Variable perm sheet material, facing, and insulation assembly

Abstract

Permeance ratings of a variable perm sheet material, facing, and faced building insulation assembly vary with ambient humidity and/or temperature. In the insulation assembly, a facing is bonded to a major surface of an insulation layer. A central field portion of the facing, as bonded to the insulation layer, has variable water vapor transmission properties that vary from a relatively low permeance when exposed to ambient conditions of low humidity to a relatively high permeance when exposed to ambient conditions of high humidity. Preferably, the facing, as part of an insulation assembly, is fungi growth-resistant and may include a bonding layer, such as a heat activated bonding layer, that bonds the facing to an insulation layer. The sheet material may be embossed to affect its water vapor transmission characteristics.

1 . A variable perm faced building insulation assembly, comprising: 
 an insulation layer; the insulation layer having a length, a width and a thickness; the insulation layer having first and second major surfaces defined by the length and width of the layer; and    a facing comprising a sheet having a central field portion overlaying and substantially coextensive with the first major surface of the insulation layer; the central field portion of the sheet having a first outer major surface and a second inner major surface bonded to the first major surface of the insulation layer; the central field portion of the sheet having a resistance to water vapor transmission that changes when ambient relative humidity changes with the resistance of the central field portion of the sheet to water vapor transmission decreasing as the ambient humidity increases and increasing as the ambient humidity decreases.    
   
   
       2 . The variable perm faced building insulation assembly according to  claim 1 , wherein: 
 the central field portion of the facing sheet is embossed to stretch and thin the central field portion of the facing sheet at numerous locations and thereby affect the water vapor transmission characteristics of the central field portion of the facing sheet.    
   
   
       3 . The variable perm faced insulation assembly according to  claim 1 , wherein: 
 the central field portion of the facing sheet is bonded to the first major surface of the insulation layer by a discontinuous bonding layer that leaves the water vapor transmission properties of the central field portion of the sheet substantially unaffected.    
   
   
       4 . The variable perm faced insulation assembly according to  claim 1 , wherein: 
 the central field portion of the facing sheet is bonded to the first major surface of the insulation layer by a discontinuous bonding layer that affects the water vapor transmission properties of the central field portion of the sheet but leaves the water vapor transmission properties of the central field portion of the sheet within a selected permeance rating range.    
   
   
       5 . The variable perm faced insulation assembly according to  claim 1 , wherein: 
 the central field portion of the facing sheet is bonded to the first major surface of the insulation layer by a bonding layer having a resistance to water vapor transmission that leaves the water vapor transmission properties of the central field portion of the sheet substantially unaffected.    
   
   
       6 . The variable perm faced insulation assembly according to  claim 1 , wherein: 
 the central field portion of the facing sheet is bonded to the first major surface of the insulation layer by a bonding layer having a resistance to water vapor transmission that affects the water vapor transmission properties of the central field portion of the sheet but leaves the water vapor transmission properties of the central field portion of the sheet within a selected permeance rating range.    
   
   
       7 . The variable perm faced building insulation assembly according to  claim 1 , wherein: 
 the central field portion of the facing sheet is bonded to the first major surface of the insulating layer by a heat activated bonding layer.    
   
   
       8 . The variable perm faced insulation assembly according to  claim 1 , wherein: 
 the central field portion of the facing sheet has a permeance rating of 1 perm or less as measured by the ASTM E 96-00 dry cup method and a permeance rating of 10 perms or more as measured by the ASTM E 96-00 wet cup method.    
   
   
       9 . The variable perm faced insulation assembly according to  claim 1 , wherein: 
 the central field portion of the facing sheet, as bonded to the insulation layer, is fungi growth resistant.    
   
   
       10 . The variable perm faced building insulation assembly according to  claim 1 , wherein: 
 the central field portion of the facing sheet, as bonded to the insulation layer, exhibits no more than traces of sporulating growth, non-sporulating growth, or both sporulating and non-sporulating growth.    
   
   
       11 . The variable perm faced building insulation assembly according to  claim 1 , wherein: 
 the central field portion of the facing sheet, as bonded to the insulation layer, exhibits no sporulating growth or non-sporulating growth.    
   
   
       12 . The variable perm faced building insulation assembly according to  claim 1 , wherein: 
 the central field portion of the facing sheet, as bonded to the insulation layer, has a flame spread and smoke developed rating equal to or less than 25/50 as measured by the ASTM E 84-01 tunnel test method.    
   
   
       13 . The variable perm faced building insulation assembly according to  claim 1 , wherein: 
 the sheet has first and second lateral tabs extending for the length of the sheet that are separated from each other by the central field portion of the sheet.    
   
   
       14 . The variable perm faced building insulation assembly according to  claim 1 , wherein: 
 the insulation layer is resilient and separable longitudinally by hand at a location spaced inwardly from lateral edge surfaces of the insulation layer; and    the central field portion of the sheet is separable longitudinally by hand at a location that is aligned longitudinally with the separable location in the insulation layer to facilitate separation by hand of the insulation layer and sheet into faced insulation sections.    
   
   
       15 . The variable perm faced building insulation assembly, according to  claim 1 , wherein: 
 the insulation layer is resilient; and the first major surface of the insulation layer has lateral edge portions extending inward from and along lateral edges of the first major surface; and    the sheet has lateral edge portions overlaying the lateral edge portions of the first major surface of the insulation layer; the central field portion of the sheet extends between the lateral edge portions of the sheet; and the lateral edge portions of the sheet are not bonded to the lateral edge portions of the insulation layer whereby when the insulation layer is compressed laterally, the lateral edge portions of the facing sheet extend beyond the lateral edges of the first major surface of the insulation layer to form tabs.    
   
   
       16 . The variable perm faced building insulation assembly, according to  claim 1 , including: 
 a backing sheet comprising a sheet having a central field portion overlaying and substantially coextensive with the second major surface of the insulation layer; the central field portion of the sheet having a first outer major surface and a second inner major surface; the central field portion of the sheet having a resistance to water vapor transmission that changes when ambient relative humidity changes with the resistance of the central field portion of the sheet to water vapor transmission decreasing as the ambient humidity increases and increasing as the ambient humidity decreases; and for a constant ambient humidity and ambient temperatures between 50° F. and 100° F., the resistance of the central field portion of the facing sheet to water vapor transmission decreases as the ambient temperature increases and increases as the ambient temperature decreases.    
   
   
       17 . The variable perm faced building insulation assembly, according to  claim 1 , wherein: 
 the first and second major surfaces and at least lateral surfaces of the insulation layer are overlaid by the facing and the backing sheet.    
   
   
       18 . A variable perm facing for a variable perm faced building insulation assembly, comprising: 
 a sheet having a length and a width; the sheet having a central field portion for overlaying and being bonded to a major surface of an insulation layer; the central field portion of the sheet having a first outer major surface and a second inner major surface for bonding to a major surface of an insulation layer overlaid by the sheet; the central field portion of the sheet having a resistance to water vapor transmission that changes when ambient relative humidity changes with the resistance of the central field portion of the sheet to water vapor transmission decreasing as the ambient humidity increases and increasing as the ambient humidity decreases; and the central field portion of the sheet being fungi growth resistant.    
   
   
       19 . The variable perm facing for a variable perm faced building insulation assembly according to  claim 18 , wherein: 
 the central field portion of the facing sheet is embossed to stretch and thin the central field portion of the facing sheet at numerous locations and thereby affect the water vapor transmission characteristics of the central field portion of the facing sheet.    
   
   
       20 . The variable perm facing for a variable perm faced building insulation assembly according to  claim 18 , wherein: 
 the central field portion of the sheet exhibits no more than traces of sporulating growth, non-sporulating growth, or both sporulating and non-sporulating growth.    
   
   
       21 . The variable perm facing for a variable perm faced building insulation assembly according to  claim 18 , wherein: 
 the sheet exhibits no sporulating growth or non-sporulating growth.    
   
   
       22 . The variable perm facing for a variable perm faced building insulation assembly according to  claim 18 , wherein: 
 the sheet has first and second lateral tabs extending for the length of the sheet that are separated from each other by the central field portion of the sheet.    
   
   
       23 . The variable perm facing for a variable perm faced building insulation assembly according to  claim 18 , wherein: 
 the central field portion of the sheet has at least one longitudinally extending line of weakness to facilitate separation of the sheet longitudinally by hand along the line of weakness.    
   
   
       24 . The variable perm facing for a variable perm faced building insulation assembly according to  claim 18 , wherein: 
 the second major surface of the central field portion of the sheet has a discontinuous bonding layer thereon that leaves the water vapor transmission properties of the central field portion of the sheet substantially unaffected.    
   
   
       25 . The variable perm facing for a variable perm faced building insulation assembly according to  claim 18 , wherein: 
 the second major surface of the central field portion of the sheet has a discontinuous bonding layer thereon that affects the water vapor transmission properties of the central field portion of the sheet but leaves the water vapor transmission properties of the central field portion of the sheet within a selected permeance rating range.    
   
   
       26 . The variable perm facing for a variable perm faced building insulation assembly according to  claim 18 , wherein: 
 the second major surface of the central field portion of the sheet has a bonding layer thereon that has a resistance to water vapor transmission that leaves the water vapor transmission properties of the central field portion of the sheet substantially unaffected.    
   
   
       27 . The variable perm facing for a variable perm faced building insulation assembly according to  claim 18 , wherein: 
 the second major surface of the central field portion of the sheet has a bonding layer thereon that has a resistance to water vapor transmission that affects the water vapor transmission properties of the central field portion of the sheet leaves the water vapor transmission properties of the central field portion of the sheet within a selected permeance rating range.    
   
   
       28 . The variable perm facing for a variable perm faced building insulation assembly according to  claim 18 , wherein: 
 the second major surface of the central field portion of the sheet has a heat activated bonding layer thereon.    
   
   
       29 . The variable perm facing for a variable perm faced building insulation assembly according to  claim 18 , wherein: 
 the central field portion of the sheet has a permeance rating of 1 perm or less as measured by the ASTM E 96-00 dry cup method and a permeance rating of 10 perms or more as measured by the ASTM E 96-00 wet cup method.    
   
   
       30 . A variable perm faced building insulation assembly, comprising: 
 a facing sheet; the facing sheet having lateral edge portions and a central field portion extending between the lateral edge portions of the facing sheet; the central field portion of the sheet having a resistance to water vapor transmission that changes when ambient relative humidity changes with the resistance of the central field portion of the sheet to water vapor transmission decreasing as the ambient humidity increases and increasing as the ambient humidity decreases.    a reflective water vapor transmitting sheet material; the reflective sheet material having lateral edge portions and a central field portion extending between the lateral edge portions of the reflective sheet material; and    the lateral edge portions of the facing sheet being bonded to the lateral edge portions of the reflective sheet material; and the central field portion of the facing sheet being spaced from the central field portion of the reflective sheet material to form an insulating space within the faced insulation assembly.    
   
   
       31 . The variable perm faced building insulation assembly according to  claim 30 , wherein: 
 the central field portion of the facing sheet is embossed to stretch and thin the central field portion of the facing sheet at numerous locations and thereby affect the water vapor transmission characteristics of the central field portion of the facing sheet.    
   
   
       32 . The variable perm faced building insulation assembly according to  claim 30 , wherein: 
 the facing sheet is fungi growth resistant.    
   
   
       33 . The variable perm faced building insulation assembly according to  claim 30 , wherein: 
 the facing sheet exhibits no more than traces of sporulating growth, non-sporulating growth, or both sporulating and non-sporulating growth.    
   
   
       34 . The variable perm faced building insulation assembly according to  claim 30 , wherein: 
 the facing sheet exhibits no sporulating or non-sporulating growth.    
   
   
       35 . An insulation system for a building wall, floor or ceiling; the wall, floor or ceiling comprising a series of cavities that are each defined in part by spaced apart parallel extending framing members; the insulation system comprising: 
 unfaced fibrous insulation batts contained within each of the series of cavities; and    a variable perm vapor water vapor transmission retarding cover overlying the series of cavities, substantially coextensive with the series of cavities, and secured to the faming members defining the cavities; the variable perm water vapor retarding cover comprising a variable perm sheet material having a first major surface, a second major surface, and being fungi growth resistant; and the variable perm sheet material having a resistance to water vapor transmission that changes when ambient relative humidity changes with the resistance of the central field portion of the sheet to water vapor transmission decreasing as the ambient humidity increases and increasing as the ambient humidity decreases; and for a constant ambient humidity and ambient temperatures between 50° F. and 100° F., the resistance of the central field portion of the facing sheet to water vapor transmission decreases as the ambient temperature increases and increases as the ambient temperature decreases.    
   
   
       36 . The insulation system according to  claim 35 , wherein: 
 the variable perm sheet material exhibits no more than traces of sporulating growth, non-sporulating growth, or both sporulating growth and non-sporulating growth.    
   
   
       37 . The insulation system according to  claim 35 , wherein: 
 the variable perm sheet material exhibits no sporulating growth or non-sporulating growth.    
   
   
       38 . The insulation system according to  claim 35 , wherein: 
 the variable perm sheet material is reinforced by an integral mat layer of a spunbond nonwoven continuous polymeric filament mat weighing between about 15 and about 30 grams per square meter.    
   
   
       39 . The insulation system according to  claim 35 , wherein: 
 the variable perm sheet material is reinforced by an integral nonwoven fiberglass mat weighing between about 20 and about 80 grams per square meter.    
   
   
       40 . The insulation system according to  claim 35 , wherein: 
 the variable perm water vapor transmission retarding cover comprises a series of sheets of the variable perm sheet material; each of the sheets has lateral longitudinally extending edge portions; and the lateral longitudinally extending edge portions of adjacent sheets are overlapped and bonded together, in situ, to form an integral variable perm water vapor transmission retarding cover.    
   
   
       41 . The insulation system according to  claim 40 , wherein: 
 the lateral longitudinally extending edge portions are adhesively bonded together by a cold seal adhesive.    
   
   
       42 . The insulation system according to  claim 35 , wherein: 
 the cover is embossed to stretch and thin the cover at numerous locations and thereby affect the water vapor transmission characteristics of the cover.    
   
   
       43 . An insulation system for an exterior of a building comprising: 
 a sheathing layer of the exterior; and    a variable perm water vapor transmission retarding layer overlying, substantially coextensive with, and secured to an outer surface of the sheathing layer; the water vapor transmission retarding layer comprising a variable perm sheet material that is reinforced and is fungi growth resistant; and the variable perm sheet material having a resistance to water vapor transmission that changes when ambient relative humidity changes with the resistance of the central field portion of the sheet to water vapor transmission decreasing as the ambient humidity increases and increasing as the ambient humidity decreases; and for a constant ambient humidity and ambient temperatures between 50° F. and 120° F., the resistance of the central field portion of the facing sheet to water vapor transmission decreases as the ambient temperature increases and increases as the ambient temperature decreases; and the variable perm water vapor transmission retarding layer functioning as an air transmission barrier and liquid water transmission barrier.    
   
   
       44 . The insulation system according to  claim 43 , wherein: 
 the variable perm sheet material exhibits no more than traces of sporulating growth, non-sporulating growth, or both sporulating growth and non-sporulating growth.    
   
   
       45 . The insulation system according to  claim 43 , wherein: 
 the variable perm sheet material exhibits no sporulating growth or non-sporulating growth.    
   
   
       46 . The insulation system according to  claim 43 , wherein: 
 the variable perm sheet material is reinforced by an integral mat layer of a spunbond nonwoven continuous polymeric filament mat weighing between about 15 and about 30 grams per square meter.    
   
   
       47 . The insulation system according to  claim 43 , wherein: 
 the variable perm sheet material is reinforced by an integral nonwoven fiberglass mat weighing between about 20 and about 80 grams per square meter.    
   
   
       48 . The insulation system according to  claim 43 , wherein: 
 the variable perm water vapor transmission retarding layer comprises a series of sheets of the variable perm sheet material; each of the sheets has lateral longitudinally extending edge portions; and the lateral longitudinally extending edge portions of adjacent sheets are bonded together, in situ, to form an integral variable perm water vapor transmission retarding layer and an air transmission barrier and liquid water transmission barrier.    
   
   
       49 . The insulation system according to  claim 48 , wherein: 
 the lateral longitudinally extending edge portions are adhesively bonded together by a cold seal adhesive.    
   
   
       50 . The insulation system according to  claim 43 , wherein: 
 the variable perm sheet material is embossed to stretch and thin the variable perm sheet material at numerous locations and thereby affect the water vapor transmission characteristics of the variable perm sheet material and the variable perm water vapor transmission retarding layer.    
   
   
       51 . The insulation system according to  claim 43 , wherein: 
 the exterior of the building is an exterior wall of the building.