Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
SYSTEMS AND METHODS FOR INSULATING A PIPE
[0001]
[0002]
BACKGROUND OF THE INVENTION
[0003] The subject invention relates generally to pipe insulation products and
more
specifically to pipe insulation products comprising a insulating material core
surrounded by a
laminate.
[0004] Piping is often used to transport one or more fluids between
destinations. For
example, piping may be used to transport water, petroleum, oxygen, etc. The
piping is often
made from a metal material, such as copper, stainless steel, galvanized steel,
aluminum,
brass, titanium, etc., or from a plastic material, such as polyvinyl chloride
(PVC), chlorinated
polyvinyl chloride (CPVC), fiber reinforced plastic (FRP), polypropylene (PP),
polyethylene
(PE), etc. Piping may also be made from a ceramic, fiberglass, or concrete
material,
although these pipes are less common.
[0005] During fluid transportation, the fluid may be subject to heating and/or
cooling from
the surrounding environment. For example, the fluid may be transported in
either a hot or
cold state relative to the surrounding environment, which induces heat
transfer to or from the
fluid and pipes. HVAC systems are a common example of systems that routinely
utilize
various pipe configurations to transport hot or cold fluids. Due to the
conductive nature of the
pipes (especially metal pipes), heat may be conducted to or from the fluid
during
transportation. The addition or removal of heat may result in the decreased
efficiency of a
system and/or increased time and/or expense in operating the system. For
example, in
HVAC systems, the addition of heat to cooled fluids may result in loss of
efficiency for a
cooling unit and may also result in increased expense because of increased
operating time
and energy needed to achieve a desired cooling level.
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. .
[0006] To reduce heat transfer during fluid transportation, pipe insulation
products are
commonly installed on the pipes of a piping system to retard the flow of heat
to and from the
pipes. Commonly, one or more sections of pipe are fitted with a pipe
insulation product
where the sections of pipe are generally fully encased within the pipe
insulation product.
Common pipe insulation products comprise a fibrous insulation material that is
surrounded by
and encased within a laminate. Separate sections of pipe insulation product
are often
coupled together via adhesive tapes. The laminates of the pipe insulation
product often
enhance the visual appeal of the piping system and serve as a means for
sealing the pipe
insulation product about the pipes of the piping system. Individual segments
of pipe
insulation products typically range in length from about 36 inches to about 48
inches; have a
wall thickness ranging from about 0.5 inches to about 3 inches; and a range in
outside
diameter from about 2 inches to about 32 inches. The pipe insulation product
may also be
used to reduce degradation and/or corrosion of the pipe.
[0007] The laminate of the pipe insulation product, however, is often
susceptible to
handling damage during installation. For example, scuff marks and/or creases
may form on
the laminate as the pipe insulation product is shipped and/or fitted about a
pipe. In addition,
the laminate is often degraded and/or damaged after prolonged exposure to one
or more
types of environments. For example, laminates may begin to form wrinkles
and/or dimples
after prolonged exposure to high heat and/or humidity environments. Other
types of damage
may include UV damage, heat damaged, etc. This damage often leaves visible
marks or
scars that are apparent to individuals viewing the piping system and pipe
insulation product.
The visible marks may degrade the overall appearance of the building or
structure in which
they are used and/or may leave a negative impression on the viewer as to the
quality of the
pipe insulation product.
BRIEF SUMMARY OF THE INVENTION
[0008] The laminate of the pipe insulation product of the present invention
provides
superior resistance to both handling damage and environmental damage. The pipe
insulation product of the present invention may include a tubular core of
insulating material
and a laminate that is bonded to the tubular core of insulating material. The
tubular core may
include a length and a longitudinal axis, a substantially cylindrical outer
surface, a
substantially cylindrical inner surface, and a wall extending between the
cylindrical outer
surface and the cylindrical inner surface. The wall may have a radially
extending thickness
and a slit extending parallel to the longitudinal axis for the length of the
tubular core and
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extending completely through the wall from the cylindrical outer surface to
the cylindrical
inner surface.
[0009] The laminate may be coextensive with and bonded to the substantially
cylindrical
outer surface of the tubular core and flexible so that the tubular core and
laminate can be
opened, placed about a pipe, and closed without degrading the laminate. The
laminate may
include a metallized polymeric film sheet layer that forms an inner layer of
the laminate (e.g.,
metallized polyethylene terphthalate (MPET)). The metallized polymeric film
sheet layer may
be bonded to the substantially cylindrical outer surface of the tubular core
and may provide a
fluid vapor barrier to minimize fluid vapor transmission through the laminate.
[0010] The laminate may also include a scrim that includes a mesh of a
plurality of fibers.
The laminate may further include a porous media sheet layer. The scrim and/or
the porous
media sheet layer may provide reinforcement for the laminate (e.g., provide
puncture
resistance, durability, tensile strength, etc.) The laminate may additionally
include a
polymeric film sheet layer that forms an outer exposed layer of the laminate.
The laminate
may additionally include an adhesive that bonds the metallized polymeric film
sheet layer, the
scrim, the porous media sheet layer, and the polymeric film sheet layer
together. The
adhesive may be a latex based adhesive and may contain either or both a flame
retardant
additive and an anti-microbial agent additive.
[0011] The pipe insulation product (i.e., the tubular core and laminate) may
be used in a
high heat and/or humidity environment where the laminate is substantially free
from wrinkling
and/or dimpling after prolonged exposure to the high heat and/or humidity
environment. In
addition, fluid (e.g., hot or cold fluid relative to the environment) may be
passed through the
interior of the insulated pipe where the metallized polymeric film sheet layer
substantially
reduces the amount of fluid vapor that is able to penetrate through the
laminate from the
environment.
[0012] The present invention may also include a method for producing a
laminate jacket for
a pipe insulation product. The method may include obtaining a metallized
polymeric sheet
material, where the metallized polymeric sheet material forms an inner layer
of the laminate
and where the metallized polymeric sheet material provides a fluid vapor
barrier to minimize
fluid vapor transmission through the laminate. The metallized polymeric sheet
material may
include a length, a width, a first face, and a second face. The length and
width may form an
area that defines the first face and the second face. The metallized polymeric
sheet material
may be made of metallized polyethylene terphthalate (MPET).
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[0013] The method may also include positioning a scrim adjacent to the second
face. The
scrim may be substantially coextensive with the second face and may include a
mesh of a
plurality of fibers. The method may further include positioning a porous media
sheet material
directly adjacent to the scrim. The porous media sheet material may be
substantially
coextensive with the second face. The method may additionally include
positioning a
polymeric sheet material directly adjacent to the porous media sheet material.
The polymeric
sheet material may be made form polypropylene, polyethylene, etc. The
polymeric sheet
material may be coextensive with the second face and may form an outer exposed
layer of
the laminate. The method may additionally include bonding the metallized
polymeric sheet
material, the scrim, the porous media sheet material, and the polymeric sheet
material
together with an adhesive material to form the laminate jacket. The adhesive
may include a
flame retardant additive and an anti-microbial agent additive.
[0014] The laminate may be bonded with a tubular core of insulating material
to form a pipe
insulation product. The method for bonding the laminate and tubular core may
include
positioning the tubular core of insulating material directly adjacent to the
first face of the
metallized polymeric sheet material. The tubular core may include a length and
a longitudinal
axis, a substantially cylindrical outer surface that includes a surface area
roughly equivalent
to the area of the first face, a substantially cylindrical inner surface, and
a wall extending
between the cylindrical outer surface and the cylindrical inner surface. The
wall may include
a radially extending thickness and a slit extending parallel to the
longitudinal axis of the
tubular core for the length of the tubular core and extending completely
through the wall from
the cylindrical outer surface to the cylindrical inner surface.
[0015] The method may also include bonding the tubular core of insulating
material and the
first face of the metallized polymeric sheet material with an adhesive
material to form the pipe
insulation product. The pipe insulation product may be flexible so that the
tubular core and
laminate jacket can be opened, placed about a pipe, and closed without
degrading the
laminate jacket.
[0016] The present invention may further include an insulated pipe. The
insulated pipe
may include a pipe with a cylindrical outer surface and a hollow interior for
passing a fluid
there through. The insulated pipe may also include a tubular core of
insulating material that
includes a length and a longitudinal axis, a substantially cylindrical outer
surface, a
substantially cylindrical inner surface that is sized to correspond with the
diameter of the pipe
outer surface; and a wall extending between the cylindrical outer surface and
the cylindrical
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inner surface. The wall may have a radially extending thickness and a slit
that extends
completely through the wall and that extends parallel to the longitudinal axis
of the tubular
core.
[0017] The insulated pipe may further include a laminate that is coextensive
with and
bonded to the substantially cylindrical outer surface of the tubular core and
that is flexible so
that the tubular core and laminate can be opened, placed about the pipe, and
closed without
degrading the laminate. The laminate may include a metallized polymeric film
sheet layer
that forms an inner layer of the laminate. The metallized polymeric film sheet
layer may be
bonded to the substantially cylindrical outer surfaca of the tubular core and
may provide a -
fluid vapor barrier to minimize fluid vapor transmission through the laminate.
The laminate
may also include a scrim positioned adjacent to the metallized polymeric film
sheet layer.
The laminate may further include a porous media sheet layer that is positioned
adjacent to
the scrim.
[0018] The laminate may additionally include a polymeric film sheet layer that
is positioned
adjacent to the porous media sheet layer and that forms an outer exposed layer
of the
laminate. The polymeric film sheet layer may inhibit the absorption of fluid
by the porous
media sheet layer. The metallized polymeric film sheet layer, the scrim, the
porous media
sheet layer, and the polymeric film sheet layer may be bonded together using
an adhesive.
The laminate may provide increased resistance to handling damage during
installation and/or
shipment of the laminate and/or may provide increased resistance to wrinkling
when exposed
to conditions of high or low humidity and/or high heat.
[0019] A fluid may be passed through the hollow interior of the pipe where the
fluid has a
lower temperature than the surrounding environment. The metallized polymeric
film sheet
layer may substantially reduce the amount of fluid vapor that penetrates
through the laminate
from the surrounding environment. In addition, the insulated pipe that
includes the pipe,
tubular core, and laminate may be utilized in a high heat and/or humidity
environment and the
laminate may be substantially free from wrinkling after a prolonged exposure
to the high heat
and/or humidity environment.
[0020] The present invention may additionally include a method for insulating
a pipe having
a cylindrical outer surface and a hollow interior for passing a fluid there
through. The method
may include providing a tubular core of insulating material. The tubular core
may include a
length and a longitudinal axis, a substantially cylindrical outer surface, a
substantially
cylindrical inner surface that is sized to correspond to cylindrical outer
surface of the pipe,
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and a wall extending between the cylindrical outer surface and the cylindrical
inner surface.
The wall may have a radially extending thickness and a slit that extends
completely through
the wall from the cylindrical outer surface to the cylindrical inner surface.
The slit may further
extend parallel to the longitudinal axis of the tubular core for the length of
the tubular core.
[0021] The method may also include bonding a laminate to the tubular core,
where the
laminate is coextensive with the cylindrical outer surface of the tubular
core. The laminate
may include a metallized polymeric film sheet layer that forms an inner layer
of the laminate.
The metallized polymeric film sheet layer may be bonded to the cylindrical
outer surface of
. the tubular core and may provide a fluid vapor barrier to minimize
fluid vapor transmission
through the laminate. The laminate may also include a scrim that is positioned
adjacent to
the metallized polymeric film sheet layer, The laminate may further include a
porous media
sheet layer that is positioned adjacent to the scrim. The laminate may
additionally include a
polymeric film sheet layer that is positioned adjacent to the porous media
sheet layer and that
forms an outer exposed layer of the laminate. The polymeric film sheet layer
may inhibit the
absorption of fluid by the porous media sheet layer. The metallized polymeric
film sheet
layer, the scrim, the porous media sheet layer, and the polymeric film sheet
layer may be
bonded together using one or more adhesives.
[0022] The method may also include flexing the tubular core and laminate to
open the
laminate and tubular core. The method may further include placing the laminate
and tubular
core about the pipe and closing the laminate and tubular core about the pipe
without
degrading the laminate. Upon closing the laminate and tubular core, at least a
portion of the
pipe may be fully encased within the laminate and tubular core. The laminate
may provide
increased resistance to handling damage during installation and/or shipment of
the laminate
and tubular core. Similarly, the laminate may provide increased resistance to
wrinkling when
exposed to conditions of high or low humidity and/or conditions of high heat.
[0023] The method may additionally include flowing a fluid through the pipe,
where the
temperature of the fluid is lower than the temperature of the surrounding
environment in close
proximity to the laminate's outer surface. The metallized polymeric film sheet
layer may
substantially reduce the amount of fluid vapor that penetrates through the
laminate from the
laminate's exterior (i.e., the surrounding environment).
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is a schematic perspective view of a laminate jacket pipe
insulation product
wherein the jacket is made from a laminate of the present invention.
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[0025] FIG. 2 is a schematic perspective view of a laminate jacket according
to one
embodiment of the present invention with portions of the laminate broken away
to show the
various layers of the laminate.
[0026] FIG. 3 is a schematic perspective view of a laminate jacket according
to another
embodiment of the present invention with portions of the laminate broken away
to show the
various layers of the laminate.
[0027] FIG. 4 is a schematic perspective view of a laminate jacket pipe
insulation product
fitted onto a cylindrical pipe section wherein the laminate jacket shows signs
of handling
. damage. .
[0028] FIG. 5 is a schematic perspective view of a laminate jacket pipe
insulation product
fitted onto a cylindrical pipe section where the laminate jacket shows signs
of environmental
damage.
[0029] FIG. 6 is a box plot graph showing the handling damage resistance for a
variety of
laminates.
[0030] FIG. 7 illustrates a method for producing a laminate jacket for a pipe
insulation
product.
DETAILED DESCRIPTION OF THE INVENTION
[0031] The present invention relates to a laminate jacket, or simply a
laminate, that is used
with a tubular core of insulating material (i.e., fiberglass pipe insulation)
to insulate one or
more sections of pipe. Laminates used to cover fiberglass pipe insulation have
to meet many
performance requirements. These include minimal flame and smoke propagation,
tensile
strength, puncture resistance, mold growth resistance, high temperature
resistance,
dimensional stability, UV and visible light stability, and low water vapor
permeance. Low
water vapor permeance may be an important feature in pipe insulation involving
chilled water
systems to prevent condensation on pipes, which could lead to mold growth,
water damage,
dripping water damage, staining, loss of insulating value, pipe corrosion,
etc. Preferably, the
laminate has a water vapor transmission rate of a maximum of 0.02 perms.
[0032] In addition, there are many other qualitative customer requirements
that the jacket
must meet including environmental damage resistance (e.g., wrinkling or
dimple), handling
damage resistance, low reflectivity, and a smooth, uniform surface. The
handling required by
installers to transport, cut, hang, seal a closure flap, install butt strips,
etc. often results in
wrinkles, hand prints, and other visual scars that lack aesthetic appeal.
Likewise, after
prolonged exposure to one or more environmental conditions in which the
laminate is used
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(e.g., high humidity, direct sunlight, etc.), the laminate may begin to show
visual scars from
the environment condition (e.g., wrinkling, dimpling, fading, etc.). The
aesthetic value of the
laminate is important because customers desire pipe insulation products that
have both
exceptional functionality as well as appearance. The overall appearance of the
installed pipe
insulation product may result in increased sales and/or market share. Thus,
providing a
product that is superior in both performance and appearance is highly desired.
[0033] The laminate of the present invention exhibits enhanced dimensional
stability;
reduced deformation and wrinkling/dimpling; mold and mildew growth resistance;
stain
resistance; improved tape adhesion; improved ease of cleaning; enhanced flame
spread
resistance; good handleability; UV resistance; surface abrasion resistance;
and overall good
surface aesthetics prior to, during, and after installation.
[0034] As shown in Fig. 1, a laminate jacket pipe insulation product 100 may
include a
tubular core of insulating material 104 that may include a substantially
cylindrical outer
surface (i.e., the outside of the tubular core that directly contacts the
laminate) and a
substantially cylindrical inner surface 114. Extending between the cylindrical
outer surface
and the cylindrical inner surface 114 may be a wall of insulating material.
The insulating
material provides the insulating properties of the laminate jacket pipe
insulation product 100.
In one embodiment, the insulating material may be a fibrous material (e.g.,
fiberglass, mineral
wool, refractory ceramic fiber, chopped strand fiber glass, etc.). In other
embodiments the
insulating material may be a foam (e.g., phenolic foam, polyisocyanurate,
polyolefin,
polystyrene, polyurethane), a polymer, foam glass, microporous insulation
(e.g.,
Microtherm0), or any other material that provides insulation.
The cylindrical inner surface 114 may be configured to correspond with a
specific pipe outer
diameter (e.g., 1/2 inch, 1 inch, etc.). The tubular core 104 may also include
a longitudinally
extending slit 112 that passes completely through the wall of insulating
material on one side
and into the interior of the substantially cylindrical inner surface 114 so
that the tubular core
104, and thus the laminate jacket pipe insulation product 100, can be opened,
passed over,
and closed about a pipe.
[0035] Circumferentially surrounding and encasing the tubular core 104 is a
laminate jacket
or simply a laminate 102. The laminate 102 has a thickness 106 that includes
one or more
layers of various materials as described below. The laminate 102 is roughly co-
extensive
with the tubular core 104 and bonded to the cylindrical outer surface. The
laminate 102 may
be positioned so that a longitudinal edge portion 116 extends parallel and
adjacent to the slit
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112, but does not overlap the slit 112. The laminate 102 includes a closure
flap 108 that may
have a pressure sensitive adhesive layer 110 so that the laminate 102 may be
adhesively
sealed in a closed position fully encasing the tubular core 104 within the
laminate 102. The
laminate may be sealed by folding or overlapping the closure flap 108 over the
longitudinal
edge portion 116 of the laminate 102 and by applying pressure to the pressure
sensitive
adhesive layer 110 so that the closure flap 108 adhesively seals to the
longitudinal edge
portion 116. The closure flap 108 may include a removable silicone treated
release strip (not
shown) removably adhered to the pressure sensitive adhesive layer 110 to
protect the
adhesive material from degradation prior to installation. Maintaining a sealed
closed position . .
is an important function of the closure flap 108 and adhesive layer 110 so
that the insulated
pipe is not subjected to one or more environmental elements, such as water
vapor.
[0036] The laminate 102 of the present invention may include one or more flame
retardants, fungi growth inhibiting agents, and/or other additives to enhance
the performance
and/or the adhesion of the laminate. The laminate jacket pipe insulation
product 100 may be
used with one or more of the following: pipe insulation, duct board, duct wrap
insulation,
metal building insulation, and other building insulation products. The
insulated pipes may be
used in various environmental conditions including cycles of high heat and
humidity, which
may affect the laminate 102 as described below (e.g., wrinkling, dimpling,
fading, etc.). The
laminate 102 is particularly well suited for insulating pipes in such
conditions.
[0037] Fig. 2 depicts a laminate jacket 200 according to one embodiment of the
present
invention. Fig. 2 shows portions of the laminate 200 broken away to reveal the
various layers
of the laminate. The laminate 200 may include an inner layer composed of a
foil or
metallized polymeric film sheet 206. The foil 206 may include an aluminum foil
between
about 0.00025 inches and about 0.001 inches in thickness (between about 0.25
mils and
about 1 mil in thickness) and/or the metallized polymeric film sheet 206 may
include
metallized polyethylene terphthalate (MPET) between about 0.48 mils and about
100 mils in
thickness (between about 48 and 100 gauge in thickness). The inner layer
aluminum foil or
MPET provides a nearly impermeable fluid vapor barrier to fluids that are
external to and
surrounding the laminate jacket pipe insulation product 100. For example, the
foil or
metallized polymeric film sheet 206 is nearly impermeable to water vapor,
which protects the
insulated pipe from water condensation, corrosion, loss of insulating value,
mold growth, etc.
The use of either a foil (e.g., aluminum foil) or a metallized polymeric film
sheet (e.g., MPET)
206 enables the laminate to provide a water vapor transmission rate of less
than 0.02 perms.
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. =
By using the foil or metallized polymeric film sheet 206, fluid may be passed
through the
insulated pipe and fluid vapor (e.g., water vapor) in the surrounding
environment may be
restricted (or kept) from penetrating through laminate to the pipe. When cold
fluid is passed
through the pipe, the foil or metallized polymeric film sheet 206 prevents
water vapor from
condensing on the pipes and corroding or degrading the pipes, staining the
laminate jacket or
other surrounding objects, dripping onto a surface and causing damage, causing
mold or
fungal growth, etc.
[0038] The laminate 200 may also include a layer of scrim 204 that may be
positioned
directly. adjacent to the metallized polymeric film sheet 206. The scrim 204
may function to
reinforce and strengthen the laminate 200. For example, the scrim provides the
laminate with
increased tensile strength, puncture resistance, etc. The scrim 204 may be
made of
fiberglass reinforcing yarn, such as but not limited to a G75 or H110 yarn. In
addition, the
yarn may be configured to be from 2 to 6 strands per inch in both the machine
and cross
machine direction, with a typical scrim being about 5 strands per inch in both
directions. In
some embodiments the scrim 204 may be made of polyester strings or any other
synthetic
string.
[0039] The laminate 200 may further include a porous media outer sheet layer
202 that
may be positioned directly adjacent to the scrim 204. The porous media may
include a kraft
paper sheet that is preferably between about 35 and 55 pounds/3000 square feet
and that
may include one or more additives to enhance the performance of the laminate
200. For
example, the porous media may include one or more fire retardant additives
and/or anti-
microbial agents to prevent mold or fungal growth and to prevent propagation
of smoke
and/or fire. The porous nature of the porous media may facilitate in absorbing
and retaining
the one or more additives within the porous media, and hence, within the
laminate. For ease
of description, the porous media will be referred to herein as kraft paper,
although it should
be understood that various types of porous media may be used (e.g., fiberglass
mat,
synthetic mat, paper, etc.). The foil or polymeric film sheet 206, the scrim
204, and the kraft
paper/porous media 202 may be bonded or adhered using one or more adhesives as
described below.
[0040] The kraft paper and polymeric film (including MPET) may be potential
fuel sources
for a fire. Because both the kraft paper and polymeric film sheet (metallized
and non-
metallized) are potential fuel sources, including additional layers and/or
increasing the
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thickness of the kraft paper and/or polymeric film in traditional laminate
jackets may be limited
due to smoke and fire propagation regulations and/or other concerns.
[0041] Some laminate jackets have eliminated the kraft paper layer entirely in
favor of an
all polymeric film outer layer. The polymeric materials are generally non-
porous and, thus,
not able to absorb and retain fire retardant additives and/or other additives.
As such, these
jackets may be more susceptible to burning and/or may drip burning plastic
when ignited.
These jackets may pose an un-acceptable fire hazard in buildings or systems in
which they
are installed. As described below, the laminate jacket of the present
invention is able to
. utilize additional layers and/or thicknesses of polymeric film-materials
and/or kraft papers .
without posing an increased fire hazard.
[0042] Fig. 3 depicts a laminate jacket 300 according to another embodiment of
the present
invention. Fig. 3 shows portions of the laminate 300 broken away to reveal the
various layers
of the laminate. The laminate 300 may include an inner layer composed of a
foil or
metallized polymeric film sheet 308. Preferably, the laminate 300 includes an
inner layer that
is made of metallized polyethylene terphthalate (MPET) between about 0.48 mils
and about
100 mils in thickness (between about 48 and 100 gauge in thickness). The MPET
inner layer
provides the various advantages described above (e.g., water vapor barrier).
In addition, the
use of the MPET in the laminate application provides increased resistance to
handling
damage such as creasing or wrinkling as described below.
[0043] The laminate 300 also include a scrim 306, such as a mesh of glass
fibers, as
previously described. The scrim 306 may reinforce the laminate 300 as
previously described.
The laminate 300 may further include a kraft paper or porous media layer 304,
such as the
kraft paper layer previously described, and/or may include another porous
media layer such
as a fiberglass or synthetic media layer. The stiffness of the kraft paper may
provide
increased stiffness and/or durability to the laminate 300. The scrim 306 and
kraft paper 304
provide multiple reinforcing layers for the laminate 300. In some embodiments,
a single
reinforcement layer may be used in place of the scrim 306 and the kraft paper
304 (i.e., the
scrim 306 and kraft paper 304 may be eliminated in favor of a single,
preferably, porous
media layer that provides similar stiffness and/or durability). In some
embodiments the scrim
306 can be repositioned in relation to the kraft paper 304 so that the kraft
paper 304 directly
contacts the foil or metallized polymeric film sheet 308.
[0044] The laminate 300 additionally includes a polymeric film sheet outer
layer 302 that
may be positioned directly adjacent to the kraft paper 304. The polymeric film
sheet may be
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. .
made of polypropylene, polyethylene, polyvinyl chloride, vinyl, saran,
polyethylene
terephthalate, thermoplastic polyolefin, etc. The polymeric film sheet is
generally non-porous
and thus, unlike a kraft paper outer layer, the polymeric film may not be
capable of absorbing
and retaining additives (e.g., flame retardant). To ensure that the laminate
300 using the
polymeric film sheet outer layer 302 is sufficiently resistant to flame and
smoke propagation,
the flame retardant additives and/or other additives may be included within
the laminate.
Using a porous media layer, such as the kraft paper 304, along with the proper
type and
amount of additives ensures that the polymeric film sheet outer layer provides
sufficient fire
and smoke propagation resistance (i.e., the polymeric film will not burn
and/or drip burning .
plastic during a fire) even though the additives may not be present within the
polymeric film
layer.
[0045] In addition, the polymeric film sheet outer layer 302 may provide
increased
resistance to fluid absorption by the kraft paper/porous media 304 and/or by
the insulating
material (e.g., fiberglass material). For example, the polymeric film sheet
302 may shield or
protect the kraft paper/porous media 304 from water vapor absorption during
use in high
temperature and high humidity environments (e. g. temperatures equal to or
greater than 75
F. and relative humidities equal to or greater than 50%). The resistance to
fluid absorption
helps to minimize internal stresses within the laminate and/or prevent mold,
mildew, and/or
fungal growth. Likewise, the polymeric film sheet 302 may shield or protect
the insulating
material from fluid vapor (e.g., water vapor) absorption. This prevents the
insulating material
from becoming heavy or saturated with fluid and thereby prevents a loss in
insulation value.
[0046] The metallized polymeric film sheet (i.e., MPET) inner layer 308, the
scrim 306, the
kraft paper 304, and the polymeric film sheet outer layer 302 may be bonded or
adhered
together using one or more adhesives (not shown).
[0047] The adhesive or adhesives used may be contact type, pressure sensitive,
heat seal,
etc. and may include one or more additives to enhance the performance,
stiffness,
dimensional stability, moisture resistance, handleability, fire and smoke
propagation
resistance, and/or durability of the laminate 300. Examples of adhesives that
can be used
include, but are not limited to, melamine, urea formaldehyde, phenolic,
polyurethane, acrylic,
latex, and acrylo-nitrile. Additional adhesives that can be used include
adhesives that can
migrate into the kraft paper layer 304 or other porous media to improve the
physical
characteristics of the laminate 300 by improving UV stability, flame spread
resistance,
opacification, color, etc. Examples of such migrating adhesives are colloidal
silica or
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CA 02748741 2011-08-11
. .
alumina, sodium or potassium silicate, ammonium phosphate stabilized with zinc
oxide,
magnesia or alumina; borax, and oxi-chloride stabilized with zinc oxide or
magnesia. Of the
above adhesives, a latex-laminating adhesive is the preferred adhesive.
[0048] While the adhesive does not need to contain fibers, the adhesive may
include
between about 1% and about 5% by weight synthetic and/or inorganic fibers such
as but not
limited to the synthetic and inorganic fibers and/or blends thereof set forth
above for inclusion
into the kraft paper 304 or other porous media layer of the laminate 300.
Preferably, the
adhesive also includes between about 0.5% and about 30% by weight flame
retardant (e.g.
. aluminum tri-hydrate (ATH), decabrom with or without. antimony,
etc.),.between.about 10 ppm
and about 100 ppm (0.01 to about 0.10% by dry weight) thiabendazole such as
Metasol TK-
100 or about 200 ppm and about 2000 ppm (preferably between 400 ppm and 600
ppm) 2-
(4-Thiazoly1) Benzimidazole ("TBZ") as a mold and mildew growth retardant, and
about 9%
by dry weight magnesium hydrate to scavenge chlorine and protect the aluminum
foil or
metallized polyester film sheet 308 from chlorine degradation.
[0049] The laminate depicted in Fig. 3 includes an additional layer of
polymeric film in
comparison to the laminate depicted in Fig. 2 and includes more polymeric film
layers and/or
kraft paper layers than traditional laminates. As previously described,
polymeric film and kraft
paper materials provide a potential fuel source for potential fires. The use
of the proper
adhesives and/or kraft paper 304 or other porous media can ensure that the
laminate
provides sufficient flame and smoke propagation resistance and that the
laminate passes all
fire and smoke propagation regulations as well as all other necessary
regulations. In some
embodiments, the adhesive material is applied to one or more of the layers or
between the
layers during lamination and the adhesive material is absorbed by the kraft
paper 304 or
porous media The adhesive material and/or the additives in the adhesive
material may
saturate and remain in the kraft paper 304 or porous media and thereby provide
flame and
smoke resistance and/or other resistances. In other embodiments, the kraft
paper 304 or
other porous media may be pre-saturated with one or more additives prior to
applying the
adhesive material (which may also contain one or more additives) during the
lamination
process.
[0050] Figs. 4 and 5 depict one or more types of damage that the laminate
jacket pipe
insulation product, 400 & 500 respectively, may experience during handling
(e.g., shipping,
installation, etc.) and/or during use. Fig. 4 depicts what may be referred to
as handling
damage. Handling damage generally results after the various layers are
laminated together
13
CA 02748741 2011-08-11
and the laminate is shipped, installed, and/or used. For example, during
shipping,
installation, and/or use, the laminate jacket pipe insulation product 400 may
be bent, dinged,
impressed, imprinted, etc. which may result in one or more visible scars. The
visible scars
degrade the overall appearance of the laminate jacket pipe insulation product
400, which is
manufactured to provide a smooth and visually appealing surface.
[0051] Fig. 4 depicts the laminate jacket pipe insulation product 400 fitted
around a section
of pipe 406. The laminate jacket 402 of the laminate pipe insulation product
400 includes
one or more visible scars 404 that may occur during handling of the laminate
jacket pipe
. .
insulation product 40Ø For example, during installation, the installer may
bend, cut, impress,
etc. the laminate 402 as the laminate jacket pipe insulation product 400 is
fitted around the
pipe 406 and sealed to itself or to another laminate insulation product. The
visible scars 404
may include impressions or imprints from the installer's fingers, creases from
bending the
laminate, impressions from one or more dents, etc.
[0052] Employing a metallized polymeric film sheet inner layer in the laminate
application
of the present invention (e.g., metallized polyethylene terphthalate (MPET)),
greatly reduces
the visible scars due to handling. In other words, the metallized polymeric
film sheet inner
layer provides increased resistance to handling damage. Compared to
traditional laminates,
these laminates may take more abuse during shipment, handling, or in use while
maintaining
a visually appealing appearance.
[0053] A laminate's resistance to handling damage may be measured using one or
more
methods. One such method may include applying a crease to the laminate, such
as by using
a weighted jig to bend a portion of the laminate 180 degrees so that the bent
portion of the
laminate folds back onto the laminate. The jig may then be removed and the
angle of
recovery may be measured. The angle of recovery is the angle formed as the
crease unfolds
(i.e., as the bent portion unfolds). For example, if a corner of the laminate
is folded 180
degrees and the corner unfolds so that it is substantially perpendicular to
the laminate, the
angle of recovery would be roughly 90 degrees. The greater the angle of
recovery
measured, the more resistant the laminate is to handling damage, or in other
words, the more
able the laminate is to recover from any handling damage. An angle of recovery
of 180
degrees would indicate essentially no damage due to handling while an angle of
5 degrees or
less would indicate virtually no recovery (i.e., nearly 100% damage). The
described method
of testing handling damage resistance was applied to various laminates with
the results
provided in Fig. 6.
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CA 02748741 2011-08-11
[0054] As shown in Fig. 6, employing the MPET material in a laminate
application provides
significant handling damage resistance compared to laminates that employ
aluminum foil.
The polymeric film outer layer ¨ MPET inner layer laminate provides nearly
three times the
resistance to handling damage compared with a paper outer layer ¨ aluminum
foil inner layer
laminate. Similarly, the polymeric film outer layer ¨ MPET inner layer
laminate provides
nearly two times the resistance compared to a laminate employing a combination
of a
polymeric film outer layer ¨ aluminum foil inner layer. Thus compared to other
laminates, a
laminate comprising a polymeric film outer layer and a metallized polymeric
film inner layer
(i.e., MPET) may take increased abuse during shipment, handling, or in use and
maintain a .
more scar free visually appealing outer surface.
[0055] Fig. 5 depicts environmental damage that may occur after installation
of the
laminate jacket (i.e., while the laminate is in use). Fig. 5 shows a laminate
jacket pipe
insulation product 500 that includes a laminate jacket 502 that is fitted
about a pipe section
506. The laminate jacket 502 includes a plurality of visual scars 504 due to
one or more
environmental conditions that the laminate jacket 502 may be exposed to (e.g.,
temperature,
humidity, sunlight, etc.). One type of common visual scar 504 due to
environmental
conditions is what may be referred to as dimpling or wrinkling of the outer
layer of the
laminate. This deformation or wrinkling of the laminate outer surface may
adversely affect
the visual appeal of the laminate jacket pipe insulation product 500 by
changing the surface
from a smooth visibly pleasing surface to a surface having a visually
unappealing mottled
finish that can resemble the dimples on a golf ball. The deformation and
wrinkling (i.e.,
dimpling) of the laminate outer layer is generally caused by stresses within
or internal to the
laminate. The internal stresses may be caused by and/or enhanced when the
laminate is
used in high heat and humidity environments. The internal stresses cause the
laminate to
become dimensionally unstable, expand, deform, and wrinkle when exposed to
conditions of
high heat and humidity.
[0056] Utilizing a polymeric film sheet outer layer in addition to the
metallized polymeric film
sheet inner layer in the laminate application described herein provides
superior resistance to
environmental damage, such as dimpling. Such laminates are ideal for use in
high heat and
humidity environments due to the increased resistance to wrinkling or
dimpling. The
combination of the polymeric film sheet outer layer and metallized polymeric
film sheet inner
layer reduces the internal stresses otherwise present in other laminates under
these
conditions. For example, a laminate that employs a combination of a kraft
paper outer layer
CA 02748741 2011-08-11
with an metallized polymeric film inner layer may be more susceptible to
wrinkling or dimpling
because the internal stresses are increased.
[0057] A laminate's resistance to environmental damage may be measured using
one or
more methods. One such method may include placing one or more laminate jacket
pipe
insulation products in a controlled environment to evaluate the effects of the
environment on
the laminate. For example, to evaluate the effects of high heat and humidity,
laminate jacket
pipe insulation products may be placed for a predetermined amount of time in
an
environment that simulates a high heat and humidity environment (e.g., 3 or 4
laminate jacket
. pipe insulation products may be placed in a environment of 85 degrees
Fahrenheit and 85%
relative humidity for 3-5 days). The effects of the environment on the
laminate may be
accelerated by increasing the heat, humidity, and/or exposure to the
environment (e.g.,
temperature greater than or equal to 90 degrees Fahrenheit; relative humidity
greater than or
equal to 90% relative humidity; exposure between 1 and 30 days, etc.).
[0058] After being exposed to the controlled environment, the dimpling or
wrinkling of the
laminate's outer surface may be measured and quantified. The dimpling or
wrinkling may be
quantified using a 10 pt scale where the following scores indicate the
following amount of
environmental damage: a score of 2 indicates a laminate with large and deep
dimples/wrinkles that cover the majority of the laminate's outer surface; a
score of 4 indicates
a laminate with a mixed combination of large, small, deep, and shallow
dimples/wrinkles that
are fewer in overall number, but still prevalent over the laminate's surface;
a score of 6
indicates a laminate with small and shallow dimples/wrinkles (may have a few
deep dimples)
that are few in overall number; a score of 8 indicates a laminate with very
few
dimples/wrinkles that are small and shallow; and a score of 10 indicate a
laminate with no
visible dimpling/wrinkling. The intermediate numbers (1, 3, 5, 7, 9) may be
used to show
environmental damage between these numbers. This testing method was applied to
various
laminate configurations with the results provided in Table 1 below.
TABLE 1
Paper outer Paper outer Poly
outer layer Poly outer layer
layer w/ Foil layer w/ MPET wi Foil w/ MPET
Environmental
6 4 9-10 9-10
Damage Score
Table 1: Environmental damage for various laminates. The table uses a 10 pt
scale to
quantify the damage with a score of 10 indicating no visible environmental
damage.
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CA 02748741 2011-08-11
[0059] As can be seen from Table 1, the addition of the MPET layer with the
kraft paper
outer layer decreases the laminates resistance to environmental damage (i.e.,
makes the
laminate more susceptible to environmental damage), while the polymeric film
outer layer and
metallized polymeric film inner layer provides superior resistance to such
damage (i.e., the
laminate exhibits virtually no visible damage after exposure to the controlled
environment).
Table 2 below provides a brief overview of the two types of damage described
herein and a
comparison of the various laminates of the present invention in relation to
the two types of
damage. The environmental damage score provided in Table 2 is taken from Table
1, while
the handling damage score represents the angle of recovery measured for each
of the -
laminates in the manner described previously.
TABLE 2
Paper outer Paper outer Poly outer layer Poly outer layer
layer w/ Foil layer w/ MPET w/ Foil w/ MPET
Environmental
6 4 9-10 9-10
Damage Score
Handling
25 90 40 90
Damage Score
Table 2: Summary of environmental and handling damage for various laminates.
The
environmental damage score is based on the scores provides in Table 1, while
the handling
damage score paper represents the angle of recovery described in relation to
Fig. 6.
[0060] As provided in Table 2, the laminate that employs a polymeric film
outer layer and a
metallized polymeric film inner layer is the only laminate that provides
superior resistance to
both environmental damage and handling damage. While each of the laminates of
the
present invention provide some protection against both types of damage and/or
provide
increased protection against one type of damage, the laminate that employs
both the
polymeric film outer layer and metallized polymeric film inner layer is better
able to retain the
initial, as installed, smooth unwrinkled (i.e., undimpled) appearance even
after being
subjected to numerous cycles of high heat and humidity and after being
impressed, cut,
dented, etc. during handling, shipping, or use.
[0061] Fig. 7 illustrates a method 700 for producing a laminate jacket for a
pipe insulation
product. At block 705, a metallized polymeric sheet material may be obtained.
The
metallized polymeric sheet material may form an inner layer of the laminate
and may provide
a fluid vapor barrier to minimize fluid vapor transmission through the
laminate. At block 710,
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CA 02748741 2011-08-11
a scrim may be positioned in relation to the metallized polymeric sheet
material (e.g.,
adjacent to the metallized polymeric sheet material). At block 715, a porous
media sheet
material may be positioned in relation to the scrim or metallized polymeric
sheet material
(e.g., adjacent to the scrim).
[0062] At block 720, a polymeric sheet material may be positioned in relation
to the other
layers of the laminate (e.g., adjacent to the porous media). The polymeric
sheet material
may form an outer exposed layer of the laminate. At block 725, the metallized
polymeric
sheet material, the scrim, the porous media, and the polymeric sheet material
may be bonded
together with an adhesive.to.form the laminate jacket. At block 730, a tubular
core of
insulating material may be positioned in relation to the laminate (e.g.,
adjacent to the
metallized polymeric sheet material). The tubular core may include a length
and a
longitudinal axis, a cylindrical outer surface, a substantially cylindrical
inner surface, and a
wall extending between the cylindrical outer surface and the cylindrical inner
surface.
[0063] At block 735, the laminate and tubular core may be bonded together with
an
adhesive material to form a pipe insulation product. The pipe insulation
product may be
flexible so that the tubular core and laminate jacket can be opened, placed
about a pipe, and
closed without degrading the laminate jacket. At block 740, the laminate and
tubular core
may be flexed, placed about a pipe, and closed about the pipe.
[0064] In describing the invention, certain embodiments have been used to
illustrate the
invention and the practices thereof. However, the invention is not limited to
these specific
embodiments as other embodiments and modifications within the spirit of the
invention will
readily occur to those skilled in the art on reading this specification. Thus,
the invention is not
intended to be limited to the specific embodiments disclosed, but is to be
limited only by the
claims appended hereto.
[0065] As used herein and in the appended claims, the singular forms "a",
"an", and "the"
include plural referents unless the context clearly dictates otherwise. Thus,
for example,
reference to "a process" includes a plurality of such processes and reference
to "the device"
includes reference to one or more devices and equivalents thereof known to
those skilled in
the art, and so forth.
(0066] Also, the words "comprise," "comprising," "include," "including," and
"includes" when
used in this specification and in the following claims are intended to specify
the presence of
stated features, integers, components, or steps, but they do not preclude the
presence or
addition of one or more other features, integers, components, steps, acts, or
groups.
18
