Concrete cure blanket having reflective bubble layer and method of manufacturing

• US 8,398,807 B2
• Filed: 10/15/2010
• Issued: 03/19/2013
• Est. Priority Date: 02/19/2002
• Status: Active Grant

• Current Assignee: Midwest Canvas Corporation
• Original Assignee: Midwest Canvas Corporation
• Inventors: Handwerker, Gary
• Primary Examiner(s): Tucker, Philip
• Assistant Examiner(s): Slawski, Brian R
• Application Number:
  US12/905,570
• Publication Number:
  US 20110139349A1
• Time in Patent Office: 886 Days
• Field of Search: 156/145, 156/146, 156/147, 156/182, 156/210, 156/278, 156/279, 156/292, 156/308.2, 156/308.4, 156/313, 428/68, 428/72, 428/76, 525/060.1
• US Class Current: 156/292
• CPC Class Codes: B28B 11/245 Curing concrete articles B28B11/242 takes precedence
• CPC Class Codes: B32B 3/12 characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
• CPC Class Codes: B32B 3/26 characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids foam layer B32B5/18; layer of synthetic resin characterised by fillers that create voids or cavities B32B27/205; characterised by an apertured layer
• CPC Class Codes: B32B 37/14 characterised by the properties of the layers
• CPC Class Codes: C04B 40/04 Preventing evaporation of the mixing water permanent coverings C04B41/00
• CPC Class Codes: Y10T 156/1025 to form undulated to corrugated sheet and securing to base with parts of shaped areas out of contact
• CPC Class Codes: Y10T 428/234 including elements cooperating to form cells
• CPC Class Codes: Y10T 428/239 Complete cover or casing
• CPC Class Codes: Y10T 428/24562 Interlaminar spaces
• CPC Class Codes: Y10T 428/24661 Forming, or cooperating to form cells

Abstract

A method of manufacturing a lightweight multilayer heat reflective concrete cure blanket having a moisture-impervious top outer layer, a moisture-impervious bottom outer layer, and the top and bottom layers sealingly connected to each other at the boundaries of the layers to form a moisture-impervious chamber between the first and second layers. The chamber includes at least one bubble type insulative layer therein, and the bottom surface of the blanket comprises a heat reflective material to reflect heat emanating from the concrete when the blanket is placed over the concrete. In a further embodiment, heat reflective material is applied to at least one inner bubble type layer to reflect additional heat which radiates from the concrete through the insulative layer and back towards the concrete.

Claims

1. A method for manufacturing a lightweight multilayer heat reflective concrete cure blanket, comprising:

a. forming a first flexible structure having a first outer peripheral edge and comprising a first moisture-impervious outer film and a first flexible undulating film;

b. heat sealing the first flexible undulating film to the first moisture-impervious outer film to form a plurality of first air-filled insulative pockets and a plurality of first open spaces between the first air-filled pockets;

c. forming a second flexible structure having a second outer peripheral edge and comprising a second moisture-impervious outer film and a second flexible undulating film;

d. heat sealing the second flexible undulating film to the second moisture-impervious outer film forming a plurality of second air-filled insulative pockets and a plurality of second open spaces between the second air-filled insulative pockets, wherein the second moisture-impervious outer film includes a plurality of heat reflective elements dispersed throughout the second moisture-impervious outer film; and

e. sealing the first flexible structure to the second flexible structure about the first and second outer peripheral edges to include a moisture-impervious chamber space formed between the first air-filled insulative pockets and the second air-filled insulative pockets, facing the first open spaces to the second air-filled pockets and facing the second open spaces to the first air-filled pockets while maintaining a gap between the first air-filled pocket and the second air-filled pocket, overlapping the first air-filled pockets with the second air-filled pockets to form a gap between first air-filled pockets and the second air-filled pockets as to communicate in a heat transfer path therebetween, and forming a flexible heat reflective concrete cure blanket.

2. The method of claim 1, further comprising providing a rope attachment device to the peripheral edges of the flexible heat reflective concrete cure blanket.

3. The method of claim 1, further comprising applying a reflective material to the second undulating film.

4. The method of claim 1, further comprising applying a reflective material to the first moisture-impervious outer film.

5. The method of claim 1, wherein the first moisture-impervious outer film is substantially dark in color to absorb ambient heat into the concrete cure blanket.

6. The method of claim 1, further comprising a nonstick smooth substance to the second outer film.

7. A method of manufacturing a lightweight multilayer heat reflective concrete cure blanket, comprising the steps of:

a. forming a first flexible structure having a first unslitted moisture-impervious outer film and a first flexible undulating film by heat sealing the first flexible undulating film to the first unslitted moisture-impervious outer film to form a first bubble-type insulative layer;

b. forming a second flexible structure having a second unslitted moisture-impervious outer film and a second flexible undulating film by heat sealing the second flexible undulating film to the second unslitted moisture-impervious outer film to form a second bubble-type insulative layer, and applying a reflective material to the second unslitted moisture-impervious outer film as to reflect heat away from the second flexible structure;

c. forming the first bubble-type layer having a plurality of first insulative pockets and a plurality of first open spaces between the first insulative pockets, and forming the second bubble-type layer having a plurality of second insulative pockets and a plurality of second open spaces between the second insulative pockets, wherein the first and second insulative pockets alternately face the second and first open spaces, respectively, to form a chamber space between the first and second insulative pockets; and

d. sealing, in a moisture impervious manner, the first flexible structure to the second flexible structure about the first and second outer peripheral edges, maintaining a gap between the first open spaces and the second open spaces, maintaining a gap between the overlapping first insulative pockets and the second insulative pockets as to communicate in a heat transfer path to form a flexible heat reflective concrete cure blanket.

8. The method of claim 7, further comprising providing a rope attachment device to the peripheral edges of the flexible heat reflective concrete cure blanket.

9. The method of claim 7, further comprising applying a reflective material applied to the second bubble-type insulative layer.

10. The method of claim 7, wherein the second unslitted moisture-impervious outer film is not covered by any material.

11. The method of claim 7, further comprising forming a third flexible structure comprising a third unslitted moisture-impervious film and a second flexible undulating film, and heat sealing the second flexible undulating film to the third unslitted moisture-impervious film to form a third bubble-type insulative layer, and applying a reflective material to the third unslitted moisture-impervious film;

and, heat sealing the third flexible structure in between the first flexible structure and the second flexible structure.