Paper-scrim-foil core having extruded polypropylene resin
AssigneeJohns Manville
InventorsRalph Michael Fay, Anthony Edward Moore, Edward Albert Bright
Life of this patent
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Abstract
Embodiments of the invention provide a facer used as protective covering for an insulation product. The facer may include a metallic foil layer, a scrim layer, and a paper layer positioned adjacent the scrim layer. The facer may also include a polypropylene material forming a polypropylene layer positioned adjacent the paper layer and heat bonded to an exposed major surface of the paper layer such that a portion of the polypropylene extends into pores of the paper layer to assist in coupling the polypropylene material to the paper layer.
Claims26
A facer used as protective covering for an insulation product, the facer comprising:
- a metallic foil layer;
- a scrim layer;
- a paper layer positioned adjacent the scrim layer;
- a polypropylene material forming a polypropylene layer positioned adjacent the paper layer and heat bonded to an exposed major surface of the paper layer such that a portion of the polypropylene extends into pores of the paper layer to assist in coupling the polypropylene material to the paper layer;
- and
- a treatment on an exposed surface of the polypropylene layer by plasma or enhanced plasma.
A method of manufacturing a facer used as a protective covering for an insulation product, the method comprising:
- providing a jacketing material comprising:
- a metallic foil layer;
- a fiberglass reinforcing scrim layer;
- and
- a paper layer positioned adjacent the scrim layer;
- coating an exposed major surface of the paper layer of the jacketing material with a layer of melted polypropylene;
- applying pressure to the coated jacketing material using a cooled nip-roll assembly such that the layer of melted polypropylene solidifies into a polypropylene film to form the facer, wherein a portion of the polypropylene film extends into pores of the paper layer.
A method of applying a protective facer to an insulation product, the method comprising:
- wrapping an insulation product and a facer around a conduit, the insulation product comprising a first end and a second end separated by a gap such that the insulation product is separable to receive the conduit through the gap, wherein the facer wraps around the insulation product such that a flap extending from a first end of the facer overlaps a second end of the facer, wherein the facer comprises:
- a metallic foil layer;
- a scrim layer;
- a paper layer positioned adjacent the scrim layer;
- and
- a polypropylene layer positioned adjacent the paper layer and heat bonded to an exposed major surface of the paper layer such that a portion of the polypropylene extends into pores of the paper layer to facilitate coupling of the polypropylene to the paper layer;
- and
- securing the flap to the polypropylene layer.
Dependencies are inferred from the claim text.