Laminated, thermal insulation panel

• US 4,828,635 A
• Filed: 04/13/1988
• Issued: 05/09/1989
• Est. Priority Date: 04/13/1988
• Status: Expired due to Fees

• Current Assignee: Les Produits Isolofoam Incorporated
• Original Assignee: Les Produits Isolofoam Incorporated
• Inventors: Bailey, David W., Flack, John
• Primary Examiner(s): Van Balen, William J.
• Application Number:
  US07/180,884
• Time in Patent Office: 391 Days
• Field of Search: 156/71, 428/198, 428/201, 428/286, 428/296, 428/316.6, 428/317.7
• US Class Current: 156/71
• CPC Class Codes: B32B 2262/0253 Polyolefin fibres vinyl or acrylic copolymers B32B2262/0223 or B32B2262/0246
• CPC Class Codes: B32B 2266/0228 Aromatic vinyl resin, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 2307/304 Insulating
• CPC Class Codes: B32B 2307/724 Permeability to gases, adsorption
• CPC Class Codes: B32B 2419/00 Buildings or parts thereof walls, panels B32B2607/00
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/245 another layer next to it being a foam layer
• CPC Class Codes: B32B 5/32 at least two layers being foamed and next to each other
• CPC Class Codes: E04B 1/80 slab-shaped
• CPC Class Codes: Y10T 428/24826 Spot bonds connect components
• CPC Class Codes: Y10T 428/24851 Intermediate layer is discontinuous or differential
• CPC Class Codes: Y10T 428/249981 Plural void-containing components
• CPC Class Codes: Y10T 428/249985 Composition of adhesive or bonding component specified
• CPC Class Codes: Y10T 442/681 Spun-bonded nonwoven fabric

Abstract

A laminated, thermal insulation panel comprises a board made of expanded, molded polystyrene, and a membrane laminated on one side of the polystyrene board by means of an adhesive. The board and membrane are both permeable to water vapor, but the membrane is also impervious to air and moisture. The adhesive is applied under the form of strips and presents permeability to water vapor while being compatible with both the board polystyrene and the membrane material. Accordingly, the adhesive does not chemically attack the polystyrene and membrane material, whereby the water vapor permeability and air/moisture imperviousness of the latter are not affected. It can be appreciated that the resulting insulation panel is impervious to air and moisture from the outside but is permeable to water vapor from the inside. The joints between adjacent, laminated insulation panels are sealed by means of an adhesive tape applied on the membranes of the adjacent panels.

Claims

1. A laminated, thermal insulation panel comprising:

a board made of expanded polystyrene permeable to water vapor;

a membrane laminated over one side of the polystyrene board, said membrane presenting imperviousness to air and moisture and being permeable to water vapor; and

an adhesive applied between said membrane and board for laminating said membrane on said one side of the polystyrene board, said adhesive being applied in a pattern to ensure permeability to water vapor and being compatible with both the polystyrene of the board and the material constituting the membrane, so that the adhesive does not chemically attack the board polystyrene and the membrane material whereby the water vapor permeability of the board polystyrene and of the membrane material as well as the air/moisture imperviousness of the membrane material are not affected by the adhesive.

2. An insulation panel according to claim 1, wherein said membrane is composed of fine synthetic fibers.

3. An insulation panel according to claim 2, in which said membrane is made of non-woven, spunbonded olefin.

4. An insulation panel according to claim 1, wherein said board is made of expanded, molded polystyrene.

5. An insulation panel according to claim 1, wherein said adhesive is a pressure-sensitive adhesive.

6. An insulation panel according to claim 5, wherein said adhesive comprises a blend of synthetic rubber and of aliphatic/aromatic hydrocarbons in a solvent.

7. An insulation panel according to claim 5, in which said adhesive comprises natural rubber.

8. An insulation panel according to claim 5, wherein said adhesive comprises moisture cured urethane.

9. An insulation panel according to claim 1, wherein said pattern comprises a plurality of strips of said adhesive applied between the said membrane and polystyrene board.

10. An insulation panel according to claim 3, wherein said adhesive comprises as elastomeric base a blend of polybutene and styrene-isoprene-styrene block copolymer, and as tackifying resins, a blend of synthetic hydrocarbon resins and rosin esters.

11. An insulation panel according to claim 4, wherein the expanded polystyrene of said board has a bulk density of 15.5 kg/m³ and a thermal resistance of 26.6 m °

K./W.

12. A method of thermally insulating the exterior walls of a construction, such as a residential house, comprising the steps of:

in-plant manufacturing laminated, thermal insulation panels each obtained by laminating a membrane over one side of a board made of expanded polystyrene, said board and membrane being both permeable to water vapor and said membrane being further impervious to air and moisture;

covering the outside of said walls with a plurality of said insulation panels with the membrane thereof at the exterior; and

sealing the joints between adjacent ones of said covering panels with an adhesive tape impervious to air and moisture, said tape comprising an adhesive surface applied on the membranes of said adjacent panels.

13. An insulating method according to claim 12, wherein said tape comprises permanent acrylic adhesive with an oriented polypropylene backing.

14. An insulating method according to claim 12, wherein said membrane is composed of non-woven, spunbonded olefin.

15. An insulating method according to claim 12, wherein said in-plant manufacturing step comprises applying between the membrane and the polystyrene board an adhesive, which adhesive is applied in a pattern to ensure permeability to water vapor and is compatible with both the polystyrene of the board and material of the membrane, so that the adhesive does not chemically attack the polystyrene of said board and the material of said membrane whereby the water vapor permeability of the board polystyrene and of the membrane material as well as the air/moisture imperviousness of the membrane material are not affected by the adhesive.

16. An insulating method according to claim 15, wherein said pattern comprises a plurality of strips of said adhesive.