Perforated closed cell foam insulation, apparatus and method for perforating closed cell foam insulation, and insulated article

Abstract

The present invention is directed to perforated closed cell foam insulation. A sheet of closed cell foam insulation has opposing first and second major surfaces, and a plurality of spaced openings extending from the first major surface to the second major surface. Apparatus and methods for perforating a sheet of closed cell foam insulation are also disclosed. The present invention also relates to an insulated metal panel including the disclosed perforated closed cell foam insulation.

1 . Perforated closed cell foam insulation, comprising: 
 a sheet of closed cell foam insulation having opposing first and second major surfaces; and    a plurality of spaced openings extend from said first major surface through said second major surface.    
   
   
       2 . The insulation of  claim 1 , further comprising an adhesive layer covering at least one of said major surfaces.  
   
   
       3 . The insulation of  claim 2 , further comprising a liner material releasably attached to said adhesive layer.  
   
   
       4 . The insulation of  claim 3 , wherein said liner material is selected from the group consisting of silicone coated release paper, polyethylene coated release paper, and mylar.  
   
   
       5 . The insulation of  claim 3 , wherein said liner material and said adhesive layer include a plurality of openings aligned with said plurality of spaced openings.  
   
   
       6 . The insulation of  claim 2 , wherein said adhesive layer is water based acrylic adhesive.  
   
   
       7 . The insulation of  claim 1 , wherein said sheet has a thickness of at least about 0.030 inch.  
   
   
       8 . The insulation of  claim 7 , wherein said sheet has a thickness of between about 0.030 inch and about 2.0 inch.  
   
   
       9 . The insulation of  claim 1 , wherein said sheet is polyethylene closed cell foam insulation.  
   
   
       10 . An apparatus for perforating a sheet of closed cell foam insulation, comprising: 
 a supply section for holding sheet insulation;    a nip roller spaced from said supply section, said nip roller having a cylindrical configuration and a motor operably associated therewith for causing axial rotation of said nip roller;    an aerator roller having a plurality of spaced projections, said aerator roller parallel to said nip roller and spaced from said nip roller a sufficient distance so that the sheet insulation is perforated by said spaced projections when passing therebetween.    
   
   
       11 . The apparatus of  claim 10 , wherein said supply section includes a rod for holding a roll of the sheet insulation.  
   
   
       12 . The apparatus of  claim 10 , further comprising a guide roller for aligning an adhesive coated release material with a side of the insulation.  
   
   
       13 . The apparatus of  claim 12 , wherein said guide roller is upstream said nip roller so that the sheet insulation and the release material are simultaneously perforated by said aerator roller.  
   
   
       14 . The apparatus of  claim 13 , further comprising first and second compression rollers intermediate and aligned with said nip roller and said guide roller, said rollers positioned so that the sheet insulation and release material are pressed together while passing therebetween.  
   
   
       15 . The apparatus of  claim 12 , wherein said guide roller is downstream said nip roller so that the release material is adhered to perforated insulation.  
   
   
       16 . The apparatus of  claim 15 , further comprising first and second compression rollers intermediate and aligned with said nip roller and said guide roller, said rollers positioned so that the perforated sheet insulation and release material are pressed together while passing therebetween.  
   
   
       17 . The apparatus of  claim 10 , wherein said spaced projections are uniformly spaced from each other by at least about 0.125 inch.  
   
   
       18 . The apparatus of  claim 10 , wherein said spaced projections are formed from a material selected from the group consisting of polypropylene, steel, and aluminum.  
   
   
       19 . The apparatus of  claim 10 , wherein said aerator roller has a length at least equal to the width of the sheet insulation.  
   
   
       20 . The apparatus of  claim 10 , wherein said apparatus includes at least two of said aerator rollers axially aligned with each other, said rollers having a total length at least equal to the width of the sheet insulation.  
   
   
       21 . A method of perforating closed cell foam insulation, comprising the steps of: 
 providing a supply of closed cell foam sheet insulation;    providing a pair of rollers parallel and adjacent to each other, one of the rollers having a plurality of spaced projections; and    passing the sheet insulation between the rollers so that the spaced projections perforate the sheet insulation.    
   
   
       22 . The method of  claim 21 , including the further steps of: 
 providing a supply of adhesive coated release material;    aligning the release material with the sheet insulation;    bonding the aligned release material to the sheet insulation; and    perforating the bonded release material and sheet insulation simultaneously during said passing step.    
   
   
       23 . The method of  claim 21 , including the further steps of: 
 providing a supply of adhesive coated release material;    aligning the release material with the perforated sheet material;    bonding the aligned release material to the perforated sheet insulation.    
   
   
       24 . An insulated metal panel, comprising: 
 a metal planar portion; and    a sheet of closed cell foam insulation having a first major surface adhered to said metal planar portion and an opposing second major surface, said sheet having a plurality of spaced openings extending from said first major surface through said second major surface.    
   
   
       25 . The metal panel of  claim 24 , wherein said panel comprises a portion of a metal cabinet.  
   
   
       26 . The metal panel of  claim 24 , wherein said metal cabinet is associated with an HVAC unit.  
   
   
       27 . The metal panel of  claim 24 , wherein said openings are uniformly distributed throughout said sheet.  
   
   
       28 . An apparatus for perforating a sheet of closed cell foam insulation, comprising: 
 a supply section for holding sheet insulation;    a press spaced from said supply section, said press having a major surface including a plurality of spaced projections;    an actuator operably associated with said press for causing said major surface to contact the sheet insulation when passing under said press so that the sheet insulation is perforated by said spaced projections.    
   
   
       29 . The apparatus of  claim 28 , wherein said press includes an upper die and a lower die, at least one of said dies having said major surface including said spaced projections.  
   
   
       30 . A method of perforating closed cell foam insulation, comprising the steps of: 
 providing a supply of closed cell foam sheet insulation;    providing a press having a major surface including a plurality of spaced projections;    disposing the sheet insulation under the press;    pressing the sheet insulation against the major surface so that the sheet insulation is perforated by the spaced projections.