Process for forming a durable low emissivity moisture vapor permeable metallized sheet including a protective metal oxide layer
AssigneeE. I. Du Pont de Nemours and Company
InventorsJohn James Barnes, Ioannis V. Bletsos, Angelo Yializis, Michael G. Mikhael
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Abstract
A process for forming a low emissivity, moisture vapor permeable metallized composite sheet by coating a moisture vapor permeable sheet with at least one metal and exposing the freshly deposited metal to an oxidizing plasma thereby forming a protective synthetic metal oxide over the metal. The composite sheet material is suitable for use as a building construction barrier layer such as roof lining and house wrap.
Claims20
A process for forming a moisture vapor permeable metallized composite sheet comprising:
- placing a porous moisture vapor permeable sheet in a vacuum chamber and drawing a vacuum within said vacuum chamber;
- depositing a metal coating onto at least one surface of a porous moisture vapor permeable sheet so as to substantially cover the outer surfaces of the moisture vapor permeable sheet while leaving the pores thereof substantially uncovered;
- and
- oxidizing the surface of the metal coating with an oxygen-containing plasma within said vacuum chamber to form a synthetic metal oxide coating.
A moisture vapor permeable metallized composite sheet comprising a porous moisture vapor permeable sheet having first and second outer surfaces and at least one multilayer coating comprising:
- a metal coating having a thickness between about 15 nanometers and 200 nanometers deposited on the first outer surface of the porous moisture vapor permeable sheet;
- a synthetic metal oxide coating having a thickness of less than about 10 nm formed by oxidizing the metal coating with an oxygen-containing plasma;
- and
- an outer organic coating having a thickness between about 0.05 μm and about 1 μm deposited on the metal oxide coating;
- wherein the multilayer coating substantially covers the outer surface of the porous moisture vapor permeable sheet, while leaving the pores thereof substantially uncovered.
A construction barrier layer comprising:
- a porous moisture vapor permeable sheet selected from the group consisting of nonwoven fabrics, woven fabrics, microporous films, microperforated films and composites thereof, having first and second outer surfaces and at least one multilayer coating comprising:
- a metal coating having a thickness between about 15 nanometers and 200 nanometers deposited on the first outer surface of the moisture vapor permeable sheet;
- a synthetic metal oxide coating having a thickness of less than about 10 nm formed by oxidizing the metal layer with an oxygen-containing plasma;
- and
- an outer organic coating having a thickness between about 0.05 μm and about 1 μm deposited on the metal layer;
- wherein the multilayer coating substantially covers the outer surface of the moisture vapor permeable sheet while leaving the pores substantially uncovered.
Dependencies are inferred from the claim text.