Facing for insulation and other applications

Abstract

A method and material for covering exposed insulation surfaces to protect them from moisture and other environmental factors. The covering typically includes a first, exposed layer of a metal-containing foil, a second layer of a metal-containing foil, a layer of a polymer disposed between the first two layers of foil, a third layer of a metal-containing foil, and a second layer of polymer disposed between the second and third layers of foil. A layer of a pressure sensitive adhesive is applied to one of the exposed layers of foil, and the pressure sensitive adhesive layer is covered with a release liner prior to application. The foil provides the necessary moisture and weather seal while the polymer provides the necessary strength and puncture resistance. The overall thickness of the laminate typically is less than 100 microns, permitting it to be easily cut and manipulated at the job site while providing an effective, long lasting weather seal.

What is claimed is:  
     
         1 . A covering for insulation comprising: 
 a first layer of a metal-containing foil;    a second layer of a metal-containing foil;    a third layer of a metal-containing foil;    a first layer of a puncture resistant polymer film disposed between said first and said second layers of metal-containing foil; and    a second layer of a puncture resistant polymer film disposed between said second and said third layers of metal-containing foil.    
     
     
         2 . The covering as recited in  claim 1  wherein at least said first layer of metal-containing foil is a sheet of aluminum foil.  
     
     
         3 . The covering as recited in  claim 2  wherein said first foil layer has a thickness in the range of from about 5 microns to about 50 microns.  
     
     
         4 . The covering as recited in  claim 3  wherein said first foil layer has a thickness of about 9 microns.  
     
     
         5 . The covering as recited in  claim 1  wherein at least said first layer of a puncture resistant polymer film is formed of polyester.  
     
     
         6 . The covering as recited in  claim 5  wherein said first layer of a puncture resistant polymer film has a thickness in the range of about 10 microns to about 50 microns.  
     
     
         7 . The covering as recited in  claim 6  wherein said first layer of a puncture resistant polymer film material has a thickness of about 23 microns.  
     
     
         8 . The covering as recited in  claim 1  wherein said first and said second layers of a metal-containing foil are bonded to the first layer of a puncture resistant polymer film by an adhesive, and wherein said second and said third layers of a metal-containing foil are bonded to said second layer of a puncture resistant polymer film by an adhesive.  
     
     
         9 . The covering as recited in  claim 1  further comprising: 
 a layer of a pressure sensitive adhesive applied to said third layer of a metal-containing foil; and  
 a release liner covering said layer of a pressure sensitive adhesive.  
 
     
     
         10 . A weather seal for use on exposed surfaces comprising: 
 a first layer of an aluminum foil;    a second layer of a metal-containing foil;    a third layer of a metal-containing foil;    a first layer of a puncture resistant material disposed between said first layer of aluminum foil and said second layer of a metal-containing foil;    a second layer of a puncture resistant material disposed between said second layer of a metal-containing foil and said third layer of a metal-containing foil; and    a layer of a pressure sensitive adhesive disposed on said third layer of a metal-containing foil.    
     
     
         11 . The weather seal as recited in  claim 10  wherein said first and said second layers of a puncture resistant material are formed of a polyester.  
     
     
         12 . The weather seal as recited in  claim 10  wherein a combined thickness of said first layer of an aluminum foil, said second layer of a metal-containing foil, said third layer of a metal-containing foil, and said first and said second layers of a puncture resistant material is less than 100 microns.  
     
     
         13 . The weather seal is recited in  claim 10  wherein said first layer of an aluminum foil has a thickness of about 9 microns.  
     
     
         14 . The weather seal is recited in  claim 10  wherein said first and said second layers of a puncture resistant material each have a thickness of about 23 microns.  
     
     
         15 . The weather seal as recited in  claim 10  wherein said second and said third layers of a metal-containing foil are formed of a metalized foil.  
     
     
         16 . A covering for exterior and interior insulation which may be applied to the insulation after installation comprising: 
 a first layer of aluminum foil having a thickness in the range of from about 5 microns to about 50 microns;    a first layer of polyester material adhered to said first layer of aluminum foil with an adhesive, said polyester layer having a thickness greater than about 23 microns;    a second layer of aluminum foil adhered to said first layer of polyester material by an adhesive, said second layer of aluminum foil having a thickness in the range of from about 5 microns to about 50 microns;    a second layer of polyester material adhered to said second layer of aluminum foil by an adhesive, said second layer of polyester material having a thickness greater than about 23 microns;    a third layer of aluminum foil adhered to said second layer of polyester material by an adhesive, said third layer of aluminum foil having a thickness in the range of from about 5 to about 20 microns; and    a pressure sensitive adhesive layer disposed on said third layer of aluminum foil which remains tacky in a temperature range of from about minus 17° Fahrenheit to about 284° Fahrenheit.    
     
     
         17 . A method for protecting insulation from damage due to moisture and other environmental factors, said method comprising: 
 providing a covering material having a metal-containing layer on one surface and a layer of a pressure sensitive adhesive on a second, opposite surface, said covering material including at least one layer of a puncture resistant material disposed between the metal-containing layer and the adhesive layer;    manually cutting from the covering material an appropriately sized first sheet at a job site;    removing a release liner covering the pressure sensitive adhesive layer of the first sheet;    applying the first sheet to the insulation so that the adhesive layer bonds to the insulation and the metal-containing layer is exposed; and    applying additional sheets of covering material directly to the insulation such that each sheet of covering material overlaps sheets of covering material directly adjacent thereto.    
     
     
         18 . The method as recited in  claim 17  wherein said manually cutting step comprises cutting the covering material into sheets having shapes that conform to an external shape and size of the insulation being covered.  
     
     
         19 . The method as recited in  claim 17  further comprising, for a pipe having a curved portion, wrapping lengths of a pressure sensitive adhesive tape having a layer of a metal-containing foil and a layer of a puncture resistant polymer about the sheets of covering material to conform the covering material to the configuration of the pipe.  
     
     
         20 . The method as recited in  claim 17  further comprising sealing seams between adjacent sheets of covering material with a pressure sensitive adhesive tape.  
     
     
         21 . The method as recited in  claim 17  wherein the covering material is formed of a laminate of aluminum foil, and polyester in multiple, alternating layers.  
     
     
         22 . The method as recited in  claim 17  wherein for an insulated duct having a substantially rectangular cross-sectional shape, the first and second applying steps comprise: 
 applying the first sheet of covering material to a bottom wall of the duct so that an overlapping portion of the sheet extends upwardly along each side wall of the insulated duct immediately adjoining the bottom wall;  
 thereafter applying a cut sheet of covering material to each side wall of the insulated duct so that each sheet on the side wall overlaps the overlapping portion of the first sheet extending upwardly from the bottom wall and so that another overlapping portion of each sidewall sheet of material extends beyond the side wall and along the top wall of the insulated duct; and  
 applying a fourth sheet of a covering material to the top wall of the duct to overlap the overlapping portions of the sheets of material on the side wall which extend along the top wall.  
 
     
     
         23 . The covering as recited in  claim 1  further comprising a protective layer disposed on said first layer of a metal-containing foil, said protective layer being resistant to ultraviolet radiation, acid and salt.  
     
     
         24 . The covering as recited in  claim 1  wherein one of said first, second and third layers of a metal-containing foil is formed of a metal foil, and the others of said first, second and third layers of a metal-containing foil are formed of a metalized foil.  
     
     
         25 . A covering as recited in  claim 1  where each of said first, second and third layers of a metal-containing foil is formed of a metal foil.  
     
     
         26 . A covering as recited in  claim 1  further comprising a layer of scrim.  
     
     
         27 . A covering as recited in  claim 1  further comprising additional, alternating layers of a metal-containing foil and a puncture resistant polymer film.  
     
     
         28 . A covering for insulation comprising: 
 multiple layers of a metal-containing foil;    multiple layers of a puncture resistant, polymer film, said layers of puncture resistant, polymer film alternating with said layers of a metal-containing foil;    a layer of a pressure sensitive adhesive disposed on one side of said covering; and    a layer of material disposed on a side of the covering that is opposite of the one side and that is exposed, the layer of material being resistant to ultraviolet radiation, acid rain and salt, said covering being sufficiently flexible that it may be conformed to the shape of an insulated pipe.