AU2003270945A1 - Insulation panel - Google Patents

Description

P/00/011 Regulation 3.2

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION Invention Title: INSULATION

PANEL

The following statement is a full description of this invention, including the best method of performing it known to me: In addition to the matter disclosed in Provisional Patent Applications 523177 and 524084 we now wish to disclose further developments in the Insulation Panel in this cognated application. The above identified are included within the scope of this document.

This invention relates to an insulation panel. The invention is directed particularly, but not solely, toward a portable, removable, modular and or demountable insulation panel or bulkhead for refrigerated transport vehicles, containers and buildings.

BACKGROUND OF THE INVENTION Existing portable bulkheads or insulation panels are used as portable insulation barriers, dividers etc for buildings or containers or transport vehicles such as trucks, trains, ships or planes or cool-stores in general.

Difficulties arise due to the weight and required ruggedness of the existing insulation barriers. They are either robust and too heavy or light and easily damaged. They are often too heavy and bulky to be readily moved when being installed or when needed to arrange different storage compartments depending on what has been carried or removed during delivery by truck etc. Damage and repair are constant problems combined with excessive manufacturing costs.

It is the object of the present invention to provide an improved insulation panel which will obviate or minimize the aforementioned problems in a simple yet effective manner or which will at least provide the public with a useful choice.

STATEMENT OF INVENTION In a first aspect the invention consists in an insulation panel, the panel including a body having an outer surface, a core, and in use the panel having a top, base and sides, wherein the core includes material having a different density from the centre portion to the outer portion.

In a further aspect, the invention consists in an insulation panel, the panel including a body having an outer surface, a core, and in use the panel having a top, base and sides, wherein the core includes at least an insulation material or medium.

The outer surface can be a skin or skeletal in form.

The outer surface can be a separate member.

The core density can be less dense in the center portion than the outer portion wherein the density increases away from the centre.

The core can include being in the form of a frame.

The insulation panel can be a portable, detatchable, modular and movable bulkhead panel.

The core can include a closed cell foam material.

Alternatively the core includes open cell foam material.

Alternatively the core includes substantially fibrous material.

Alternatively the core includes substantially organic material Alternatively the core includes polyurethane foam material.

Alternatively the core includes air therein.

Alternatively the core is a polystyrene material or expanded polystyrene material.

Alternatively the core is substantially a polyethylene or polypropylene material or polystyrene or ABS material or acrylic or high impact polystyrene (HIPS) material.

The outer surface can be substantially a polyethylene or polypropylene material or polystyrene or ABS material or acrylic or high impact polystyrene (HIPS) material.

At least one sealing member can be attached to the outer surface.

The sealing member(s) can be deformable and flexible and/or are inflatable members.

The sealing member(s) are flaps.

Reinforcing members can be attached to or are formed with the sides of the outer surface of the panel.

Alternatively reinforcing members are moulded on either the inner or outer surface of the panel.

The panel can have at least one vent therethrough with or without hingedly attached cover flap.

The panel can have at least one recessed hingedly attached handle therein.

The panel has attachment means enabling pivoting from another attachment means such that a panel(s) can be moved in place or out of place.

In yet a further aspect, the invention consists in a method of installation of the said insulation panei(s), the steps including: -installing tracking or supports-optional; -sliding at least one panel into place with or without seal flaps; -installing and or activating hinging/pivoting to enable at least one panel to be movable.

DRAWING DESCRIPTION Preferred forms of the invention will now be described by way of illustration only with reference to the accompanying drawings.

Figure 1 shows a perspective view of the panel of the invention.

Figure 2 shows a cross sectional view of the panel with sealing and reinforcing members.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to the drawings as shown in Figure 1 there is an insulation panel which can be formed from components or be integrally formed. The panel in use is a portable or removable bulkhead panel 10. Examples for the use of this panel are a partition for separating compartments in buildings or containers or vehicles such as trucks, trains, ships and aircraft. The panel 10 includes a core 11 enveloped by a skin or surface 12. The skin can be formed integrally from the core 11 or it can be separately formed as a skeletal structure from the same or different material. The panel 10 in use has a top 13, bottom 14, and sides 15 and 16.

The panel can be demountable, slidable and or movable. In use the panel may be swung down slidably within tracks with pulleys, to fall into place whereby pivoting opening portion can be formed. Alternatively the panel or linked panels can be swung down on hinges for use and then swung back up and out of the way when required. The panels can be semi permanently installed and completely removed if necessary.

As shown in the example in figure 2 the panel 10 can also have sealing members 17 as well as or reinforcing members 18 and 19 affixed to or formed with the sides and or ends. There can also be a kick board or channel member 20 (portable components or integrally formed) that serves to protect the panel during movement and collisions etc. These members can be integrally moulded with the panel or can be separate members. Suitable attaching means useful for removably or permanently attaching the members or the panel to a vehicle or room or to another panel can also be included. For example the attaching means can be hook/loop or heating or adhesive or suction or inflation or friction gripping/wedging or 'cold sticking' or fasteners or dovetail or tongue and groove etc. These members can be made of similar material as the core and skin combination or they can be inflatable and or they can be made of plies or strips. Sealing members and or reinforcing members can be formed intregrally or separately with the rest of the panel whereby flexible edge flaps 21 are in use oversized with respect to any sized gap between the panel and existing surface (eg wall or ceiling of truck or adjacent panel etc), to enable folding to 'wipe' a sealed area sealingly shut. Flaps 21 can be continuous in extent with regard to the edge being sealed or whatever is needed. Further flaps can also be installed parallel to others to provide further sealing or positioning means when in use. The flaps can be located on the panel edge or face and or in any position thereof The core 11 can be a different or substantially similar material to that of the skin 12. For example, the core and or skin can be manufactured from any suitable insulative material such as plastics material, fibrous material or organic material or air (eg in pockets or section or cavities), in many different combinations and permutations. For example the plastics material can be substantially polyurethane or polypropylene or polyethylene or polystyrene or polystyrene foam material or expanded polystyrene foam material. Also the plastics can be ABS material or acrylic material or high impact polystyrene (HIPS) material. For fibrous material an example can be a typical pink-batt (trade mark) and for organic material this can be a fleece material.

The plastics can be open celled or closed celled material. One preferred combination can be substantially polyurethane foam core while the skin 12 can comprise a substantially polyethylene material. Another combination can be at least a polyethylene skin and a polystyrene core or an expanded polystyrene core. The polystyrene core or expanded polystyrene core can be in any suitable physical form. For example the form can be beads, strips, layers or one piece. The core can be simply inserted adjacent to the skin or it can be positively joined.

It is also envisaged that various other insulating layers can be added as necessary. For example, foil(s) and plastics in more than one layer, strip(s) or laminates etc.

The sealing members 17 serve to seal and insulate the particular cavity or compartment that the panel forms. The panel 10 is strong enough to resist normal wear and tear from moving, shifting and impact from forklifts, etc but is conveniently repairable and cleanable. The ability to be able to be cleaned is important from both a hygiene and health perspective.

Other normal use that the panel must withstand can include movement during transportation.

The reinforcing strips or members 18 and 19 and the sealing members 17 can be fabricated from any compressible foam material which can be attached by adhesive or heating or wedging or other means to the outer surface member 12. These members can also be integrally moulded with the panel during its formation.

The outer surface can be formed in any convenient method. For example by moulding such as thermo-forming or non-rotational moulding or rotational moulding, vacuum forming etc or formed separately eg components, kitset. Assembly also can be in any suitable manner.

Initially the outer surface can be rotationally formed. The foam for the core, can be injected or pumped into a first formed outer surface enclosure member or skin 12. Alternatively the outer surface can be integrally formed with the core as a one piece panel. After injection, the foamed core can have the configuration or density which can either gradually vary from the centre to the outside of the core or will utilize an air cavity(ies) or can vary in non graduation or it can be a combination of densities or it can a single density. The core can be less dense in the middle from that of the density of the outer surface. The change in density could mean that the core could be softer towards the central section of the core than the outer region.

This density property is useful in providing good wearing and damage resistance for the outer surface while the less dense inner saves on material and weight. Also the density of the core or foaming having air cells enhances the insulative properties of the panel.

The skin 12 can be pressed or formed with suitable recesses, patterning or profiling which are useful for strength enhancing and or affixing other attachments or allowing for lifting eg handle recesses. For example, the patterning can be in the form of corrugations or dimples etc. Also flaps can be added to the panel to enhance sealing. Inserts with or without threads can also be added to the panel during the moulding process. Also loops can be added or integrally moulded to assist in portability and allow the use of restraining straps to allow the panels to be used more robustly as restraining barrier panels to constrain any stored products.

The panels can be constructed as one-piece panels or they can be made up from modular panels which can then be interlocked or fastened to form at least one standard height panel or standard width panel.

A panel can have recesses formed therein, to allow hingedly attached handles which can be folded or rotated such that they do not protrude from the panel outer surface. Alternatively there maybe no recess and the handles can be hinged flaps. The insulation panel can be formed with vents which can be opened fully or partly by lifting and fixing hinged flaps.

The vents can include apertures either directly through the panel or in an offsetting form with a serpentine pathway. The vents can be formed during manufacture or once the panel is in place kitsets.

The panel core can be formed from an insulative solid or non-solid tubular frame, having a skin applied completely thereover. Any gaps not having the frame can include air or a material having air cavities therein. The frame can also be formed after manufacture of the panel whereby portions are cut out and a second skin or the first skin can be applied over the whole panel or panel section or part thereof.

To those skilled in the art to which the invention relates, many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the scope of the invention as defined in the appended claims. The disclosures and the descriptions herein purely illustrative and are not intended to be in any sense limiting.

To use the panel(s) to insulate an area the following method steps can be used: -install tracking or supports-optional; -slide at least one panel into place with or without seal flaps; -install and or activate hinging/pivoting to enable at least one panel to be movable.

Other variations on these steps are equally possible. In use a panel can also be modular enabling panel to panel jointing. This can be in the form of for example at least two panels joined by a living hinge or a common wall face to enable folding or moving. If the room to be insulated has a track and or hanging tabs and the panel also has protruding tabs with apertures or not. Whereby in use the tabs are paired such that a at least one pin can be attached therethrough each opposing pair of tabs, to enable the panel(s) to be moved or swung into and out of place. This can be achieved in the wall and or ceiling.

Throughout the description and claims of this specification the word "comprise" and variations of that word, such as "includes" and "including", are not intended to exclude other additives, components, integers or steps.

The insulation panel has the following advantages: 1. Easytouse.

2. Efficient insulation.

3. Pleasing appearance.

4. Easy to manufacture.

Modest manufacturing costs.

6. Easy to keep clean.

7. Strong and rugged.

8. Light-weight.

Claims (21)

1. An insulation panel, the panel including a body having an outer surface, a core, and in use the panel having a top, base and sides, wherein the core includes material having a different density from the centre portion to the outer portion.

2. An insulation panel, the panel including a body having an outer surface, a core, and in use the panel having a top, base and sides, wherein the core includes at least an insulation material.

3. An insulation panel as claimed in claims 1 and 2 wherein the outer surface is a skin or skeletal in form.

4. An insulation panel as claimed in claim 3 wherein the outer surface is a separate member. An insulation panel as claimed in claim 4 wherein the core density is less dense in the center portion than the outer portion wherein the density increases away from the centre.

6. An insulation panel as claimed in claim 5 wherein core can be include being in the form of a frame.

7. An insulation panel as claimed in claim 6 wherein the insulation panel is a portable or demountable, modular and or removable bulkhead panel.

8. An insulation panel as claimed in claim 7 wherein the core member includes a closed cell foam material.

9. An insulation panel as claimed in claim 8 wherein the core includes open cell foam material. An insulation panel as claimed in claim 9 wherein the core includes substantially fibrous material.

11. An insulation panel as claimed in claim 10 wherein the core includes substantially organic material

12. An insulation panel as claimed in claim 11 wherein the core includes polyurethane foam material.

13. An insulation panel as claimed in claim 12 wherein the core includes air therein.

14. An insulation panel as claimed in claim 13 wherein the core is a polystyrene material or expanded polystyrene material.

15. An insulation panel as claimed in claim 14 wherein the core is substantially a polyethylene or polypropylene material or polystyrene or ABS material or acrylic or high impact polystyrene (HIPS) material.

16. An insulation panel as claimed in claim 15 wherein the outer surface is substantially a polyethylene or polypropylene material or polystyrene or ABS material or acrylic or high impact polystyrene (HIPS) material.

17. An insulation panel as claimed in claim 16 wherein at least one sealing member is attached to the outer surface member.

18. An insulation panel as claimed in claim 17 wherein the sealing member(s) are or are inflatable members.

19. An insulation panel as claimed in claim 18 wherein the sealing member(s) are flap(s). An insulation panel as claimed in claim 19 wherein reinforcing members are attached to or formed with the sides of the outer surface member of the panel.

21. An insulation panel as claimed in claim 20 wherein reinforcing members are moulded on either the inner or outer surface of the panel.

22. An insulation panel as claimed in claim 21 wherein the panel can have at least one vent there through with or without hingedly attached cover flaps.

23. An insulation panel as claimed in claim 22 wherein the panel can have at least one recessed hingedly attached handle therein.

24. An insulation panel as claimed in claim 23 wherein the panel has attachment means enabling pivoting from another attachment means such that a panel(s) in use can be moved in place or out of place. An insulation panel substantially herein before described with reference to the accompanying drawings. PIPERS Attorneys for the Applicant: Rubbermark Industries Limited