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Breathable low-emissivity metalized sheets

a technology of metalized sheets and breathable sheets, applied in the field of metalized sheets, can solve the problems of less effective thermal barrier, higher emissivity of oxidized metal layers, and susceptibility to metal layer oxidation

Inactive Publication Date: 2006-02-23
EI DU PONT DE NEMOURS & CO
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

While the breathable metalized sheets described above provide a thermal barrier by reflecting infrared radiation, they are susceptible to oxidation of the metal layer upon exposure to air and moisture.
An oxidized metal layer generally has a higher emissivity than the corresponding metal and is less effective as a thermal barrier.
In addition, a thin exposed metal layer can be damaged during processing, installation, etc.
However, the polymeric coating is applied using methods that significantly reduce the moisture vapor permeability compared to the uncoated metalized nonwoven sheet.
However, when the starting moisture vapor permeable sheet has a highly closed structure with very low air permeability, such as nonwoven and other sheets used as house wrap or roof lining in the construction industry, conventional coatings result in significant covering of the pores on the surface of the sheet.
This results in a coated sheet having significantly lower moisture vapor permeability than the starting sheet.
This is undesirable in house wrap and roof lining products, which are desirably permeable to moisture vapor while at the same time forming a barrier to infiltration by air and liquid water.

Method used

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  • Breathable low-emissivity metalized sheets
  • Breathable low-emissivity metalized sheets
  • Breathable low-emissivity metalized sheets

Examples

Experimental program
Comparison scheme
Effect test

example 1

[0098] This Example demonstrates that the moisture vapor permeability of moisture permeable nonwoven sheets that have low air permeability is substantially unchanged when the sheet is coated and metalized according to the present invention.

[0099] Roll samples (460 m long by 41 cm wide) of HW1, HW2, CW1, and RF1, listed above in Table I, were coated with various polyacrylate layers and metalized with aluminum in a vacuum coating / metallization machine to form the structures listed in Table II (where Al=aluminum and L1, L2, and L3 are diacrylates selected from TRPGDA, SR606, HDODA20% C18, SR9003, and Zonyl®TM / TRPGDA). In structures containing more than one polyacrylate layer, the composition of the polyacrylate layers were the same in some Examples and different in others. The Al thickness was either 22 or 36 nm and the polymer layer thickness (L1, L2, L3) was 0.5 μm.

[0100] The vacuum chamber of the vacuum coating / metallization machine included a plasma treatment station, one vapor d...

example 3

[0109] This example shows the impact of using an intermediate polymer coating (L1) between the sheet layer and the metal layer on the emissivity of metalized sheets prepared according to the present invention.

[0110] Samples of CW1 house wrap measuring 30.5 cm×30.5 cm were coated and / or metalized using separate metalizer and vacuum flash evaporation machines so that, after metallization or polymer deposition, the samples were exposed to air during transfer from one machine to the other. The samples were plasma treated as described in Example 1. Metalized samples were formed having different metal layer thicknesses of 10, 50, and 100 nm using gold or aluminum metal. The thickness of the polyacrylate layer was approximately 0.5 μm. After polymer deposition and / or metallization, the emissivity was measured in multiple locations throughout the sample area. The structures and their properties are shown in Table IV below.

TABLE IVComparison of Emissivity for Metalized Sheets With andWith...

example 4

[0112] This Example demonstrates the impact of an outer polyacrylate coating layer (L2) on emissivity of metalized sheets.

[0113] Coated metalized sheet samples (30.5 cm×30.5 cm) were prepared as described in Example 3. Both samples were prepared during the same coating run with SR606 followed by the same metallization run with aluminum to ensure that the thicknesses of the metal and polymer coating layers were substantially the same for all samples. The structure of the coated samples and emissivities are shown in Table V below.

TABLE VEmissivity of Metalized Sheets With and Without an OutsideLayer of PolyacrylateCoated Sheet StructureEmissivityCW1 / SR606 (0.5 μm) / Al (50 nm)0.18 ± 0.02CW1 / SR606 (0.5 μm) / Al (50 nm) / SR606 (0.5 μm) 0.14 ± 0.0001

[0114] The data in Table V show that samples with L2 have lower emissivity when compared to samples made in the same metallization and coating runs but without L2.

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Abstract

A moisture vapor permeable metalized composite sheet is formed by coating a moisture vapor permeable sheet-with at least one metal layer and at least one outer organic coating layer. The moisture vapor permeability of the composite sheet is at least about 80% of the moisture vapor permeability of the starting sheet. The composite sheet provides a barrier to air and liquid water infiltration while having high moisture vapor permeability and good thermal barrier properties. The composite sheet material is suitable for use as a building construction wrap such as roof lining and house wrap.

Description

BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] The present invention relates to metalized sheets having improved moisture vapor permeability and thermal barrier properties suitable for use as thermal barriers in building construction. [0003] 2. Description of the Related Art [0004] It is known in the art to use moisture vapor permeable (breathable) metalized sheets as house wrap in building construction. The metalized sheets allow moisture vapor to pass through the sheet, thus preventing moisture condensation in insulation that is installed behind the sheet, while at the same time providing a barrier to air and liquid water and enhancing the energy efficiency of the building. U.S. Pat. No. 4,999,222 to Jones et al. describes moisture vapor permeable metalized polyethylene sheets with low emissivity prepared by calendering a plexifilamentary film-fibril sheet followed by vacuum metallization. U.S. Pat. No. 4,974,382 to Avellanet describes an infiltration and ener...

Claims

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Application Information

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IPC IPC(8): B32B3/10
CPCB32B5/022Y10T428/24322B32B5/22B32B5/26B32B2250/20B32B2255/02B32B2255/205B32B2255/26B32B2255/28B32B2260/021B32B2260/046B32B2307/304B32B2307/724B32B2307/7242B32B2307/7265B32B2419/00B32B2607/00C23C14/562D04H13/002E04B1/625E04B2001/7691E04D12/002E04D13/1625E04D2015/047D06N7/0094D06N5/00D06N2209/123Y10T428/12361B32B5/024Y10T442/3398Y10T442/3439Y10T428/249987Y10T428/24998Y10T442/657Y10T442/2148Y10T428/249955Y10T442/2139Y10T428/249953
Inventor BLETSOS, IOANNIS V.DEVAQUET, EDMEE LYDIE MARIE-JEANNEKING, JOSEPH ANTHONY JR.MIKHAEL, MICHAEL G.RODRIGUEZ-PARADA, JOSE MANUELYIALIZIS, ANGELO
Owner EI DU PONT DE NEMOURS & CO
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