AIR-PERMEABLE LAMINATE INSULATION MATERIAL

Abstract

The present invention relates to an air-permeable laminate insulation material, and more specifically, to an air-permeable laminate insulation material including: an insulation material layer; an aluminum coating layer formed on one or both surfaces of the insulation material layer; a non-woven fabric layer formed on the aluminum coating layer; and a polyolefin composite layer which is made from a mixture of polyolefin and inorganic particles and laminated on top of the non-woven fabric layer.

Claims

1. An air-permeable laminate insulation material, comprising: an insulation material layer; an aluminum coating layer formed on one or both surfaces of the insulation material layer; a non-woven fabric layer formed on the aluminum coating layer; and a polyolefin composite layer which is made from a mixture of polyolefin resin and inorganic particles and laminated on the non-woven fabric layer.

2. The air-permeable laminate insulation material of claim 1, wherein the polyolefin composite layer has air permeability by producing an extrusion sheet including 10 to 200 parts by weight of inorganic particles with respect to 100 parts by weight of the polyolefin resin and stretching the extrusion sheet.

3. The air-permeable laminate insulation material of claim 1, wherein an air-permeable adhesive layer is further included between the non-woven fabric layer and the polyolefin composite layer.

4. The air-permeable laminate insulation material of claim 3, wherein the air-permeable adhesive layer has a coated portion and an uncoated portion of an adhesive by spray coating or gravure roll coating the adhesive to have air permeability.

5. The air-permeable laminate insulation material of claim 1, wherein the aluminum coating layer is produced by coating or depositing a solution including an aluminum particle.

6. The air-permeable laminate insulation material of claim 5, wherein the coating is performed by screen coating or gravure roll coating.

7. The air-permeable laminate insulation material of claim 1, wherein the insulation material of the insulation material layer is one or two or more selected from cotton, needle punching non-woven fabric, plastic foam, melt blown non-woven fabric, fiber fabric, and woven fabric.

8. The air-permeable laminate insulation material of claim 1, wherein the insulation material layer has a basis weight of 25 to 800 g/m.sup.2, the aluminum coating layer has a basis weight of 1 to 80 g/m.sup.2, the non-woven fabric layer has a basis weight of 10 to 60 g/m.sup.2, and the polyolefin composite layer has a basis weight of 10 to 100 g/m.sup.2.

9. The air-permeable laminate insulation material of claim 3, wherein the air-permeable adhesive layer has a basis weight of 1 to 10 g/m.sup.2.

Description

DESCRIPTION OF DRAWINGS

[0040] FIG. 1 is a diagram illustrating a structure of an air-permeable laminate insulation material formed on one surface in the present invention.

[0041] FIG. 2 is a diagram illustrating a structure of the air-permeable laminate insulation material formed on both surfaces in the present invention.

DETAILED DESCRIPTION OF MAIN ELEMENTS

[0042] 10: Insulation material layer

[0043] 20: Aluminum coating layer

[0044] 30: Non-woven fabric layer

[0045] 40: Polyolefin composite layer

BEST MODE

[0046] Hereinafter, the present invention will be described in more detail by way of examples, but the present invention is not limited to the following examples.

[0047] The following properties were measured by the following methods.

[0048] 1) Tensile Properties [0049] Strength and elongation at the time of breaking of a sample were each measured in a MD direction and a CD direction according to ASTM D5034.

[0050] 2) Trapezoidal Tear [0051] The tearing of the sample was each measured in the MD direction and the CD direction according to the ASTM D5733-95.

[0052] 3) PEEL measurement of non-woven fabric layer and polyolefin composite layer [0053] The size of the sample was set to be 25×150 cm in width x height according to the ASTM D 751 and then the MD direction of the sample was measured using a tensile tester (INSTRON).

[0054] 4) Moisture Permeability [0055] The amount of moisture passed through the film made according to ASTM E-96-96 for 24 hours per 1 m.sup.2 was represented by g.

[0056] The air-permeable film was exposed for about 2 hours in a thermohygrostat of a temperature of 38° C. and a relative humidity of 90% and then the moisture absorption of calcium chloride which is generated by passing moisture through the air-permeable film was measured.

[0057] 5) Resistance to Water Pressure [0058] The resistance of the sample to permeation of liquefied water under a constant resistance to water pressure was measured using AATCC 127-1998.

[0059] In the physical property measurement of the present invention, the MD direction represents a running direction and the CD direction represents a width direction perpendicular to the running direction.

EXAMPLE 1

[0060] After the insulation material layer was formed to have a basis weight of 170 g/m.sup.2 by using an insulation material (air-permeable polyethylene_UPC (Co.), B-UP30, polypropylene non-woven fabric_UPC (Co.), NAP06003), a solution in which aluminum power (IDI Chemical, silver 2) is dispersed in thinner (Misung Chemical, P.E. thinner) was gravure printed on one surface of the insulation material layer to have a basis weight of 1.5 g/m.sup.2 and then dried at 60° C. to form the aluminum coating layer on the insulation material layer.

[0061] As another process, 55 parts by weight of calcium carbonate (YABASHI KOREA, YK1C) with respect to 100 parts by weight of low density polyethylene (Hanwha Chemical, HANWHA LDPE 955, density: 0.913) was mixed and melted. The polyolefin composite layer was extruded in T-die by a film extruder and then uniaxially stretched 2.5 times at a stretching temperature of 70° C. to have a basis weight of 30 g/m.sup.2.

[0062] As another process, the non-woven fabric layer was formed by being laminated in the multi-layer web on the belt continuously moving and thermally bonded so that it has a basis weight of 30 g/m.sup.2 by spinning a polypropylene filament fiber. The produced polyolefin composite layer was laminated on the produced non-woven fabric, and then heated and pressed at a temperature of 170° C. and at a pressure of 75 kg/cm.sup.2 to press and laminate the polyolefin composite layer on the non-woven fabric.

[0063] After the non-woven fabric layer surface of the laminated polyolefin composite layer and the non-woven fabric layer, and the aluminum coating layer surface of the aluminum coating layer formed on the insulation material layer faced each other, the air-permeable laminate insulation material was prepared by the heating and pressing at a temperature of 170° C. and a pressure of 78 kg/cm.sup.2.

EXAMPLE 2

[0064] After the insulation material layer was formed to have a basis weight of 170 g/m.sup.2 by using an insulation material (air-permeable polyethylene_UPC (Co.), B-UP30, polypropylene non-woven fabric_UPC (Co.), NAP06003), a solution in which aluminum power (IDI Chemical, silver 2) is dispersed in thinner (Misung Chemical, P.E. thinner) was gravure printed on one surface of the insulation material layer to have a basis weight of 1.5 g/m.sup.2 and then dried at 60° C. to form the aluminum coating layer on the insulation material layer.

[0065] As another process, 55 parts by weight of calcium carbonate (YABASHI KOREA, YK1C) with respect to 100 parts by weight of low density polyethylene (Hanwha Chemical, HANWHA LDPE 955, density: 0.913) was mixed and melted. The polyolefin composite layer was extruded in the T-die by the film extruder and then uniaxially stretched 2.5 times at a stretching temperature of 70° C. to have a basis weight of 30 g/m.sup.2.

[0066] As another process, the non-woven fabric layer was formed by being laminated in the multi-layer web on the belt continuously moving and thermally bonded so that it has a basis weight of 30 g/m.sup.2 by spinning a polypropylene filament fiber. A polyurethane adhesive (Sungdo Chemical, D-9800) was coated on the produced polyolefin composite layer by the gravure roll coating method to have a basis weight of 5 g/m.sup.2 and the produced non-woven fabric was laminated on the polyolefin composite layer and then passed through the pressing roller to press and laminate the polyolefin composite layer on the non-woven fabric.

[0067] After the non-woven fabric layer surface of the laminated polyolefin composite layer and the non-woven fabric layer, and the aluminum coating layer surface of the aluminum coating layer formed on the insulation material layer faced each other, the air-permeable laminate insulation material was prepared by the heating and pressing.

EXAMPLE 3

[0068] Example 3 was performed by the same method as the above Example 2 except that polyurethane adhesive (Sungdo chemical, D-9800) was coated on the polyolefin composite layer produced in the above Example 2 by the spray, thereby preparing the air-permeable laminate insulation material.

EXAMPLE 4

[0069] After the insulation material layer was formed to have a basis weight of 170 g/m.sup.2 by using an insulation material (air-permeable polyethylene_UPC (Co.), B-UP30, polypropylene non-woven fabric_UPC (Co.), NAP06003), a solution in which aluminum power (IDI Chemical, silver 2) is dispersed in thinner (Misung Chemical, P.E. thinner) was gravure printed on both surfaces of the insulation material layer to have a basis weight of 3 g/m.sup.2 and then dried at 60° C. to form the aluminum coating layer on the insulation material layer.

[0070] As another process, 55 parts by weight of calcium carbonate (YABASHI KOREA, YK1C) with respect to every 100 parts by weight of low density polyethylene (Hanwha Chemical, HANWHA LDPE 955, density: 0.913) was mixed and melted. The polyolefin composite layer was extruded in the T-die by the film extruder and then uniaxially stretched 2.5 times at a stretching temperature of 70° C. to have a basis weight of 30 g/m.sup.2.

[0071] As another process, the non-woven fabric layer was formed by being laminated in the multi-layer web on the belt continuously moving and thermally bonded so that it has a basis weight of 30 g/m.sup.2 by spinning a polypropylene filament fiber. A polyurethane adhesive (Sungdo Chemical, D-9800) was coated on the produced polyolefin composite layer by the gravure roll coating method to have a basis weight of 5 g/m.sup.2 and the produced non-woven fabric was laminated on the polyolefin composite layer and then passed through the pressing roller to press and laminate the polyolefin composite layer on the non-woven fabric.

[0072] After and the non-woven fabric layer surface of the laminated air-permeable adhesive layer the non-woven fabric layer, and the aluminum coating layer surface of the aluminum coating layer formed on the insulation material layer faced each other, the air-permeable laminate insulation material was prepared by the heating and pressing.

COMPARATIVE EXAMPLE 1

[0073] The insulation material layer was formed so as to have a basis weight of 170 g/m.sup.2 by using the insulation material (air-permeable polyethylene_UPC (Co.), B-UP30, polypropylene non-woven fabric_UPC (Co.), NAP06003).

[0074] As another process, 55 parts by weight of calcium carbonate (YABASHI KOREA, YK1C) with respect to 100 parts by weight of low density polyethylene (Hanwha Chemical, HANWHA LDPE 955, density: 0.913) was mixed and melted. The polyolefin composite layer was extruded in the T-die by the film extruder and then uniaxially stretched 2.5 times at a stretching temperature of 70° C. to have a basis weight of 30 g/m.sup.2.

[0075] As another process, the non-woven fabric layer was formed by being laminated in the multi-layer web on the belt continuously moving and thermally bonded so that it has a basis weight of 30 g/m.sup.2 by spinning a polypropylene filament fiber. The produced polyolefin composite layer was laminated on the produced non-woven fabric layer, and then heated and pressed at a temperature of 170° C. and at a pressure of 75 kg/cm.sup.2 to press and laminate the polyolefin composite layer on the non-woven fabric.

[0076] After the non-woven fabric layer surface of the laminated polyolefin composite layer and the non-woven fabric layer, and the insulation material layer surface faced each other, the air-permeable laminate insulation material was prepared by the heating and pressing at a temperature of 170° C. and a pressure of 75 kg/cm.sup.2.

COMPARATIVE EXAMPLE 2

[0077] The insulation material layer was formed so as to have a basis weight of 170 g/m.sup.2 by using the insulation material (air-permeable polyethylene_UPC (Co.), B-UP30, polypropylene non-woven fabric_UPC (Co.), NAP06003).

[0078] As another process, 55 parts by weight of calcium carbonate (YABASHI KOREA, YK1C) with respect to 100 parts by weight of low density polyethylene (Hanwha Chemical, HANWHA LDPE 955, density: 0.913) was mixed and melted. The polyolefin composite layer was extruded in the T-die by the film extruder and then uniaxially stretched 2.5 times at a stretching temperature of 70° C. to have a basis weight of 30 g/m.sup.2.

[0079] As another process, the non-woven fabric layer was formed by being laminated in the multi-layer web on the belt continuously moving and thermally bonded so that it has a basis weight of 30 g/m.sup.2 by spinning a polypropylene filament fiber. A polyurethane adhesive (Sungdo Chemical, D-9800) was coated on the produced polyolefin composite layer by the gravure roll coating method to have a basis weight of 5 g/m.sup.2 and the produced non-woven fabric was laminated on the polyolefin composite layer and then passed through the pressing roller to press and laminate the polyolefin composite layer on the non-woven fabric.

[0080] After the non-woven fabric layer surface of the laminated air-permeable adhesive layer and the non-woven fabric layer, and the insulation material layer surface faced each other, the air-permeable laminate insulation material was prepared by the heating and pressing at a temperature of 170° C. and a pressure of 75 kg/cm.sup.2.

TABLE-US-00001 TABLE 1 Comparative Comparative Example 1 Example 2 Example 3 Example 4 Example 1 Example 2 Basic Weight (g) 74 75 75 76 73 74 Tensile Strength MD 11 12 14 15 9 10 (kgf/2 inch) CD 4 5 6 6 3 4 Breaking Strength MD 16 17 20 20 13 14 (kgf/2 inch) CD 7 8 9 10 6 6 Elongation MD 80 95 100 80 65 70 (%) CD 95 110 120 95 80 105 Trapezoidal Tear MD 8 8 11 13 7 7.5 (kg) CD 3 4 5 6 3 4 Peel 350 540 540 500 300 320 Moisture Permeability 5700 6000 6100 5700 5800 5700 (g/uf, 24 hr) Resistance to 250 270 270 300 220 230 Water Pressure (cu)

[0081] From Table 1, it was confirmed that the air-permeable laminate insulation material includes the aluminum coating layer formed on one surface or both surfaces to keep the moisture permeability and improve the tensile strength, the breaking strength, the elongation, the trapezoidal tear, and the water permeation resistance.