/2011
• Published: 10/27/2011
• Est. Priority Date: 10/13/2008
• Status: Abandoned Application

• Current Assignee: Sigma Laboratories Of Arizona LLC
• Original Assignee: Sigma Laboratories Of Arizona LLC
• Inventors: Yializis, Angelo, Goodyear, Gordon, Yializis, Steven
• Application Number:
  US13/175,865
• Publication Number:
  US 20110262699A1
• Time in Patent Office: Days
• US Class Current: 428/138
• CPC Class Codes: B32B 15/046 of foam
• CPC Class Codes: B32B 15/08 of synthetic resin
• CPC Class Codes: B32B 15/12 of paper or cardboard
• CPC Class Codes: B32B 15/14 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 2255/06 on metal layer
• CPC Class Codes: B32B 2255/20 Inorganic coating
• CPC Class Codes: B32B 2307/304 Insulating
• CPC Class Codes: B32B 2307/3065 Flame resistant or retardant, fire resistant or retardant
• CPC Class Codes: B32B 2307/416 Reflective
• CPC Class Codes: B32B 2307/538 Roughness
• CPC Class Codes: B32B 2307/546 Flexural strength; Flexion stiffness
• CPC Class Codes: B32B 2307/712 Weather resistant
• CPC Class Codes: B32B 2307/714 Inert, i.e. inert to chemical degradation, corrosion
• CPC Class Codes: B32B 2307/7145 Rot proof, resistant to bacteria, mildew, mould, fungi
• CPC Class Codes: B32B 2307/724 Permeability to gases, adsorption
• CPC Class Codes: B32B 2307/7265 Non-permeable
• CPC Class Codes: B32B 2307/732 Dimensional properties
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 29/002 as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/06; next to a bituminous or tarry layer B32B11/06; next to a water-setting substance layer B32B13/08; next to a metal layer B32B15/12; next to a glass layer B32B17/065; next to a layer formed of natural mineral fibres or particles B32B19/046; next to a wood layer B32B21/06; next to a cellulosic plastic layer B32B23/06; next to a natural or synthetic rubber layer B32B25/06; next to a synthetic resin layer B32B27/10
• CPC Class Codes: B32B 5/022 Non-woven fabric
• CPC Class Codes: B32B 5/024 : Woven fabric
• CPC Class Codes: B32B 5/026 : Knitted fabric
• CPC Class Codes: B32B 5/18 : characterised by features of a layer of foamed material
• CPC Class Codes: B82Y 10/00 : Nanotechnology for information processing, storage or transmission, e.g. quantum computing or single electron logic
• CPC Class Codes: C23C 14/022 : by means of bombardment with energetic particles or radiation
• CPC Class Codes: C23C 14/20 : on organic substrates
• CPC Class Codes: C23C 14/562 : for coating elongated substrates
• CPC Class Codes: C23C 14/5826 : Treatment with charged particles C23C14/582 takes precedence
• CPC Class Codes: C23C 14/5853 : Oxidation
• CPC Class Codes: G21K 1/062 : Devices having a multilayer structure
• CPC Class Codes: G21K 2201/061 : characterised by a multilayer structure
• CPC Class Codes: Y10T 428/24331 : including nonapertured component
• CPC Class Codes: Y10T 428/24851 : Intermediate layer is discontinuous or differential
• CPC Class Codes: Y10T 428/24975 : No layer or component greater than 5 mils thick
• CPC Class Codes: Y10T 428/249976 : Voids specified as closed
• CPC Class Codes: Y10T 428/24998 : Composite has more than two layers
• CPC Class Codes: Y10T 428/249987 : With nonvoid component of specified composition
• CPC Class Codes: Y10T 428/249991 : Synthetic resin or natural rubbers
• CPC Class Codes: Y10T 442/3398 : Vapor or sputter deposited metal layer
• CPC Class Codes: Y10T 442/475 : Including a free metal or alloy constituent
• CPC Class Codes: Y10T 442/657 : Vapor, chemical, or spray deposited metal layer

Abstract

A multilayer radiant-barrier structure is formed on one or both sides of a substrate that can be attached to an insulating layer to produce a reflective insulating material. The metallized layer is protected from environmental degradation without interfering with flammability properties that are critical for radiant and reflective insulation materials used in housing applications. The metal layer is modified to insulate enclosures without blocking cellular communications and the protective functional layer in modified to minimize emissivity, create a hydrophobic and/or oleophobic surface, and/or prevent mold, fungi and bacteria growth. Solutions are provided to solve occupational-hazard problems associated with the use of these materials in enclosures that include power wires.

Claims

1. A thermal radiant barrier structure comprising:

a) a flexible substrate;

b) an oxygen-rich layer on the surface of the substrate;

c) a metal layer deposited in vacuum in-line on the oxygen-rich layer;

d) a metal-oxide layer formed on the metal layer as the metal layer is deposited in vacuum in-line; and

e) a protective functional polymer layer deposited in vacuum in-line on the metal-oxide layer.

2. The barrier structure of claim 1, wherein layers b) through e) are deposited on both sides of said substrate.

3. The barrier structure of claim 1, wherein the substrate includes a flexible material selected from the group consisting of a polymer film, a polymer and inorganic composite, paper, a non-woven polymer, a foam, a vapor-transmitting and water-blocking film, a micro-porous membrane, a woven textile, a knitted textile, or a combination thereof.

4. The barrier structure of claim 3, wherein the substrate is first coated with a leveling polymer layer.

5. The barrier structure of claim 1, wherein the substrate is further attached to one side of an insulating layer including an insulating material selected from the group consisting of foam, bubble pack, organic and inorganic fiber-based composites, cellulose-based composites, plywood, and sheet-rock.

6. The barrier structure of claim 1, wherein the substrate is further attached to both sides of an insulating layer including an insulating material selected from the group consisting of foam, bubble pack, organic and inorganic fiber-based composites, cellulose-based composites, plywood, and sheet-rock.

7. The barrier structure of claim 1, wherein the structure has a Class A fire rating.

8. The barrier structure of claim 1, wherein the structure is attached to one side of an insulating material that is a Class A fire-rated material.

9. The barrier structure of claim 8, wherein the structure is coupled to an object that requires a Class A fire rating.

10. The barrier structure of claim 7, wherein the structure is attached to both sides of an insulating material that is a Class A fire-rated material.

11. The barrier structure of claim 10, wherein the structure is coupled to an object that requires a Class A fire rating.

12. The barrier structure of claim 1, wherein said protective functional polymer layer is hydrophobic and oleophobic.

13. The barrier structure of claim 1, wherein said protective functional polymer layer is anti-mold, anti-fungi and antibacterial.

14. A thermal radiant barrier structure comprising:

a) a flexible substrate;

b) a leveling polymer layer;

c) an oxygen-rich layer on the surface of the leveling polymer layer;

d) a metal layer deposited in vacuum in-line on the oxygen-rich layer;

e) a metal-oxide layer formed on the metal layer as the metal layer is deposited in vacuum in-line; and

f) a protective functional polymer layer deposited in vacuum in-line on the metal-oxide layer.

15. The barrier structure of claim 14, wherein layers b) through f) are deposited on both sides of said substrate.

16. The barrier structure of claim 14, wherein the substrate includes a flexible material selected from the group consisting of a polymer film, a polymer and inorganic composite, paper, a non-woven polymer, a foam, a vapor-transmitting and water-blocking film, a micro-porous membrane, a woven textile, a knitted textile, or a combination thereof.

17. The barrier structure of claim 14, wherein the structure is attached to a material that has additional insulating value.

18. The barrier structure of claim 14, wherein the structure has a Class A fire rating.

19. The barrier structure of claim 18, wherein the structure is attached to one side of an insulating material that is a Class A fire-rated material.

20. The barrier structure of claim 18, wherein the structure is attached to both sides of an insulating material that is a Class A fire-rated material.

21. The barrier structure of claim 14, wherein the structure is coupled to an object that requires a Class A fire rating.

22. The barrier structure of claim 14, further comprising a cover material attached the functional polymer layer, said cover material being substantially transparent to radiation and being in contact with only a fraction of the protective functional polymer layer.

23. The barrier structure of claim 22, wherein said cover material is selected from the group consisting of a continuous fibrous material, a fibrous material with holes, and a non-fibrous material with holes.

24. A thermal radiant barrier structure comprising:

a) a flexible substrate;

b) a leveling polymer layer;

c) an oxygen-rich layer on the surface of the leveling polymer layer;

d) a metal layer deposited in vacuum in-line on the oxygen-rich layer;

e) a metal-oxide layer formed on the metal layer as the metal layer is deposited in vacuum in-line; and

f) a self-assembled molecular layer formed in vacuum in-line on the metal-oxide layer.

25. The barrier structure of claim 24, wherein layers b) through f) are deposited on both sides of said substrate.

26. The barrier structure of claim 24, wherein the substrate includes a flexible material selected from the group consisting of a polymer film, a polymer and inorganic composite, paper, a non-woven polymer, a foam, a vapor-transmitting and water-blocking film, a micro-porous membrane, a woven textile, a knitted textile, or a combination thereof.

27. A thermal radiant barrier structure with reduced metallic glint comprising:

a) a flexible substrate;

b) a patterned polymer layer formed on the substrate to diffuse visible radiation;

c) a metal layer deposited on said patterned polymer layer; and

d) a functional polymer layer deposited on said metal layer.

28. The barrier structure of claim 27, wherein layers b) through f) are deposited on both sides of said substrate.

29. The barrier structure of claim 27, wherein the substrate includes a flexible material selected from the group consisting of a polymer film, a polymer and inorganic composite, paper, a non-woven polymer, a foam, a vapor-transmitting and water-blocking film, a micro-porous membrane, a woven textile, a knitted textile, or a combination thereof.

30. The barrier structure of claim 27, wherein the structure has a Class A fire rating.

31. The barrier structure of claim 30, wherein the structure is attached to one side of an insulating material that is a Class A fire-rated material.

32. The barrier structure of claim 31, wherein the structure is coupled to an object that requires a Class A fire rating.

33. The barrier structure of claim 30, wherein the structure is attached to both sides of an insulating material that is a Class A fire-rated material.

34. The barrier structure of claim 33, wherein the structure is coupled to an object that requires a Class A fire rating.

35. A thermal radiant barrier structure comprising a flexible substrate, a metallized aluminum layer with a thickness of 20 nm to 50 nm deposited on said flexible substrate, a polymer layer with thickness less than 1 micron deposited on said metallized aluminum layer, said aluminum layer being self-healing when in contact with a high voltage electrical conductor.

36. The barrier structure of claim 35, wherein the barrier structure is used to thermally insulate a powered object.

37. The barrier structure of claim 35, wherein the metal layer is segmented to disrupt electrical current flow and allow transmission of RF signals.

38. The barrier structure of claim 35, wherein an outer surface thereof is anti-mold, anti-fungi and antibacterial.

39. The barrier structure of claim 35, wherein an outer surface thereof is hydrophobic and oleophobic.