Reinforced reflective insulation for construction

Abstract

Described is a reflective insulating material for use in metal building insulation (MBI) or in post frame building insulation (PFBI) applications, the reflective insulating material comprising: a first outer layer and a second outer layer disposed parallel to one another, the first outer layer made of a reflective radiant barrier material; an insulation layer disposed between the first and second outer layers; and a fabric layer that is a scrim layer or a woven layer disposed between the first and second outer layers. The fabric layer can have various properties. A polymer seal layer can also be provided as part of the material. Processes for manufacturing the reflective insulating material are also provided.

1 . A reflective insulating material for use in metal building insulation (MBI) or in post frame building insulation (PFBI) applications, the reflective insulating material comprising:
 a first outer layer and a second outer layer disposed parallel to one another, the first outer layer made of a reflective radiant barrier material;   a first insulation layer disposed between the first and second outer layers; and   a fabric layer disposed between the first and second outer layers, wherein the fabric layer is a scrim layer comprising apertures or a woven textile material layer defining a generally continuous surface without apertures.   
     
     
         2 . The reflective insulating material of  claim 1 , wherein the insulation layer is a bubble layer. 
     
     
         3 . The reflective insulating material of  claim 1 , wherein the insulation layer is a foam layer. 
     
     
         4 . The reflective insulating material of  claim 1 , comprising a second insulation layer disposed between the first and second outer layers. 
     
     
         5 . The reflective insulating material of  claim 1 , comprising an intervening layer disposed between the first and second outer layers and made of one or a combination or blend of: polyethylene, polypropylene, and nylon. 
     
     
         6 . The reflective insulating material of  claim 1 , wherein the reflective radiant barrier material is made of one or a combination of: metallized polyester (METPET), and metal (e.g., aluminum) foil. 
     
     
         7 . The reflective insulating material of  claim 1 , wherein the second outer layer is made of one or a combination of: polyethylene, polypropylene, and nylon. 
     
     
         8 . The reflective insulating material of  claim 1 , wherein the second outer layer is made of the reflective radiant barrier material. 
     
     
         9 . The reflective insulating material of  claim 1 , wherein the woven threads of the fabric layer are made of one or a combination of: nylon, fiber glass, polyethylene, and polyester. 
     
     
         10 . The reflective insulating material of  claim 1 , wherein the insulation layer is made of one or a combination or blend of: polyethylene, polypropylene, and nylon. 
     
     
         11 . The reflective insulating material of  claim 1 , wherein two or more of the layers of the reflective insulating material are bonded together. 
     
     
         12 . The reflective insulating material of  claim 11 , wherein two or more of the layers of the reflective insulating material are adhesively laminated together. 
     
     
         13 . The reflective insulating material of  claim 11 , wherein two or more of the layers of the reflective insulating material are bonded together with one or a combination of: thermal, chemical, or mechanical bond. 
     
     
         14 . The reflective insulating material of  claim 1 , wherein the fabric layer is the scrim layer and the apertures are shaped as one or more of: slits, circles, ovals, ellipses, monogons, bigons, triangles, quadrilaterals, pentagons, hexagons, heptagons, octagons, nonagons, and decagons. 
     
     
         15 . The reflective insulating material of  claim 1 , wherein the material is configured such that the fastening means are one or a combination of: clips and staples. 
     
     
         16 . The reflective insulating material of  claim 14 , wherein a pattern defined by the threads of the scrim layer is configured to effectively capture in any direction, with at least one of the apertures of the scrim layer, a pin of one of the fastening means. 
     
     
         17 . The reflective insulating material of  claim 16 , wherein two pins of one of the staples are only receivable by two distinct ones of the apertures of the scrim fabric layer. 
     
     
         18 . The reflective insulating material of  claim 1 , wherein the fabric layer is continuous and does not define apertures, and wherein the fabric layer is configured to be punctured by the parts of the fastening means. 
     
     
         19 . The reflective insulating material of  claim 1 , wherein the fabric layer has one or more of the following characteristics: MD yarn of 550 Dtex HT Polyester; CD yarn of 550 Dtex HT Polyester; pattern of 1.2×1.05 yarns/cm; tensile of 209×185 N/5 cm; weight of 15.02 g/m2; coating of polyvinyl alcohol; and width of maximum 2100 mm. 
     
     
         20 . The reflective insulating material of  claim 1 , wherein the reflective insulating material has a width between about 24 to about 104 inches, and a thickness of between about 0.1 to about 0.75 inches. 
     
     
         21 . The reflective insulating material of  claim 1 , wherein the reflective insulating material passes one or more of the following tests:
 ASTM E84-08 Steiner tunnel test with a fire rating value of at least class A, a flame spread value under 25 and a smoke developed value under 450;   ASTM G155 UV test with a value of at least 90% retained retention after 4000 hours;   NFPA 286 fire rating full room burn test;   ASTM C1371-04A emissivity test with a value of at least 0.04;   ASTM E903 reflectivity test with a value of at least 0.96;   ASTM E96 water vapor permeability test with a value of at least 0.01 Perms;   ASTM C1149 resistance to fungi and bacteria test;   ASTM C1224-03 pliability test with no cracking;   ASTM C1224-03 bleeding and delamination test with no bleeding or delamination; and   ASTM D3310-00 corrosiveness test.   
     
     
         22 . A reflective insulating material for use in metal building insulation (MBI) or in post frame building insulation (PFBI) applications, the reflective insulating material comprising:
 a first outer layer made of a reflective radiant barrier material;   an adhesive layer disposed on the first outer layer;   a polymer film layer disposed on the adhesive layer;   an insulation layer contiguous with the first polymer film layer, the insulation layer being composed of bubbles or foam;   a polymer seal layer contiguous with an opposed side of the insulation layer;   a reinforcement assembly laminated to the polymer seal layer, the reinforcement assembly comprising:
 a first polymer film; 
 a second polymer film; and 
 a reinforcement layer comprising a fabric sandwiched between the first and second polymer films. 
   
     
     
         23 . A reflective insulating material for use in metal building insulation (MBI) or in post frame building insulation (PFBI) applications, the reflective insulating material comprising:
 a first outer layer made of a reflective radiant barrier material;   an adhesive layer disposed on the first outer layer;   a polymer film layer disposed on the adhesive layer;   an insulation layer contiguous with the first polymer film layer, the insulation layer being composed of foam;   a polymer seal layer contiguous with an opposed side of the insulation layer; and   a multi-layer component disposed on the polymer seal layer.   
     
     
         24 . A reflective insulating material for use in metal building insulation (MBI) or in post frame building insulation (PFBI) applications, the reflective insulating material comprising:
 an outer laminated assembly comprising:
 a first outer layer made of a reflective radiant barrier material; 
 an adhesive layer disposed on the first outer layer; and 
 a polymer film layer disposed on the adhesive layer; 
   an inner multi-layer assembly comprising:
 an insulation layer contiguous with the first polymer film layer, the insulation layer being composed of foam; 
 a second outer layer disposed on the insulation layer; 
   wherein the outer laminated assembly and the inner multi-layer assembly are laminated together using a film bubble line such that the insulation layer is adhered to the first polymer film layer, to form the reflective insulating material.