Method of making an asphalt and fiber laminated insulation product

• US 5,743,985 A
• Filed: 10/31/1996
• Issued: 04/28/1998
• Est. Priority Date: 10/31/1996
• Status: Expired due to Term

• Current Assignee: Owens- Corning Fiberglas Technology Incorporated (Owens Corning)
• Original Assignee: Owens- Corning Fiberglas Technology Incorporated (Owens Corning)
• Inventors: Van Sloun, Jeffrey J., Weir, Charles R., Ernest, Frederick R.
• Primary Examiner(s): Ball, Michael W.
• Assistant Examiner(s): YAO, SAMCHUAN CUA
• Application Number:
  US08/742,191
• Time in Patent Office: 544 Days
• Field of Search: 156/62.2, 156/243, 156/245, 156/309.6, 156/309.9, 156/308.2, 264/112, 264/113, 264/DIG. 32
• US Class Current: 156/243
• CPC Class Codes: B29C 51/082 by shaping between complementary mould parts
• CPC Class Codes: B29C 51/145 having at least one layer of textile or fibrous material combined with at least one plastics layer
• CPC Class Codes: B29C 53/04 of plates or sheets B29C63/04 takes precedence; bending or folding paper B31F1/0003; folding films B65H45/00
• CPC Class Codes: B29C 70/50 for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
• CPC Class Codes: B32B 11/10 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 2260/042 Bituminous or tarry substance
• CPC Class Codes: B32B 2307/102 Insulating
• CPC Class Codes: B32B 2309/06 Angles
• CPC Class Codes: B32B 2395/00 Bituminous material, e.g. tar, asphalt
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 37/0053 Constructional details of laminating machines comprising rollers; Constructional features of the rollers
• CPC Class Codes: B32B 37/24 with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate B32B37/15 takes precedence
• CPC Class Codes: Y10S 264/32 Processes in molding using asbestos or asphalt

Abstract

A method of forming an insulation product includes heating a thermoplastic material to a softened condition, and applying the thermoplastic material to a blanket of fibrous insulation material to form a laminated insulation material comprising a layer of the thermoplastic material bonded to the fibrous insulation material. The laminated insulation material is heated to soften it and molded to form it into a desired shape, and the molded laminated insulation material is cooled to form an insulation product.

Claims

1. A method of forming an insulation product comprising:

heating a thermoplastic material to a softened condition;

applying a layer of reinforcement material to a blanket of fibrous insulation material;

applying the thermoplastic material to the layer of reinforcement material and the blanket of insulation material to form a laminated insulation material comprising a layer of the thermoplastic material bonded to the layer of reinforcement material and the blanket of insulation material, wherein the viscosity of the thermoplastic material is established so that some of the thermoplastic material passes through the layer of reinforcement material and penetrates only minimally into the blanket of insulation material;

heating the laminated insulation material to soften the layer of thermoplastic material to form a heated laminated insulation material which is more flexible;

molding the heated laminated insulation material to form the laminated insulation material into a desired shape; and

cooling the molded laminated insulation material to form an insulation product.

2. The method of claim 1 in which the thermoplastic material is at least 50 percent by weight asphalt, exclusive of filler materials.

3. The method of claim 1 in which the step of molding the laminated insulation material is carried out in a mold.

4. The method of claim 1 in which the density of the insulation material in the insulation product is within the range of from about 0.4 to about 12 pounds per ft³ (about 6.4 to about 192 kg per m³), and the density of the thermoplastic material in the insulation product is within the range of from about 40 to about 100 pounds per ft³ (about 640 to about 1,600 kg per m³).

5. The method of claim 1 in which the density of the insulation material in the insulation product is within the range of from about 0.5 to about 3 pounds per ft³ (about 8 to about 48 kg per m³), and the density of the thermoplastic material in the insulation product is within the range of from about 50 to about 70 pounds per ft³ (about 800 to about 1,120 kg per m³).

6. The method of claim 1 in which the thickness of the thermoplastic material is within the range of from about 1 mil to about 6 mils (about 0.025 mm to about 0.15 mm).

7. The method of claim 1 including cooling the laminated insulation material prior to the step of heating the laminated insulation material.

8. The method of forming an insulation product comprising:

heating an asphalt material to a softened condition;

applying a layer of reinforcement material to a blanket of insulation material of mineral fibers;

applying the asphalt material to the layer of reinforcement material and the blanket of insulation material to form a laminated insulation material comprising a layer of the asphalt material bonded to the layer of reinforcement material and the blanket of insulation material, wherein the viscosity of the asphalt material is established so that some of the asphalt material passes through the layer of reinforcement material and penetrates only minimally into the blanket of insulation material;

heating the laminated insulation material to soften the layer of asphalt material to form a heated laminated insulation material which is more flexible;

molding the heated laminated insulation material to form the laminated insulation material into a desired shape; and

cooling the molded laminated insulation material to form an insulation product.

9. The method of claim 8 in which the asphalt material is at least 70 percent by weight asphalt, exclusive of filler materials.

10. The method of claim 8 in which the density of the insulation material in the insulation product is within the range of from about 0.5 to about 3 pounds per ft³ (about 9.6 to about 48 kg per m³), and the density of the thermoplastic material in the insulation product is within the range of from about 50 to about 70 pounds per ft³ (about 800 to about 1,120 kg per m³).

11. The method of claim 8 in which the thickness of the asphalt layer in the insulation product is less than about 125 mils (about 3.125 mm).

12. The method of claim 8 in which the molded shape of the laminated insulation material is a nonplanar shape.

13. The method of claim 8 including cooling the laminated insulation material prior to the heating step.

14. A method of forming an insulation product comprising:

heating a thermoplastic material to a softened condition;

applying the thermoplastic material to a blanket of fibrous insulation material to form a laminated insulation material comprising a layer of the thermoplastic material bonded to the fibrous insulation material;

heating the laminated insulation material to soften the layer of thermoplastic material, thereby making the laminated insulation material more flexible;

molding the laminated insulation material to forth the laminated insulation material into a desired shape, by positioning the laminated insulation material in contact with an article to be insulated and by conforming the laminated insulation material to the shape of the article; and

cooling the molded laminated insulation material to for an insulation product.

15. The method of claim 14 in which the thermoplastic material is at least 50 percent by weight asphalt, exclusive of filler materials.

16. The method of claim 14 in which the density of the insulation material in the insulation product is within the range of from about 0.4 to about 12 pounds per ft³ (about 6.4 to about 192 kg per m³), and the density of the thermoplastic material in the insulation product is within the range of from about 40 to about 100 pounds per ft³ (about 640 to about 1,600 kg per m³).

18. The method of claim 14 in which the thickness of the thermoplastic material is within the range of from about 1 mil to about 6 mils (about 0.025 mm to about 0.15 mm).

17. The method of claim 24 in which the insulation material comprises mineral fibers.