High thermal resistance and permeance insulation material

Abstract

A low-emittance material having improved energy efficiency protection against air infiltration and moisture build-up in buildings is disclosed. The aforementioned low-emittance material utilizes existing framing openings or without increasing the wall profile of a building. The present invention provides a low-emittance material which may be implemented on traditional 24 framing having R-15 mass insulation material within existing or newly constructed framing cavities. The material of the present invention also meets requirements for serving as a water resistive barrier as defined by ICC AC38.

Claims

1. A flexible insulation comprising: an insulating material having a thickness between 3/16 and inches, the insulating material including a closed cell polyolefin foam; a reflective covering material positioned over the insulating material, the insulating material having a side that is directly or indirectly adjoined to the reflective covering material; and a plurality of punched holes, wherein each of the plurality of punched holes has an initial diameter of at least 1/16 inch and extends completely through at least both the insulating material and the covering material, at least some of the plurality of punched holes having a spacing of about one inch between adjacent ones of the plurality of punched holes, wherein formation of the plurality of punched holes removes material in the form of the punched holes from the flexible insulation.

2. The flexible insulation of claim 1, wherein the plurality of punched holes is formed by a collar mechanism mounted to a drive roll assembly.

3. The flexible insulation of claim 2, wherein the plurality of holes causes the flexible insulation to have a permeance and water vapor transmission between about 5 to about 20 perm.

4. The flexible insulation of claim 3, where the plurality of holes is formed from punchers having a diameter to create holes having the initial diameter of 1/16 inch.

5. The flexible insulation of claim 2, wherein the reflective covering material includes aluminum or a polyolefin.

6. The flexible insulation of claim 2, further comprising a reinforcing layer between the insulating material and the reflective covering material.

7. The flexible insulation of claim 2, where the reinforcing layer is configured to be bonded to the insulating material with a polyethylene layer.

8. The flexible insulation of claim 1, wherein the plurality of punched holes provides the flexible insulation with a permeance and water vapor transmission between 5 perm and 20 perm.

9. The flexible insulation of claim 1, wherein the reflective covering material provides the flexible insulation with an emittance of about 0.10 or less, and wherein the plurality of punched holes provides the flexible insulation with a permeance and water vapor transmission between 5 perm and 20 perm.

10. The flexible insulation of claim 1, wherein the reflective facing layer provides the flexible insulation with an emittance of about 0.10 or less.

11. A method for manufacturing a flexible insulation comprising the steps of: providing a first layer and a second layer, the first layer being a first reflective facing layer that reflects radiant heat and the second layer being an insulation layer having a thickness between 3/16 and inches, the insulating layer including a closed cell polyolefin foam; adjoining at least the first reflective facing layer directly or indirectly with the insulation layer; passing the adjoined layers through a drive roll assembly; and punching a plurality of holes completely through the adjoined layers according to a perforation pattern using a collar mechanism mounted to the drive roll assembly, wherein each of the plurality of punched holes has an initial diameter of at least 1/16 inches, the collar mechanism creating openings through the reflective facing layer, the first polyethylene layer, and the insulation layer, wherein at least some of the plurality of punched holes have a spacing of about one inch between adjacent ones of the plurality of punched holes, and wherein the punching the plurality of holes removes material in the form of the punched holes from the flexible insulation.

12. The method of claim 11, further comprising the steps of: providing a first polyethylene layer and applying heat thereto; bonding the heated first polyethylene layer to the first reflective facing layer; providing a third layer and a second polyethylene layer, the third layer being a second reflective facing layer that reflects radiant heat; applying heat to the second polyethylene layer; bonding the heated second polyethylene layer to the second reflective layer; and adjoining the bonded second reflective facing layer and second polyethylene layer with the insulation layer.

13. The method of claim 12, where the polyethylene layer is bonded to the first layer or the second layer prior to the adjoining.

14. The method of claim 11, wherein the first layer includes aluminum.

15. The method of claim 11, wherein the plurality of holes causes the flexible insulation to have a permeance and water vapor transmission between about 5 to about 20 perm.

16. The flexible insulation of claim 1, further comprising a polyethylene layer disposed between the insulating material and the reflective covering material.

17. The flexible insulation of claim 1, wherein the reflective covering material is non-reinforced on one side thereof.

18. The method of claim 11, further comprising providing a second reflective facing layer, wherein the adjoining includes the second reflective facing layer as the adjoined layers, and wherein the punching includes punching the plurality of holes completely through the second reflective facing layer.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The present invention will be understood more fully from the detailed description given below and from the accompanying drawings of various embodiments of the invention, which, however, should not be taken to limit the invention to the specific embodiments, but are for explanation and understanding only.

(2) FIG. 1 provides a top view of a low-emittance housewrap material according to an exemplary disclosed embodiment;

(3) FIG. 2 provides a cross-sectional view of a low-emittance housewrap material according to an exemplary disclosed embodiment;

(4) FIG. 3 provides a cut-away perspective view of a low-emittance housewrap material according to an exemplary disclosed embodiment;

(5) FIG. 4 provides a top view of a low-emittance housewrap materials during an assembly method according to an exemplary disclosed embodiment;

(6) FIG. 5 provides a perspective view of the low-emittance housewrap materials during the assembly method of FIG. 4;

(7) FIG. 6 provides a top view of a low-emittance housewrap materials during a continued assembly method according to an exemplary disclosed embodiment;

(8) FIG. 7 provides a perspective view of the low-emittance housewrap materials during the assembly method of FIG. 6;

(9) FIG. 8 provides a top view of low-emittance housewrap materials after assembly according to an exemplary disclosed embodiment;

(10) FIG. 9 provides a bottom view of low-emittance housewrap materials prior to assembly according to an exemplary disclosed embodiment;

(11) FIG. 10 provides a top view of low-emittance housewrap materials during an assembly method according to an exemplary disclosed embodiment;

(12) FIG. 11 provides a bottom view of low-emittance housewrap materials after assembly according to an exemplary disclosed embodiment;

(13) FIG. 12 provides an exemplary exterior wall according to an exemplary disclosed embodiment; and

(14) FIG. 13 provides a low-emittance housewrap material application to the exemplary wall structure of FIG. 12 according to an exemplary disclosed embodiment.

DETAILED DESCRIPTION

(15) A low-emittance housewrap is described. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the exemplary embodiments. It is apparent to one skilled in the art, however, that the present invention can be practiced without these specific details or with an equivalent arrangement.

(16) Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, FIG. 1 illustrates a top view of low-emittance housewrap materials according to one disclosed embodiment of the present invention. By way of example, two pieces of the low-emittance housewrap materials 10, 12 are shown. Each of the two pieces of low-emittance housewrap materials 10, 12 may comprise flap portions 14, 16, respectively, at one end thereof. At another end the low-emittance housewrap material may include an adhesive strip 18 such as that provided on low-emittance housewrap material 10. In a preferred embodiment, the top surface 20, 22 of the low-emittance housewrap materials 10, 12, respectively, is a reflective material such as a layer of reinforced foil material.

(17) Turning to FIG. 2, a cross-section of the low-emittance housewrap material 12 is shown. The low-emittance housewrap material 12 may comprise an assembly of product component parts including, for example, a reflective foil material 34, foil reinforcement 26, and a foam material 28. In one embodiment, the reflective material may comprise a facing of approximately 99.4% polished aluminum. It is noted that the reflective material may comprise a facing having any suitable amount of aluminum, for example, greater than about 90%, preferably between about 90% and about 99.9%, even more preferably between about 99.0% and about 99.9%. The reflective foil material 34 may be nonreinforced on one side. On the other side, the reflective foil material 34 may comprise a foil reinforcement 26 including, for example, a scrim foil reinforcing 30 (e.g., see FIG. 3). Scrim is a term known in the art to consist of crossed lines of plastics material which serve to strengthen the overall product and to prevent stretching damage to the layers. The reflective foil material 34 and foil reinforcement 26 may be applied over and bonded to the foam material 28. The scrim foil reinforcing 30 is sufficient to provide a tensile strength of approximately 23 pounds per inch width in a machine direction and 25 pounds per inch width in a cross machine direction on a low-emittance housewrap material test specimen cut approximately 1 wide by 9 long in standard ambient lab conditions. The foam material 28 serves as a polyolefin thermal break such as one comprising a closed cell polyethylene foam. In a preferred embodiment, the nominal thickness of the polyolefin thermal break is approximately (0.25). It is noted that the nominal thickness of the polyolefin thermal break may be any suitable thickness, for example, greater than about (0.125) and less than about (0.375). Thicknesses above about are within the scope of the present invention. It is noted that a thickness greater than about may require use of 26 framing instead of the more traditional 24 framing. The low-emittance housewrap 12 may also incorporate a self adhered drainage plane 24 feature as further described below.

(18) Thus, the invention includes a layer of polyethylene foam which serves as a support for the other added component layers. Polyethylene foam or equivalent polypropylene foam may be utilized, both being in the chemical family designated as polyolefins. A thin layer of aluminum foil is bonded indirectly to one or both sides of said foam layer. Thin polyethylene layers are placed between the aluminum foil and the foamed layer. The thin polyethylene is bonded to the aluminum foil layer to greatly improve its resistance to tearing. This strengthening feature means that the end product has a much wider use than has been known in the art. A layer of strengthening scrim may be added to further enhance the product integrity. In practice of the invention, the various layers adjoin one another after being flame or heat roller laminated together.

(19) In certain embodiments and in practice of the invention, both sides of the foam layer may be covered with layers as described above. The end product may thus appear identical on either side with the aluminum foil layers being externally located. Thus, use and installation is simplified since the product may be used with either side facing out since both external faces are identical. The resulting bonded layers are easily rolled, transported and installed without requiring special tools or environmental precautions which must be taken with many other prior art insulations.

(20) Turning to FIG. 3, the low-emittance housewrap 12 comprises perforations 32 sufficiently spaced to ensure that the low-emittance housewrap material does not act as a vapor barrier. In one preferred embodiment, the perforations in the low-emittance housewrap are generated from perforation system consisting of 1/16 punchers placed in four holes per 1.25 square inch sequence on a collar mechanism. The collar mechanism is mounted to a drive roll assembly for perforation of the low-emittance housewrap wherein a 1.25 square inch perforation pattern is achieved on the finished product. A perforation pattern of 1.25 square inch allows low-emittance housewrap 12 to meet the criteria for perms, water vapor transmission and water resistance while maintaining an effective emissivity rating. This is unique and contrary to industry standards wherein in many applications, micro perforations are generated in housewraps using needles for vapor penetration. However, in such convention applications, the micro perforations are susceptible to resealing when exposed to higher temperatures. This affect may trap moisture and induce undesirable results such as mold and rot. In contrast, the present perforation pattern of the prescribed invention eliminates the possibility resealing when exposed to higher temperatures. Spaced in approximately 1.25 square perforations, the low-emittance housewrap material achieves a preferred permeance and water vapor transmission of approximately 7 perm or 40 g/day/m.sup.2. As such, the present low-emittance housewrap material performs within the optimal permeance and water vapor transmission range of about 5 to about 20 perm.

(21) The present low-emittance housewrap material meets the Standard Specification for Reflective Insulation, C 1224-03, Section 6, 6.1, which states that Low emittance materials shall have a surface with an emittance of 0.10 or less, in accordance with test Method C 1371. Specifically, the present low-emittance housewrap material achieves an emittance of 0.10 or less, more specifically within a range of about 0.03 to about 0.05, in accordance with test Method C 1371.

(22) Accordingly, the product low-emittance housewrap material of the present invention is constructed to include the following approximate performance characteristics:

(23) TABLE-US-00001 Test Description Test Results Perm Test 7 perms ASTM E-96 Water As Received 23 hrs Resistance Pass ASTM D-779 Weathered 23 hrs Pass Ultraviolet light No Cracking Accelerated Aging No Cracking Tensile Strength 23 lbs/inch (machine direction) 25 lbs/inch (cross direction) U-value Wall .056 vinyl (zone 5-7) 2010 IECC U-value Wall .051 brick (zone 5-7) 2010 IECC U-value Wall .063 Stone (zone 5-7) 2010 IECC

(24) Although the use of 1/16 punchers at a rate of four holes per 1.25 square inch is described above and represents one of many preferred embodiments of the present invention, other size punchers may be used and other rates of holes per given area are within the scope of the present invention. For example, the diameter of the puncher may be varied to any suitable size and the rate may be modified to achieve the particular permeance and emittance standards required by a particular building code, specification or other requirement.

(25) The system U-values described in The Evaluation of Thermal Resistance of a Building Envelope Assembly demonstrates the performance of wood framed walls (24 construction 16 on center). The U-value calculations are based on methods outlined by the ASHRAE Handbook of Fundamentals. The U-value performance of these systems achieve a U-value between 0.051 (brick), 0.056 (vinyl) and 0.063 (stone) satisfying or exceeding requirements for zones 1-7 established by 2010 IECC Code Table 402.1.3 or equivalent UA alternative values established by other code bodies.

(26) Flap portion 16 is illustrated in FIG. 3. This overlapping flange serves as a self adhered drainage plane 24. During assembly of one or more low-emittance housewrap sections, the flap portion 16 may be assembled to cover an edge of an abutting portion of another low-E housewrap material section in order to seal the edge. For example, turning to FIGS. 4 and 5, a first section 10 of low-emittance housewrap material is positioned near a second section 12 of low-emittance housewrap material. The flap portion 16 of the second section 12 of low-emittance housewrap material may be disposed over an edge portion 38 of the first section 10 of low-emittance housewrap material. In one embodiment, the aforementioned edge portion 38 may include an adhesive strip 18 for retaining the flap portion 16 thereon. The adhesive strip 18 may be employed on the top surface 20 such as on the reflective foil material 34. While the adhesive strip 18 has been described and shown in the drawings for illustrative purposes, any means may be employed which is suitable for retaining the flap portion 14 over the edge portion 38 in order to provide a water resistive barrier between the abutting sections of low-emittance housewrap materials.

(27) Turning to FIGS. 6 and 7, a protective film is removed to expose the adhesive strip 18 in preparation for securing the flap portion 16 over the edge portion 38. The flap portion 16 is contacted to the adhesive strip 18 and secured over the edge portion as illustrated in FIG. 8. This assembly serves to provide a water resistive barrier between two abutting sections of low-emittance housewrap materials of the present invention to effectively seal their respective edges and allow water runoff from one low-emittance housewrap material section to another low-emittance housewrap material section.

(28) A bottom view vantage point of abutting low-emittance housewrap materials is illustrated in FIGS. 9-10. Again, the first section 10 of low-emittance housewrap material is positioned near the second section 12 of low-emittance housewrap material. The flap portion 16 of the second section 12 of low-emittance housewrap material is disposed over an edge portion 38 of the first section 10 of low-emittance housewrap material. Edge portion 38 may include an adhesive strip 18 for retaining the flap portion 16 thereon. As a sufficient force is applied, for example, to flap portion 16 to contact the adhesive strip 18, the flap portion 16 is held in retention over the edge portion 38 as shown, for example, in FIG. 11. It is clear from FIG. 11 that, in a final assembly arrangement, a foam edge portion 56 of a first low-emittance housewrap material 10 abuts a foam edge portion 58 of a second low-emittance housewrap 12. Accordingly, the assembled sections serve to provide a water resistive barrier between two abutting sections of low-emittance housewrap materials of the present invention.

(29) In order to improve the energy efficiency of new and existing building structures, application of the herein described low-emittance housewrap serves to cover the exterior wall sheathing with an infiltration barrier, for example, prior to installation of a covering material or exterior finish such as siding, brick, stone, masonry, stucco and concrete veneers, for examples. The herein described low-emittance housewrap also serves to protect against air infiltration and damaging moisture build-up. Air infiltration may occur in typical construction through, among other places, sheathing seams and cracks around windows and doors. Moisture build-up can occur externally in the wall cavity from, for example, leaking exterior finishes or coverings, and cracks around windows and doors. The low-emittance housewrap of the present invention does not trap the water, but rather allows it to flow downward so as to exit the wall system.

(30) Installation procedures of the presently described low-emittance housewrap include those as described, for example, in the technical manual for ESP Low-E Housewrap utilized on exterior walls and under a primary barrier. The technical manual for ESP Low-E Housewrap is submitted herewith and is hereby fully incorporated herein by reference. Turning to FIG. 12, an exemplary exterior wall assembly 40 is constructed and prepared for receiving the low-emittance housewrap material of the present invention. In the illustrated example, a window opening 42 is shown. In a preferred embodiment, the low-emittance housewrap is employed after the walls have been construction and all sheathing and flashing details have been installed. The low-emittance housewrap material is preferably applied before doors and windows have been set inside framed openings and prior to the installation of the primary wall covering.

(31) Turning to FIG. 13, a first low-emittance housewrap material is applied to the wall assembly 40. The reflective side of the low-emittance housewrap material is installed facing outwardly. In one preferred embodiment, a roll of low-emittance housewrap material is unrolled horizontally starting at the corner of a preferred exterior wall 40. The flange side or flap portion (e.g., 14, 16 of FIG. 1) of the roll is installed facing downwardly. The low-emittance housewrap material is secured to the exterior wall with fasteners 48 such as staples or cap nails (or any other suitable fasteners) at preferably every 8-12. When applying another horizontal run of low-emittance housewrap material 44, the foam ends of each applied section of rolled low-E housewrap material abut together such that the flange 52 of the additionally applied low-emittance housewrap material 44 is allowed to overlap the outside edge 50 of the adjacent low-emittance housewrap material 46. This installation ensures that any intruding water is encouraged by the drainage plane (e.g., 24 of FIG. 2) to flow downwardly.

(32) In a preferred embodiment, the flange 52 is installed to overlap the abutting foam edge by approximately 2. The low-emittance housewrap material is installed to extend over all of the sill plates by a minimum of approximately 1. The vertical and horizontal seam areas are sealed with suitable low-emittance foil tape. The low-emittance housewrap material may be trimmed around each framed opening with additional appropriate detailing applied as per window/door manufacturer and/or code standards.

(33) Once installed, an appropriate exterior covering may be applied/installed over the low-emittance housewrap. Such covering may include, but not limited to, siding, brick, stone, masonry, stucco and concrete veneers. The utilization of the herein described low-emittance housewrap provides, inter alia, a protective wrap that not only improves energy efficiency in accordance with newly implemented industry-wide energy/code regulations, but enhances drainage of damaging moisture build-up while protecting against air infiltration.

(34) Moreover, other implementations of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. Various aspects and/or components of the described embodiments may be used singly or in any combination. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.