Coated air duct insulation sheets and the like and the method of coating such sheets

• US 6,399,186 B2
• Filed: 06/06/2001
• Issued: 06/04/2002
• Est. Priority Date: 05/14/1999
• Status: Active Grant

• Current Assignee: Johns Manville International, Inc. (Berkshire Hathaway Incorporated)
• Original Assignee: Johns Manville International, Inc. (Berkshire Hathaway Incorporated)
• Inventors: Terry, James R., Matthews, Kent R., Mitchell, Thomas Louis, Ryan, Kimberly Noel
• Primary Examiner(s): CAMERON, ERMA C
• Application Number:
  US09/875,837
• Publication Number:
  US 20010033926A1
• Time in Patent Office: 363 Days
• Field of Search: 428/411.1, 428/306.6, 428/316.6
• US Class Current: 428/306.6
• CPC Class Codes: B05D 7/546 each layer being cured, at least partially, separately
• CPC Class Codes: F24F 13/0263 Insulation for air ducts
• CPC Class Codes: F24F 13/0281 Multilayer duct
• CPC Class Codes: Y10T 428/249955 Void-containing component partially impregnated with adjacent component
• CPC Class Codes: Y10T 428/249981 Plural void-containing components
• CPC Class Codes: Y10T 428/249986 Void-containing component contains also a solid fiber or solid particle
• CPC Class Codes: Y10T 428/31504 Composite [nonstructural laminate]

Abstract

An on-line method of forming a multilayered coating on a sheet of fibrous or foam insulation, includes: applying a first coating layer of a first coating composition directly to a first major surface of the insulation sheet; heating an exposed major surface of the first coating layer to stabilize the coating composition at the exposed major surface of the first coating layer so that the first coating layer remains an essentially discrete layer when a second coating layer is applied to the exposed major surface of the first coating layer and to only partially cure the coating composition at the exposed major surface of the coating composition so that a second coating layer applied to the exposed major surface of the first coating layer will readily bond to the first coating layer; applying a second coating layer of a second coating composition directly to the exposed major surface of the first coating layer subsequent to heating the exposed major surface of the first coating layer; and heating the insulation sheet and the first and second coating layers, subsequent to the application of the second coating layer, until the first and second coating layers are substantially dried and cured.

Claims

1. An insulation sheet with a multilayered coating, comprising:

an insulation sheet, the insulation sheet having first and second major surfaces, lateral edges and end edges;

a first discrete coating layer formed from a first foamed or frothed cross-linkable elastomeric aqueous emulsion coating composition applied directly to the first major surface of the insulation sheet with the concentration of the coating composition being substantially uniform over the first major surface; and

a second discrete coating layer formed from a second foamed or frothed cross-linkable elastomeric aqueous emulsion coating composition which differs from the first coating composition applied directly to a major surface of the first coating layer with the concentration of the coating composition being substantially uniform over the exposed major surface of the first coating layer and an exposed major surface of the coating layer having a generally smooth surface.

2. The insulation sheet with a multilayered coating according to claim 1, wherein:

the insulation sheet is a fibrous air duct insulation sheet.

3. The insulation sheet with a multilayered coating according to claim 1, wherein:

the insulation sheet is a foam air duct insulation sheet.

4. The insulation sheet with a multilayered coating according to claim 1, wherein:

the first coating layer is more elastic than the second coating layer; and

the second coating layer is more abrasion resistant than the first coating layer.

5. The insulation sheet with a multilayered coating according to claim 4, wherein:

the insulation sheet is a fibrous air duct insulation sheet.

6. The insulation sheet with a multilayered coating according to claim 4, wherein:

the insulation sheet is a foam air duct insulation sheet.