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EP1268182A1 - Revetement semipermeable destine a des materiaux de construction - Google Patents

Revetement semipermeable destine a des materiaux de construction

Info

Publication number
EP1268182A1
EP1268182A1 EP01903463A EP01903463A EP1268182A1 EP 1268182 A1 EP1268182 A1 EP 1268182A1 EP 01903463 A EP01903463 A EP 01903463A EP 01903463 A EP01903463 A EP 01903463A EP 1268182 A1 EP1268182 A1 EP 1268182A1
Authority
EP
European Patent Office
Prior art keywords
building product
coating
base mat
fibrous layer
building
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP01903463A
Other languages
German (de)
English (en)
Inventor
Wayne E. Shaw
Murray S. Toas
John O. Ruid
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Certainteed LLC
Original Assignee
Certain Teed Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Certain Teed Corp filed Critical Certain Teed Corp
Publication of EP1268182A1 publication Critical patent/EP1268182A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
    • D06N3/0015—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using fibres of specified chemical or physical nature, e.g. natural silk
    • D06N3/0022—Glass fibres
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/04—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N3/047—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds with fluoropolymers
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2205/00—Condition, form or state of the materials
    • D06N2205/02—Dispersion
    • D06N2205/023—Emulsion, aqueous dispersion, latex
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2205/00—Condition, form or state of the materials
    • D06N2205/04—Foam
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00—Properties of the materials
    • D06N2209/06—Properties of the materials having thermal properties
    • D06N2209/067—Flame resistant, fire resistant
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00—Properties of the materials
    • D06N2209/12—Permeability or impermeability properties
    • D06N2209/121—Permeability to gases, adsorption
    • D06N2209/123—Breathable
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00—Properties of the materials
    • D06N2209/12—Permeability or impermeability properties
    • D06N2209/126—Permeability to liquids, absorption
    • D06N2209/128—Non-permeable
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00—Properties of the materials
    • D06N2209/16—Properties of the materials having other properties
    • D06N2209/1671—Resistance to bacteria, mildew, mould, fungi
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2211/00—Specially adapted uses
    • D06N2211/06—Building materials

Definitions

  • the present invention relates in general to building materials products and, in particular, to coatings for building materials, products bearing such coatings and methods for applying coatings to building materials.
  • Ducts and conduits are used to convey air in building heating, ventilation and air conditioning (HVAC) systems.
  • HVAC building heating, ventilation and air conditioning
  • the ducts are lined with thermal and sound insulating material.
  • the lining or liner enhances the thermal efficiency of the duct work and reduce noise associated with movement of air therethrough.
  • Duct liner may comprise any suitable organic material or inorganic material, e.g., mineral fibers such as fiber glass insulation or the like.
  • Typical fiber glass duct liners for example, are constructed as fiber glass mats having densities of about 1.5 to 6 pounds per cubic foot (pcf) and thicknesses of about 0.5 to 2 inches.
  • the insulation includes a coating on its inner or "air stream" surface.
  • the air stream surface of the insulation is the surface that conveys air through the duct and is opposite the surface that contacts the duct sheet metal in the final duct assembly.
  • the coating protects the insulation, especially during brush and/or vacuum cleaning of the interior of the duct. If the insulation is unprotected, fibers might become detached from the insulation. Once detached, they may be carried away by the air stream and circulated throughout the building where they may be inhaled by persons in the building. Examples of duct liners having coatings on their inner surfaces are provided in U.S. Patent Nos. 3,861,425 and 4,101,700. Several coated insulation duct liners are also marketed under the trade designations ToughGard® by CertainTeed Corp.
  • HVAC contractors In the field or fabrication shop, HVAC contractors typically cut and pin duct liner onto sheet metal. This fabrication technique creates small holes and exposed seams in the duct liner where liquid water could seep into the insulation from the exterior of the duct. If liquid water leaks into the insulation through these surface imperfections in a duct liner coated on its air-conveying surface with a continuous layer of impermeable hydrophobic material, the water may collect and stagnate in the insulation and support the growth of microorganisms. Thereafter, the microorganisms may reenter the building' s air supply through the same surface imperfections that permitted water to enter the duct work in the first instance. To address the problem of microorganism growth in HVAC systems, U.S. Patent Nos .
  • 5,314,719; 5,379,806; 5,487,412 and 5,783,268 disclose providing antimicrobial agents on or in the air-conveying surfaces of impermeable duct liners and/or duct boards (prefabricated rigid airducts) .
  • these patents offer no insight into effective ways of preventing water that enters duct work from collecting and stagnating in fibrous mat duct liner insulation material and causing microbe formation therein.
  • antimicrobial agents have very limited zones of effectiveness. That is, they tend to prevent microbe formation only in their immediate vicinity.
  • U.S. Patent No. 5,314,719 describes a zone of antifungal inhibition of about one millimeter. Typical duct liners have insulation thicknesses ranging from about one to two inches. In these products, such a limited zone of inhibition would be essentially useless in preventing microorganism formation caused by duct liner insulation that becomes saturated by water entering through the exterior walls and seams of the duct .
  • the present invention provides coating materials, insulation-containing building material products bearing the materials and methods for applying the coatings to the building material products.
  • the coating materials possess oneway "breathability" characteristics with respect to water and aqueous solutions. That is, the coatings are essentially impermeable to liquid water and permeable to water vapor. Vapor from water in insulation coated by the material may thus pass through the coating, whereas liquid water is effectively prevented from passing through the coating and entering the insulation.
  • the coating not only prevents dry insulation from becoming wetted by liquid water residing on the surface of the coating opposite the insulation but also promotes drying of moist insulation. In the case of HVAC duct liners, for example, at least two significant advantages arise from these properties.
  • the coating material preferably comprises a foamed acrylic latex polymer that is applied to insulation at relatively low levels during manufacture of a building product. Low levels of coating are important to maintain a semipermeable surface coating layer. Excess coating material may render the coating layer an essentially impermeable film structure. An impermeable coating compromises the acoustical performance of the coated building product because it blocks some sound wave energy from being dissipated in the insulation. Additionally, excess coating adds to manufacturing costs and diminishes if not eliminates the breathability characteristics of the coating.
  • FIG. 1 is an exploded view of an building product constructed according to the present invention that also depicts the semipermeability characteristics of the product with respect to water;
  • FIG. 2 is a graphical comparison of the water repellency properties of several duct liner prototypes constructed according to the present invention and several commercially available coated duct liner products.
  • Building product 10 comprises a base mat 12 of suitable thermal and acoustic insulation material and semipermeable coating 14. Depending its intended application, building product 10 may further include one or more intermediate layers 16 of hydrophobicity enhancing and/or reinforcing material disposed between base mat 12 and coating 14.
  • Base mat 12 may be chosen from any insulation material appropriate for the building product's intended application.
  • the base mat may be fabricated from nonfibrous material such as polyimide or melamine foam or the like or from mineral fibers such as glass fibers, refractory fibers or mineral wool fibers.
  • the thickness and density of base mat 12 will be dictated by the levels of acoustic and/or thermal insulation that are desired or necessary for a particular building installation. If, for example, building product 10 is constructed to serve as an HVAC duct liner, base mat 12 may have a thickness of about 0.5 to about 2 inches and a density of about 1.5 to about 3 pcf. It will be understood that wall, floor, ceiling or other installations utilizing building product 10 may require a base mat 12 having greater or lesser thicknesses and densities.
  • base mat 12 When building product 10 is a duct liner, base mat 12 may be made from polyimide or melamine foam or fiber glass. According to a presently preferred duct liner construction, the base mat is shredded and resin-bonded textile (i.e., continuously drawn) fiber glass.
  • building product 10 when constructed as a duct liner, building product 10 preferably includes a woven or nonwoven fibrous layer 16 disposed between base mat 12 and coating 14. Suitable layers 16 include Johns Manville Corp. 8440 non-woven glass mat or 1801FX nonwoven glass mat marketed by Lydall Manning of Fort Washington, PA.
  • the 1801FX mat is desirable because it is chemically sized to enhance hydrophobicity and constructed with a modified fiber geometry to decrease the surface opacity (i.e., amount of openness) of the mats. It is believed that the latter property is achieved by combining different glass fiber diameter blends ranging from 6 to 16 microns. Various length fiber blends ranging from about 0.25 to 1.5 inches in length have also been tested in combination with hydrophobic size chemistries. While the above described non-woven glass mats have not been fully evaluated, they do show promise as an alternative method of achieving a semipermeable insulated building product.
  • Semipermeable coating 14 is essentially impermeable to liquid water and permeable to water vapor. Vapor from water in base mat 12 coated by coating 14 may thus pass through the coating, whereas liquid water is effectively prevented from passing through the coating and entering the insulation. Thus, the coating not only prevents dry base mat insulation from becoming wetted by liquid water residing on the surface of the coating opposite the insulation but also promotes drying of moist insulation.
  • Semipermeable coating 14 preferably comprises a foamed acrylic latex polymer having fire retardant, antimicrobial or other agents or additives for enhancing the performance of the coating in duct liner or other building product applications.
  • duct liner prototypes incorporating the features of the present invention were constructed and evaluated by the present inventors for liquid water repellency, liquid water hold-out and water vapor permeability.
  • the composition of the coatings for these prototypes identified respectively as Prototype I, Prototype II, Prototype III in FIG. 2, were as follows.
  • the coating for Prototype I was NW 1845 acrylic latex polymer marketed by Rohm & Haas Company of Philadelphia, PA under the trade designation ROPLEX®.
  • the coating for Prototype II included about 30 to about 80 weight percent, preferably about 45 to about 55 weight percent, Rohm & Haas Company NW 1845 acrylic latex polymer combined with about 0.12 to about 3.0 weight percent, preferably about 0.2 to about 0.5 weight percent, FC-461 water dispersible fluorocarbon marketed by Minnesota Mining & Manufacturing Co. of Minneapolis, MN .
  • the coating for Prototype III was Series 3413 acrylic latex polymer, with proprietary hydrophobic additives, marketed by BFGoodrich Company of Charlotte, NC .
  • the desired base mat 12 and intermediate layer 16 are selected and brought together and joined with a phenolic resin in the manner known in the art.
  • Base mat 12 and intermediate layer 16 are transported by a conveyor to an in-line foam coater. Air is injected by the foamer into the liquid acrylic latex polymer compound, thereby creating a frothy mixture having a density of approximately 0.15-0.25 grams per cubic centimeter (cc) .
  • cc grams per cubic centimeter
  • the coated product preferably travels on the conveyor at speeds of approximately 20-80 ft/minute and moves through an oven where the dwell time is approximately 60 seconds to 4 minutes and the oven temperature is maintained between about 350-580 ° F. Once the product exits the oven, the latex compound is fully cured. Upon curing, the preferred dry coating weights range from between about 3 to about 12 grams per square foot. Best coating performance is achieved by an acrylic latex compound that foams well but has a relatively low level of surfactant. Surfactant, being soap-like, is nee jed for efficient compound foaming but excess levels of surfactants can degrade surface repellency.
  • the semipermeable surface coatings 14 disclosed herein repel liquid water droplets 18, resist pooled water 20, and hold out a 1/8 to 1 inch (or 200- 400 grams of water in a one gallon, open bottom can) liquid water column 22 from penetrating the coating and accumulating in the insulation base mat 12.
  • the coating 14 and intermediate layer (s) 16, if present constitute a semipermeable stratum which allows water vapor 26 in the base mat 12 to move through the surface of the coating for release into the atmosphere or into the interior of an HVAC duct if building product 10 is a duct liner.
  • the present inventors discovered an alternative to the above described processes for producing semipermeable building products, particularly duct liners. More specifically, commercially available ToughGard® duct liner product marketed by CertainTeed Corp. as well as several other duct liner products were sprayed with a product called ReviveX®, a water repellent fluoropolymer marketed by . L. Gore & Associates, Inc. of Newark, DE, and cured in an oven for two hours at 250 ° F. The duct liner products treated with ReviveX® exhibited improved water repellency.
  • an acrylic latex surface coating for textile fiber glass duct liner that has the above-described semipermeable properties and hence improves building IAQ.
  • the duct liners also have solvent and liquid detergent resistance to enable wet cleaning of the duct
  • the present invention also offers a cost-effective, breathable (semipermeable) coating that may be useful in connection with any type of building product, whether insulated or not.
  • the coating allows water vapor to pass through unimpeded, whereby water vapor freely moves into and out of the insulation.
  • the coating can be applied to other HVAC products such as duct board and the like or other organic or inorganic substrates used in the building material industry where the technology described herein has merit.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Laminated Bodies (AREA)
  • Paints Or Removers (AREA)
  • Thermal Insulation (AREA)

Abstract

La présente invention concerne des matériaux de revêtement (14), des produits de matériaux de construction contenant une isolation et comportant lesdits matériaux de revêtement, ainsi que des procédés d'application desdits revêtements sur les produits de matériaux de construction. Les matériaux de revêtement (14) présentent un pouvoir respirant unidirectionnel par rapport à l'eau et à des solutions aqueuses, c.-à-d. que lesdits revêtements sont essentiellement imperméables à l'eau liquide et perméables à la vapeur d'eau. Ainsi, de la vapeur d'eau contenue dans une isolation revêtue dudit matériau peut traverser le revêtement, tandis que de l'eau liquide ne peut pas traverser le revêtement et pénétrer dans l'isolation.
EP01903463A 2000-02-04 2001-02-01 Revetement semipermeable destine a des materiaux de construction Withdrawn EP1268182A1 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US18035100P 2000-02-04 2000-02-04
US180351P 2000-02-04
PCT/US2001/003234 WO2001056779A1 (fr) 2000-02-04 2001-02-01 Revetement semipermeable destine a des materiaux de construction

Publications (1)

Publication Number Publication Date
EP1268182A1 true EP1268182A1 (fr) 2003-01-02

Family

ID=22660119

Family Applications (1)

Application Number Title Priority Date Filing Date
EP01903463A Withdrawn EP1268182A1 (fr) 2000-02-04 2001-02-01 Revetement semipermeable destine a des materiaux de construction

Country Status (7)

Country Link
EP (1) EP1268182A1 (fr)
CN (1) CN1176802C (fr)
AU (1) AU2001231270A1 (fr)
CA (1) CA2398982C (fr)
HK (1) HK1047908A1 (fr)
MX (1) MXPA02007441A (fr)
WO (1) WO2001056779A1 (fr)

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3861425A (en) * 1971-12-06 1975-01-21 Owens Corning Fiberglass Corp Coating composition
US4101700A (en) * 1976-03-12 1978-07-18 Johns-Manville Corporation Thermally insulating duct liner
CA1137364A (fr) * 1979-07-20 1982-12-14 Yoshiji Hiraoka Materiau en feuille impermeable a l'eau
US4357384A (en) * 1979-10-04 1982-11-02 Northwood Mills, Ltd. Composite structures, new adhesive, and cement composition

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See references of WO0156779A1 *

Also Published As

Publication number Publication date
CN1398222A (zh) 2003-02-19
HK1047908A1 (zh) 2003-03-14
WO2001056779A1 (fr) 2001-08-09
CN1176802C (zh) 2004-11-24
MXPA02007441A (es) 2004-08-23
AU2001231270A1 (en) 2001-08-14
CA2398982A1 (fr) 2001-08-09
CA2398982C (fr) 2006-06-13
HK1053086A1 (zh) 2003-10-10

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