Stock material or miscellaneous articles – Sheet including cover or casing – Noninterengaged fibered material encased
Reexamination Certificate
1997-09-25
2003-03-18
Yao, Sam Chuan (Department: 1733)
Stock material or miscellaneous articles
Sheet including cover or casing
Noninterengaged fibered material encased
C428S076000, C156S291000, C156S292000, C156S062200
Reexamination Certificate
active
06534144
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a synthetic resin film covered heat insulating/sound absorbing material of inorganic fibers which can eliminate a worker's discomfort due to dispersion of inorganic fibers and a method of producing the same.
2. Discussion of Background
Inorganic fiber mats made of inorganic fibers such as glass wool, rock wool or the like have widely been used as heat insulating/sound absorbing materials for buildings such as houses. The heat insulating/sound absorbing material is generally so made that front and rear surfaces of an inorganic fiber mat and both side surfaces along the direction of a longer side of the mat are covered with skin materials in order to eliminate discomfort such as an irritating feeling to a worker due to the dispersion of inorganic fibers in a construction site, and to provide the inorganic fiber mat with moisture-proofness. In a typical method of producing the heat insulating/sound absorbing materials of inorganic fibers, inorganic fiber mats are continuously delivered;
skin materials are respectively supplied to front and rear surfaces of the inorganic fiber mats; both side portions of the skin materials for covering the front and rear surfaces are jointed so that the front and rear surfaces and both side surface along the direction of a longer side of the inorganic fiber mats are covered; and
the skin materials are cut off together with the inorganic fiber mats at a predetermined length.
In the heat insulating/sound absorbing material of inorganic fibers produced by the above-mentioned typical method, end surfaces of each of the inorganic fiber mats where the skin materials are cut off at a predetermined length, namely, both side surfaces along the direction of a shorter side of each of the inorganic fiber mats are not covered with the skin materials, and the end surfaces of the inorganic fiber mats are in an exposed state. Accordingly, a worker's discomfort due to the dispersion of inorganic fibers at the exposed portions was unavoidable.
Further, when the heat insulating/sound absorbing material having an exposed portion in an inorganic fiber mat was used as a heat insulating/sound absorbing material for a wall or the like in a house, moisture enters into the wall from the interior side to the exterior side and enters into the heat insulating/sound absorbing material from the exposed portion of the inorganic fiber mat. Then there is a danger of condensation when the outer temperature decreases. The condensation reduces the heat insulating performance of the mat. Further, when the condensation continues for a long term, the foundation and beams of the house will decay.
In order to solve the above-mentioned problem, Japanese unexamined publication JP-A-6-79849 discloses that an elongated inorganic fiber mat is cut off at a predetermined length and the cut inorganic fiber mats are successively delivered; thermoplastic resin sheets are supplied to front and rear surfaces of the mats; both side portions of the thermoplastic resin sheets in the direction of a longer side of the mats are melt-bonded; the thermoplastic resin sheets at the front and rear sides are melt-bonded at portions between adjacent inorganic fiber mats followed by cutting whereby the entire surface of the inorganic fiber mat is covered with the thermoplastic resin sheets, and portions of the thermoplastic resin sheets which have not been subjecting to melt-bonding are used as air communication holes.
However, the heat insulating/sound absorbing material of inorganic fibers disclosed in Japanese unexamined publication JP-A-6-79849 has problems as follows because the thermoplastic resin sheets which cover the inorganic fiber mat are mutually melt-bonded.
A thermoplastic resin sheet used generally for a skin material has a certain amount of variation in thickness at local portions. Accordingly, when a melt-bonding operation is conducted while conditions for melt-bonding such as temperature, pressure and so on are kept constant, the melt-bonding may be insufficient due to a short of heat at a portion where the thickness of the sheet is relatively large. On the other hand, the sheet is broken before melt-bonding due to over-heating and over-pressure at a portion where the thickness is relatively small. Thus, a state of melt-bonding becomes unstable. Further, when melt-bonding is conducted for the thermoplastic resin sheets at portions between adjacent inorganic fiber mats, it takes a certain time. Accordingly, the movement of the thermoplastic resin sheets is temporarily stopped with the result that scattering of a tension in the thermoplastic resin sheets is apt to take place, which may cause an unstable melt-bonding state in the same manner as above, and wrinkles may be produced in the sheets.
Thus, in an event of insufficient melt-bonding or the breakage of the sheets which results in no melt-bonding, inorganic fibers disperse from an uncovered portion whereby a worker feels stimulation.
Further, since it takes a certain time to finish the melt-bonding of the thermoplastic resin sheets, a faster feeding speed of the thermoplastic resin sheets causes difficulty in the melt-bonding. Although the feeding speed depends on the quality and the thickness of the thermoplastic resin sheets, there is possibility of causing a trouble of melt-bonding when the feeding speed exceeds 35 m/min, for instance. Accordingly, the driving speed of the production line for the heat insulating/sound absorbing material was restricted, and therefore, productivity was low.
Further, since the melt-bonding of the thermoplastic resin sheets at both end portions along the direction of a shorter side of the inorganic fiber mats was conducted in the direction perpendicular to the feeding direction of the thermoplastic resin sheets between adjacent inorganic fiber mats i.e. in the direction perpendicular to the direction of the flow of the production line of the heat insulating/sound absorbing material of inorganic fibers, a melt-bonding device had to be moved for a predetermined time in the direction of the flow of the production line of the heat insulating/sound absorbing material in order to provide a sufficient heating-pressing time for the melt-bonding. Accordingly, the melt-bonding device should be of a special construction.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a heat insulating/sound absorbing material wherein the entire surface of an inorganic fiber mat is covered with a synthetic resin film or films while communication of air is possible and a method of producing the same at a high productivity without causing a defect of bonding in the thermoplastic resin sheets.
In accordance with a first aspect of the present invention, there is provided a synthetic resin film covered heat insulating/sound absorbing material of inorganic fibers which comprises:
an inorganic fiber mat, and a single or two synthetic resin films which cover front and rear surfaces and the both side surfaces along the direction of a longer side of the inorganic fiber mat, wherein the synthetic resin film at the front side and the synthetic resin film at the rear side respectively have extensions which extend from both sides along the direction of a shorter side of the inorganic fiber mat and which are bonded with an adhesive at mutually opposing portions so that both end surfaces along a shorter side of the inorganic fiber mat are covered with the synthetic resin films, and the inorganic fiber mat is bonded to one of the synthetic resin films and the synthetic resin films are mutually bonded in the discontinuous manners in the direction of a shorter side of the inorganic fiber mat so that air communicates through unbonded portions of the synthetic resin films.
In a second aspect of the present invention, there is provided the synthetic resin film covered heat insulating/sound absorbing material according to the first aspect wherein the inorganic fiber mat is covered with two synthetic resin films of front and rear side sy
Bando Takashi
Yamatsuta Kiichi
Yasu Masataka
Asahi Fiber Glass Company Limited
Yao Sam Chuan
LandOfFree
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