Method for Producing a Sealing Tape Roll and Sealing Tape
20200140723 ยท 2020-05-07
Assignee
Inventors
Cpc classification
E06B1/62
FIXED CONSTRUCTIONS
International classification
Abstract
A method for producing a sealing tape roll comprises the steps of providing a foam-barrier layer web comprising a plurality of foam strips, wherein a barrier layer is arranged between each pair of adjustment foam strips; applying a cover layer to the foam-barrier layer web; parting the cover layer in the longitudinal direction in an area of at least two foam strips and a certain distance away from each barrier layer adjacent to these foam strips, thus forming subsections of the cover layer, wherein a subsection of the cover layer at least partially covers two adjacent foam strips; and forming a sealing tape roll from the coated foam-barrier layer web.
Claims
1. A method for producing a sealing tape roll, comprising the steps of: providing a foam-barrier layer web, which comprises a plurality of foam strips arranged next to each other in a transverse direction, wherein a barrier layer is arranged between each pair of adjacent foam strips, wherein the foam-barrier layer web has a top surface, a bottom surface, and two side surfaces connecting the top surface and the bottom surface together, wherein a longitudinal direction of the foam-barrier layer web is parallel to the bottom surface of the foam-barrier layer web and transverse to the transverse direction; applying a cover layer to the top surface and/or bottom surface of the foam-barrier layer web to form a coated foam-barrier layer web; parting the cover layer in the longitudinal direction in an area of at least two foam strips and a certain distance away from each barrier layer adjacent to these two foam strips, thus forming subsections of the cover layer, wherein a subsection of the cover layer at least partially covers at least two adjacent foam strips; and forming a sealing tape roll by: (i) winding up the coated foam-barrier layer web around a rotational axis into a sealing tape roll; or (ii) winding up the coated foam-barrier layer web around a rotational axis into an intermediate roll and parting the intermediate roll at one or more points in an axial direction to produce a plurality of sealing tape rolls, which are narrower than the intermediate roll; or (iii) parting the coated foam-barrier layer web in the longitudinal direction to form foam-barrier layer strips and winding up the foam-barrier layer strips around a rotational axis into individual sealing tape rolls.
2. The method of claim 1 wherein parting of the cover layer in the longitudinal direction is executed in an area of each foam strip of the plurality of foam strips.
3. The method of claim 1 wherein parting of the cover layer is executed in a middle area of the associated foam strip.
4. The method of claim 1 wherein the subsections of the cover layer form strips which are arranged next to each other in the transverse direction and are parallel to each other in the longitudinal direction.
5. The method of claim 1 wherein the foam-barrier layer web comprises a plurality of barrier layers, and a subsection of the cover layer at least partially covers at least three adjacent foam strips.
6. The method of claim 1 wherein parting of the cover layer comprises introducing at least one cut into the cover layer.
7. The method of claim 1 wherein the at least one cut is introduced only into the cover layer, or the at least one cut is introduced into the cover layer and penetrates into the associated foam strip, wherein the depth of the at least one cut in the foam strip is a maximum of of a thickness of the foam strip between the top surface and the bottom surface of the foam-barrier layer web.
8. The method of claim 1 wherein parting of the cover layer comprises removing certain areas of the cover layer between the subsections of the cover layer to be formed.
9. The method of claim 8 wherein the step of removing certain areas of the cover layer comprises melting the cover layer, milling-away the cover layer, or cutting and removing certain areas of the cover layer.
10. The method of claim 1 further comprising bonding the cover layer to the foam strips of the foam-barrier layer web before parting the cover layer.
11. The method of claim 1 wherein, when the cover layer is bonded to the foam strips of the foam-barrier layer web, the cover layer is also bonded to the at least one barrier layer.
12. The method of claim 1 further comprising bonding of at least one subsection of the cover layer to the at least one barrier layer which is arranged in an area of the subsection.
13. The method of claim 1 wherein the at least one barrier layer extends from the top surface to the bottom surface through the entire foam-barrier layer web.
14. The method of claim 1 wherein the cover layer is made of a film-like material or an adhesive, in particular a film web, a film strip, an adhesive tape strip, or an adhesive-like fluid medium.
15. A sealing tape having a top surface, a bottom surface, two side surfaces connecting the top surface and the bottom surface together, wherein a longitudinal direction is parallel to the bottom surface of the sealing tape, wherein the sealing tape further comprises: a plurality of foam strips arranged next to each other in a transverse direction, wherein the transverse direction is parallel to the bottom surface of the sealing tape and transverse to the longitudinal direction of the sealing tape; at least two barrier layers, wherein a barrier layer is arranged between each pair of adjacent foam strips; and a plurality of continuous subsections of a cover layer on the top surface and/or the bottom surface of the sealing tape, wherein the subsections are separated from each other, and each subsection partially covers two adjacent foam strips and is bonded to the two foam strips; wherein the cover layer is made of a film-like material or an adhesive.
16. The sealing tape of claim 15 wherein the at least one subsection of the cover layer is bonded to the barrier layer which is arranged in an area of the subsection.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0042]
[0043]
[0044]
[0045]
[0046]
[0047]
[0048]
[0049]
[0050]
[0051]
[0052]
[0053]
[0054]
DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS
[0055]
[0056] Foam-barrier layer web 2 comprises a top surface 8, a bottom surface 10, and two side surfaces 12, 14 connecting top surface 8 and bottom surface 10 to each other; it also comprises a longitudinal direction L, which is parallel to bottom surface 10 of foam-barrier layer web 2 and transverse to the transverse direction Q. Foam-barrier layer web 2 and individual foam strips 4 preferably comprise a substantially rectangular cross section. In a compressed state of the foam, the cross-sectional shape can deviate from this.
[0057] The at least one barrier layer 6 can extend continuously from bottom surface 10 to top surface 8 of the foam-barrier layer web 2, or it can extend over only part of the distance between bottom surface 10 and top surface 8. To bring about the desired sealing action against the diffusion of water vapor, however, at least one barrier layer 6 extends over at least 500%, preferably over at least 75%, and even more preferably over at least 90% of the thickness of foam-barrier layer web 2.
[0058] Foam-barrier layer web 2 is moved in a conveying direction F, which is parallel to the longitudinal direction L of foam-barrier layer web 2.
[0059] The foam strips 4 preferably all have the same width in the transverse direction Q and the same height in the thickness direction perpendicular to both the transverse direction Q and the longitudinal direction L. The foam strips 4 can also have different widths and/or different heights so that, for example, a profiled foam-barrier layer web can be formed. As an option, a barrier layer 6 can also be arranged on the side surfaces (forming the side surfaces 12, 14) of the outermost foam strips 4 of the foam-barrier layer web 2.
[0060] The skilled person is familiar with a number of different methods for providing a foam-barrier layer web 2. US 2016/0059536 A1, for example, describes the insertion of a barrier layer 6-forming strip by a suitable insertion tool into the cuts, which have previously been made in a foam web. According to EP 2 990 552 A1 and US 2016/0060068 A1, individual foam strips can be provided, at least one of which has a side surface onto which a barrier layer material has been applied. The foam strips are then brought together and bonded in such a way that the barrier layer material is arranged between two adjacent foam strips. Alternatively, US 2013/0187348 A1, for example, discloses that a cut is introduced into a foam web which does not pass completely through the web, and that a V-shaped film is then inserted into this cut. Alternative methods can be used without further ado.
[0061]
[0062] The following description of preferred embodiments refers primarily to a cover layer 16 on the top surface 8 of the foam-barrier layer web 2. It is obvious that the explanations are applicable in analogous fashion to embodiments in which, additionally or alternatively, a cover layer 16 is provided on the bottom surface 10 of the foam-barrier layer web 2. Corresponding features can be combined in any way desired.
[0063] Alternatively, the cover layer can consist of an adhesive-like fluid medium, which is applied in the known manner to the top surface 8 and/or bottom surface 10 of foam-barrier layer web 2 by appropriate nozzles, for example.
[0064] Independently of the material and of the manner in which cover layer 16 is applied, cover layer 16 preferably covers the entire surface 8, 10 of foam-barrier layer web 2 to which it is applied. It is preferred that cover layer 16 be bonded to the foam strips 4 when it is applied to foam-barrier layer web 2. Cover layer 16 can also be bonded immediately to barrier layers 6. For example, the cover layer 16 can be adhered to foam-barrier layer web 2. For this purpose, cover layer 16 either is provided with an additional adhesive or is configured as an adhesive tape or has itself a certain adhesive property. A film-like cover layer 16 can also be laminated onto foam-barrier layer web 2, wherein the bonding occurs under the action of heat and pressure. Alternative methods for applying a cover layer 16 of the type cited above are known to the skilled person and can be used without further ado.
[0065] As previously described, foam-barrier layer web 2 and cover layer 16 continue to move in the conveying direction F during the application of cover layer 16.
[0066]
[0067] As a result of the parting of cover layer 16 in the longitudinal direction L, subsections 20 of cover layer 16 are formed, wherein a subsection 20 of cover layer 16 at least partially covers at least two adjacent foam strips 4. In the illustrated embodiment according to
[0068] The parting of cover layer 16 in the longitudinal direction L can generally be accomplished by introducing at least one cut into cover layer 16 (
[0069]
[0070] To introduce the at least one cut 22 into cover layer 16, a tool 24 is provided, which cuts through cover layer 16. In the embodiment shown, tool 24 is configured as a roller and comprises a plurality of circumferential cutting edges. Alternatively, other types of tools such as knives or saws can be used.
[0071] Cuts 22 are parallel to each other, so that subsections 20 of cover layer 16 which are formed are also parallel. Subsections 20 of cover layer 16 are thus, configured in the form of strips. It is preferred that the at least one cut 22 be introduced only into cover layer 16 without damaging the foam of foam strip 4. Because this requires a high degree of precision, however, it can also be desirable for the at least one cut 22 to be introduced into cover layer 16 and to penetrate into the associated foam strip 4. This makes it easier to carry out the method.
[0072] To preserve the integrity of foam-barrier layer web 2 in the transverse direction Q, however, and to avoid any negative influence on the sealing properties of the sealing tapes to be produced, the depth of each cut 22 into foam strip 4 should be small as possible. The depth of each cut 22 in foam strip 4 is therefore a maximum of , preferably a maximum of 1/10, and more preferably a maximum of 1/20 of the thickness of the foam strip 4 between the top surface 8 and bottom surface 10 of foam-barrier layer web 2. It is especially preferred that each cut 22 not penetrate into the associated foam strip 4 any deeper than 1-2 mm.
[0073] As
[0074] So that the advantages of the flexibility of the foam used for foam strips 4 can be exploited in optimal fashion, however, it is preferred that the parting of cover layer 16 comprise the removal of certain areas of cover layer 16 between subsections 20 of cover layer 16 to be formed, as shown in
[0075] The width of subsections 20 of cover layer 16 and of areas 26 in the transverse direction Q can basically be selected in any way desired. It is obvious that the width of subsections 20 and the width of the areas 26 influence each other. The wider the subsections 20 of the cover layer, the narrower the areas 26, in which cover layer 16 has been removed, and vice versa. The sealing tapes to be produced are thus adaptable to the existing requirements or to the desired properties.
[0076] It is also advantageous in this embodiment for only the cover layer 16 to be removed in certain areas. Because this increases the complexity of the method, however, it is also conceivable that a very small amount of the foam of the associated foam strip 4 could also be removed in the areas 26 next to the cover layer 16. The depth of the intrusion into the foam, however, should not be greater than that previously described in reference to the at least one cut 22.
[0077] In the embodiment according to
[0078] The tool 24 according to
[0079] The skilled person will readily envision alternative tools for introducing cuts or for melting the cover layer 16 in the areas 26.
[0080]
[0081]
[0082] During the winding-up process, foam-barrier layer web 2 or sealing tape roll 32 is compressed to allow space-saving storage. It is conceivable that the pressure required to bond the cover layer 16 or its subsections 20 to the at least one barrier layer 6 could be applied only at this time.
[0083] Foam-barrier layer web 2 or sealing tape 32 is wound up in such a way that the subsections 20 of cover layer 16 of one turn of sealing tape roll 28 rest flat against the bottom surface 10 of foam-barrier layer web 2 or of sealing tape 32 of the adjacent turn. Side surfaces 12, 14 of foam-barrier layer web 2 form the end surfaces 34, 36 of sealing tape roll 28.
[0084] An adhesive layer 37, furthermore, can be applied to bottom surface 10 of the foam-barrier layer web or of the sealing tape before sealing tape roll 28 is wound up or while it is being wound up. By adhesive layer 37, sealing tape 32 can be easily attached to the frame element. Adhesive layer 37 can be formed by a film-like or viscous adhesive; or it can be, for example, a double-sided adhesive tape. Adhesive layer 37 is preferably covered by a peel-off layer (not shown), which prevents adjacent turns of sealing tape roll 28 from sticking together and the roll from being damaged or soiled. Adhesive layer 37 is to be applied to surface 8, 10 of the foam-barrier layer web which is opposite the surface 8, 10 comprising cover layer 16. It is also conceivable that cover layer 16 itself could fulfill the function of adhesive layer 37.
[0085]
[0086] Intermediate roll 38 can be cut by a knife 40 or some other suitably adapted tool; for example, it can be cut by saws or by water-jet cutting. As previously mentioned, the foam-barrier layer web 2 is also compressed when it is wound up into the intermediate roll 38. Correspondingly, the bonding of the subsections 20 of cover layer 16 to barrier layers 6 can again be carried out only at this point in time, if desired.
[0087]
[0088] In the area of the rollers 47, the foam-barrier layer strips 42 can be compressed, so that each one can then be wound up around a rotational axis 30 into a sealing tape roll 28. The rotational axis 30 is parallel to the transverse direction Q in this case as well. Accordingly, a foam-barrier layer strip 42 corresponds to a sealing tape 32, and the width of each foam-barrier layer strip 42, i.e., the number of foam strips 4 and interior barrier layers 6 it has, is to be selected correspondingly. Here again, an additional adhesive layer 37 can be provided, as discussed above.
[0089]
[0090] Basically a sealing tape 32 comprises a top surface 48, a bottom surface 50, and two side surfaces 52, 54 which connect the top surface 48 and the bottom surface 50 together. A sealing tape 32 also comprises a longitudinal direction L, which is parallel here to the bottom surface 50 of the sealing tape 32. In
[0091] The top surface 48 and the bottom surface 50 of the sealing tape 32 correspond to the top surface 8 and the bottom surface 10 of the foam-barrier layer web 2, and the longitudinal direction L of the sealing tape 32 is parallel to the longitudinal direction L of the foam-barrier layer web 2.
[0092] Each sealing tape 32 comprises a plurality of foam strips 4 arranged next to each other in the transverse direction Q, wherein the transverse direction Q is parallel to the bottom surface 50 of the sealing tape 32 and transverse to the longitudinal direction L of the sealing tape 32. The sealing tape 32 also comprises at least one barrier layer 6, wherein a barrier layer 6 is arranged between each pair of adjacent foam strips 4. Each sealing tape 32 also comprises at least one continuous subsection 20 of a cover layer 16 on the top surface 48 and/or on the bottom surface 50 of the sealing tape 32, which partially covers two adjacent foam strips 4 and is bonded to the two foam strips 4. The at least one subsection 20 of the cover layer 16 is preferably bonded to the barrier layer 6 which is arranged in the area of the associated subsection 20.
[0093] In the embodiment according to
[0094] It can be seen from the cross-sectional view that, as a result, the subsections 20 increase the contact surface by which a barrier layer 6, in the installed state, can rest against a section of masonry wall. This will be made clear on the basis of
[0095] It is preferred that the cover layer 16 be parted in the middle of each associated foam strip 4. The cut 22 which is introduced into the cover layer 16 to part it or the area 26 in which a certain amount of the cover layer 6 has been removed is therefore arranged in the center of the strip and extends in the longitudinal direction L on the side forming the surface 48 of the sealing tape 32 of each foam strip 4. Each cut 22 or area 26 is therefore arranged symmetrically between the side surfaces of a foam strip 4 which are parallel to the side surfaces 52, 54 of the sealing tape 32. Each cut 22 or area 26, however, is also a certain distance away in the transverse direction Q from a barrier layer 6 to ensure that each barrier layer 6 is covered by a subsection 20 of the cover layer 16.
[0096] It can also be seen that the barrier layers 6 preferably extend continuously from the bottom surface 50 to the top surface 48 of the sealing tape 32 (and thus also continuously from the bottom surface 10 to the top surface 8 of the foam-barrier layer web 2). It is also conceivable that the barrier layers 6 could extend only part of the way through the sealing tape 32; for example, they could extend part of the way alternately from the top surface 48 and the bottom surface 50; or some of the barrier layers 6 could extend continuously from the bottom surface 50 to the top surface 48 of the sealing tape 32, and the other barrier layers 6 could extend only part of the way through the sealing tape 32. The configuration of the barrier layers 6 depends essentially on the method used to provide the foam-barrier layer web 2 and on the sealing properties required of the sealing tape 32, especially the sealing properties associated with the resistance to the diffusion of water vapor.
[0097]
[0098] In the embodiment according to
[0099] It is obvious that the subsections 20 can also cover more than three foam strips 4 in this manner. Of the foam strips 4 covered by a subsection, each subsection 20 partially covers the foam strips in the outermost positions in the transverse direction Q and covers completely the foam strips 4 arranged between these two. In addition, each subsection 20 of the cover layer 16 covers all of the barrier layers 6 which are arranged between the foam strips 4 covered by it. It must be kept in mind, however, that it is preferred that the number of subsections 20 to be produced is sufficient to ensure the necessary flexibility of the top surface 48 of the sealing tape 2. The subsections 20 of the cover layer configured in this way can also be produced by parting the cover layer 16 by at least one cut 22 or by removing certain areas of the cover layer 16.
[0100]
[0101]
[0102] The sealing tape 32 is usually attached to the frame element 60 by an adhesive layer 37 on its bottom surface 50, and its top surface 48 rests against the masonry wall section 62. The barrier layers 6 extend peripherally in the joint 58 around the frame element 60, i.e., in the longitudinal direction, and from the frame element 60 to the masonry wall section 62. In this way, the sealing tape 32 seals the joint 58 between the interior 64 of the room and the exterior 66 of the room in a functional direction X, which is parallel to the transverse direction Q.
[0103] The subsections 20 of the cover layer 16 are arranged on the top surface 48 of the sealing tape 32 and are preferably bonded both to the adjacent foam strips 4 and to the at least one adjacent barrier layer 6. As a result, the contact surface between the barrier layer 6 and the masonry wall section 62 is increased, which guarantees that at least part of the surface of the subsection 20 facing the masonry wall section 62 will rest against the masonry wall section 62. Because the subsection 20 is also bonded to the barrier layer 6, the goal is achieved that it is impossible for water vapor to diffuse around the barrier layer 6 between an edge of the barrier layer and the masonry wall section 62, but it is also impossible for it to diffuse between the barrier layer 6 and the associated subsection 20 of the cover layer 16. The water vapor impermeability of the sealing tape 32 is thus increased. It is obvious that the sealing tape 32 can also be arranged in the joint 58 in such a way that the bottom surface 50 of the sealing tape 32 rests against the masonry wall section 62 and the top surface 48 of the sealing tape 32 rests against the frame element 60. Alternatively, both the top surface 48 and the bottom surface 50 of the sealing tape 32 could also be provided with subsections 20 of a cover layer 16. All of the other embodiments described herein can also be inserted into a corresponding joint in analogous fashion.