EP3344452A1 - Multi-layered reflective insulation system - Google Patents

Multi-layered reflective insulation system

Info

Publication number
EP3344452A1
EP3344452A1 EP16842919.9A EP16842919A EP3344452A1 EP 3344452 A1 EP3344452 A1 EP 3344452A1 EP 16842919 A EP16842919 A EP 16842919A EP 3344452 A1 EP3344452 A1 EP 3344452A1
Authority
EP
European Patent Office
Prior art keywords
layer
scattering optic
optic layer
layers
scattering
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP16842919.9A
Other languages
German (de)
French (fr)
Other versions
EP3344452A4 (en
Inventor
Dennis Grubb
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Efx Energy Technologies LLC
Original Assignee
Efx Energy Technologies LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Efx Energy Technologies LLC filed Critical Efx Energy Technologies LLC
Publication of EP3344452A1 publication Critical patent/EP3344452A1/en
Publication of EP3344452A4 publication Critical patent/EP3344452A4/en
Withdrawn legal-status Critical Current

Links

Classifications

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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/32—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed at least two layers being foamed and next to each other
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    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
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    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
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    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/30—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being formed of particles, e.g. chips, granules, powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
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    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
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    • F16L59/029—Shape or form of insulating materials, with or without coverings integral with the insulating materials layered
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L59/00—Thermal insulation in general
    • F16L59/08—Means for preventing radiation, e.g. with metal foil
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    • E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B2001/7691—Heat reflecting layers or coatings

Definitions

  • the present invention relates generally to multi-layered reflective insulating composites and a method of fabricating those composites.
  • the present invention recognizes the importance of recognizing the behavior of mid-range infrared (IR) as a form of electromagnetic radiation other than x-rays, visible light, or radio waves, for example.
  • IR infrared
  • plastics In plastics, a result of this is that relatively simple, linear polymers using a few elements like polyethylene or polypropylene are nearly transparent to IR whereas plastics including more complex, non-linear polymers using many elements like polyurethane or polyetherimide are very opaque (or absorbent). This often remains true regardless of visible appearances which, again, may differ greatly.
  • the present invention comprises a low density, thermally insulating multi-layered reflective insulation system.
  • the multi-layered reflective insulation of the present invention comprises a plurality of layers, including, but not limited to, a combination of any number of the following layers disposed on each other: scattering optics, multi-layer insulation, microsphere film, and polyblend foam.
  • US 44421 65 A to Gebhardt, Joseph J., et al., entitled “Low-Density Thermally Insulating Carbon- Carbon Syntactic Foam Composite”, discloses an insulating composite comprising a syntactic foam material, pyrolytic graphite, and a boron in layer which enables the composite to reflect infrared energy.
  • Composition discloses an insulating syntactic foam composition.
  • the present invention provides a low density, thermally insulating multi-layered reflective insulation system that is easy to install, offers increased R-value resulting in increased insulation, and cost effective.
  • the present invention comprises a multi-layered reflective insulation system comprising a first protective layer; a first scattering optic layer; microsphere film layers; a polyblend foam layer; a second scattering optic layer; and a second protective layer.
  • the present invention also comprises a method of manufacture of a multi-layered reflective insulation system comprising a first protective layer; a first scattering optic layer; microsphere film layers; a polyblend foam layer; a second scattering optic layer; a second protective layer; securably disposing the layers on top of each other; and securably attaching the layers.
  • FIG. 1 illustrates a partial sectional isometric view of the multi-layered reflective insulation system of the present invention
  • FIG. 2 illustrates a partial sectional view of one embodiment of the embossed tile pattern of the scattering optic layer.
  • the term “horizontal” as used herein is defined as a plane parallel to the plane or surface of the insulation system, regardless of its orientation.
  • the term “vertical” refers to a direction perpendicular to the horizontal as just defined. Terms, such as “above”, “below”, “bottom”, “top”, “side”, “higher”, “lower”, “upper”, “over”, and “under”, are defined with respect to the horizontal plane, as shown in the figures.
  • the term “on” means that there is direct contact among elements.
  • FIG. 1 illustrates a partial sectional isometric view of the multi-layered reflective insulation system of the present invention.
  • Multi-layered reflective insulation system 101 comprises a plurality of layers, including, but not limited to, any combination of any number of the following layers disposed on each other: first protective layer 102; first scattering optic layer 103; microsphere film layers 104 and 104' ; polyblend foam layer 105; second scattering optic layer 106; and second protective layer 107.
  • the layers of multi-layered reflective insulation system 101 are arranged in the following order: first protective layer 102; first scattering optic layer 103; microsphere film layer 104; polyblend foam layer 105; microsphere film layer 104' ; second scattering optic layer 106; and second protective layer 107.
  • the layers of the multi-layered reflective insulation system 101 are disposed on each other and securably attached using a glue, resin, or other attaching material or process.
  • FIG. 2 illustrates a partial sectional view of one embodiment of the tile pattern of first scattering optic layer 103 and/or second scattering optic layer 106 of the present invention.
  • scattering optics of scattering optic pattern 201 are embossed in a hexagonal pattern.
  • First protective layer 102 and second protective layer 107 comprise a plastic, or other infrared transparent protective film, that acts as an infrared transparent protective film.
  • First scattering optic layer 103 and second scattering optic layer 106 comprise a film with an embossed pattern on a polymer foam. This layer provides reflective insulation.
  • the film with an embossed pattern of first scattering optic layer 103 and second scattering optic layer 106 are disposed on a polymer or copolymer foam.
  • the film with an embossed pattern of first scattering optic layer 103 and second scattering optic layer 106 is copper or copper-colored.
  • the film with an embossed pattern of first scattering optic layer 103 and second scattering optic layer 106 is aluminum or aluminum-colored. Aluminum is preferred for visible light, while copper is preferred for infrared light.
  • First scattering optic layer 103 and second scattering optic layer 106 reflect heat.
  • the multi-layered reflective insulation system 101 keeps warm or cold air in an enclosure or structure insulated with multi-layered reflective insulation system 101 , while reflecting warm or cold air from the outside.
  • the first scattering optic layer 103 and second scattering optic layer 106 act as a first barrier to reflect visible and infrared light. Any combination of copper, aluminum, or any metal that aids in reflectance of IR energy can be used on first scattering optic layer 103 and second scattering optic layer 106.
  • the embossed pattern of first scattering optic layer 103 and/or second scattering optic layer 106 comprise a hexagonal pattern.
  • the embossed pattern of first scattering optic layer 103 and/or second scattering optic layer 106 comprise a tiled pattern.
  • the embossed pattern of first scattering optic layer 103 and/or second scattering optic layer 106 comprise a polygon pattern.
  • the pattern of first scattering optic layer 103 and/or second scattering optic layer 106 comprise a non-embossed pattern.
  • first scattering optic layer 103 and/or second scattering optic layer 106 comprise no embossed or non-embossed pattern.
  • First scattering optic layer 103 and second scattering optic layer 106 can compromise any combination of the aforementioned embodiments.
  • the reflective film of first scattering optic layer 103 and second scattering optic layer 106 comprise Tyvek or other water-resistant, but vapor permeable, polymer textile.
  • This reflective film may or may not be disposed on the film with an embossed pattern, which may or may not be disposed on a polymer or copolymer foam.
  • Infrared transparent materials for retro-reflective microspheres including, but not limited to, glass or plastic, boost reflectivity of a first reflective surface or use of multi-layer infrared reflective films with infrared transparent scrims in a reflective insulation.
  • Microsphere film layers 104 and 104' comprise a plurality of polymers as a manufacturing adhesive and/or particle carrier of microspheres.
  • the microspheres reflect IR energy, thus aiding in overall performance and improved R-value of the multi-layered reflective insulation system 101.
  • Microsphere film layers 104 and 104' further comprise a plurality of phase-change material microspheres for temperature management or polymer microspheres that serve as conductive and radiative insulation.
  • Microsphere film layers 104 and 104' further comprise ceramic or glass microspheres that serve as conductive and radiative insulation.
  • microspheres acting as infrared retroreflectors of microsphere film layers 104 and 104' are disposed directly onto polyblend foam layer 105.
  • the microspheres acting as infrared retroreflectors of microsphere film layers 104 and 104' are made of germanium.
  • the microspheres acting as infrared retroreflectors of microsphere film layers 104 and 104' are any microspheres that aid in IR reflective energy and that improve the overall R-value of the multi-layered reflective insulation system 101.
  • microsphere film layers 104 and 104' comprise a syntactic foam.
  • Polyblend foam layer 105 comprises a polymer or copolymer with or without a fire retardant.
  • the copolymer of the polyblend foam layer 105 comprises ethylene-vinyl acetate, low-density polyethylene, or any combination of the two.
  • the copolymer of the polyblend foam layer 105 comprises, at least in part, polyethylene-vinyl acetate.
  • the copolymer of the polyblend foam layer 105 comprises a polymer alloy foam.
  • the polymer or copolymer of polyblend foam layer 105 comprises, at least in part, microspheres. The polymer or copolymer is melted and then the microspheres are added. The mixture is then cooled and may be extruded and turned into pellets. The pellets are then turned into polyblend foam layer 105.
  • multi-layered reflective insulation system 101 comprises a plurality of layers.
  • the layers of the multi-layered reflective insulation system 101 are disposed on each other and securably attached using a glue, resin, or other attaching material or process.
  • holes are displaced through multi-layered reflective insulation system 101.
  • the addition of the holes allows for air permeability.
  • the holes are formed by insertion of heated piercing means through multi-layered reflective insulation system 101. This ensures the holes have closed edges and will not close with the change of the environmental temperature.
  • the holes can be arranged in any pattern or randomly.
  • the holes are formed by punching means, with or without the addition of heat to the punching means.
  • the holes are formed by piercing means, without the addition of heat to the piercing means.
  • Prior art insulation systems do not include melted holes, copper/aluminum scattering optics layers, and/or microspheres as used in the present invention.
  • the present invention provides the following improvements over prior art insulation systems, including, but not limited to, cost and increased R-value.

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Abstract

The present invention relates generally to multi-layered reflective insulating composites and a method of fabricating those composites. The present invention comprises a multi-layered reflective insulation system comprising a first protective layer; a first scattering optic layer; microsphere film layers; a polyblend foam layer; a second scattering optic layer; and a second protective layer. The present invention also comprises a method of manufacture of a multi-layered reflective insulation system comprising a first protective layer; a first scattering optic layer; microsphere film layers; a polyblend foam layer; a second scattering optic layer; a second protective layer; securably disposing the layers on top of each other; and securably attaching the layers. The multi-layered reflective insulation system provides a cost-effective and efficient insulation system.

Description

MULTI-LAYERED REFLECTIVE INSULATION SYSTEM
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 62212486 filed August 31 , 2015, titled "MULTI-LAYERED REFLECTIVE INSULATION SYSTEM" and the subject matter thereof is incorporated herein by reference thereto.
TECHNICAL FIELD
The present invention relates generally to multi-layered reflective insulating composites and a method of fabricating those composites.
BACKGROUND ART
The present invention recognizes the importance of recognizing the behavior of mid-range infrared (IR) as a form of electromagnetic radiation other than x-rays, visible light, or radio waves, for example. There is no guarantee that what we see as transparent, opaque, or reflective always corresponds with the same optical properties in IR. Oftentimes materials that appear transparent in the visible range are opaque in the IR and vice versa. Whereas we see wavelengths from about 400 nm (Violet) to 700 nm (Red), most terrestrial objects radiate according to Planck's Law in the range of 2,000 nm to 130,000 nm with the range of peak emissions spanning 8,430 nm at 70.7° C/159.3° F to 16,240 at - 94.7° C/-135.8 ° F. Thus, the physical difference in spectrum is very large.
In the IR range of the electromagnetic spectrum, while multiple metals can be used successfully as a reflector, gold, silver, and copper are the most effective. Aluminum is frequently used because of its low cost; however, silver and aluminum both form oxides detrimental to IR reflectivity very rapidly, whereas gold and copper do not. While widely publicized that CO2 is a greenhouse gas, it is often not explained the exact mechanism by which this occurs. Additionally, it becomes a leap of perspective to realize that the same mechanism which applies to CO2 also applies to solid and liquid states of matter. Because of the large size of wavelength of mid-range infrared electromagnetic radiation, this size corresponds to harmonics of various states of different bond lengths found in organic materials. In plastics, a result of this is that relatively simple, linear polymers using a few elements like polyethylene or polypropylene are nearly transparent to IR whereas plastics including more complex, non-linear polymers using many elements like polyurethane or polyetherimide are very opaque (or absorbent). This often remains true regardless of visible appearances which, again, may differ greatly.
The present invention comprises a low density, thermally insulating multi-layered reflective insulation system. The multi-layered reflective insulation of the present invention comprises a plurality of layers, including, but not limited to, a combination of any number of the following layers disposed on each other: scattering optics, multi-layer insulation, microsphere film, and polyblend foam.
Various prior art exists in the prior art that disclose multi-layered insulating composites, but each of these have shortcoming which the present invention overcomes.
US 44421 65 A to Gebhardt, Joseph J., et al., entitled "Low-Density Thermally Insulating Carbon- Carbon Syntactic Foam Composite", discloses an insulating composite comprising a syntactic foam material, pyrolytic graphite, and a boron in layer which enables the composite to reflect infrared energy.
US 6858280 B2 to Allen, Mark S., et al., entitled "Microsphere Insulation Systems", discloses microsphere insulation systems whereby particles reduce heat transfer through reflection and scattering.
US 8857700 B2 to Jackson, Adam, et al., entitled "Low Temperature Method for Forming Field Joints on Undersea Pipelines", discloses insulation layers including microspheres.
US 8397765 B2 to Jackson, Peter, et al., entitled "High Temperature Resistant Insulation for Pipe", discloses thermal foam insulation layers with micro-spheres.
US 6284809 B1 to Plummer, John, et al., entitled "Thermally Insulating Syntactic Foam
Composition", discloses an insulating syntactic foam composition.
Although the above-referenced patents disclose insulation systems, the present invention provides a low density, thermally insulating multi-layered reflective insulation system that is easy to install, offers increased R-value resulting in increased insulation, and cost effective.
Certain embodiments of the invention have other steps or elements in addition to or in place of those mentioned above. The steps or element will become apparent to those skilled in the art from a reading of the following detailed description when taken with reference to the accompanying figures. SUMMARY OF THE INVENTION
The present invention comprises a multi-layered reflective insulation system comprising a first protective layer; a first scattering optic layer; microsphere film layers; a polyblend foam layer; a second scattering optic layer; and a second protective layer.
The present invention also comprises a method of manufacture of a multi-layered reflective insulation system comprising a first protective layer; a first scattering optic layer; microsphere film layers; a polyblend foam layer; a second scattering optic layer; a second protective layer; securably disposing the layers on top of each other; and securably attaching the layers. BRI EF DESCRI PTION OF THE DRAW INGS
FIG. 1 illustrates a partial sectional isometric view of the multi-layered reflective insulation system of the present invention ; and
FIG. 2 illustrates a partial sectional view of one embodiment of the embossed tile pattern of the scattering optic layer.
DETAILED DESCRI PTION OF THE INVENTION
The best mode for carrying out the invention will be described herein. The following embodiments are described in sufficient detail to enable those skilled in the art to make and use the invention . It is to be understood that other embodiments would be evident based on the present disclosure, and that system, process, or mechanical changes may be made without departing from the scope of the present invention.
In the following description, numerous specific details are given to provide a thorough understanding of the invention . However, it will be apparent that the invention may be practiced without these specific details. In order to avoid obscuring the present invention, some well-known system configurations, and process steps are not disclosed in detail.
The figures illustrating embodiments of the system are semi-diagrammatic and not to scale and , particularly, some of the dimensions are for the clarity of presentation and are shown exaggerated in the drawing figures. The same numbers are used in all the drawing figures to relate to the same elements. Alternate embodiments have been included throughout, and the order of such are not intended to have any other significance or provide limitations for the present invention.
For expository purposes, the term "horizontal" as used herein is defined as a plane parallel to the plane or surface of the insulation system, regardless of its orientation. The term "vertical" refers to a direction perpendicular to the horizontal as just defined. Terms, such as "above", "below", "bottom", "top", "side", "higher", "lower", "upper", "over", and "under", are defined with respect to the horizontal plane, as shown in the figures. The term "on" means that there is direct contact among elements.
FIG. 1 illustrates a partial sectional isometric view of the multi-layered reflective insulation system of the present invention. Multi-layered reflective insulation system 101 comprises a plurality of layers, including, but not limited to, any combination of any number of the following layers disposed on each other: first protective layer 102; first scattering optic layer 103; microsphere film layers 104 and 104' ; polyblend foam layer 105; second scattering optic layer 106; and second protective layer 107. In the preferred embodiment of the present invention, the layers of multi-layered reflective insulation system 101 are arranged in the following order: first protective layer 102; first scattering optic layer 103; microsphere film layer 104; polyblend foam layer 105; microsphere film layer 104' ; second scattering optic layer 106; and second protective layer 107. The layers of the multi-layered reflective insulation system 101 are disposed on each other and securably attached using a glue, resin, or other attaching material or process.
FIG. 2 illustrates a partial sectional view of one embodiment of the tile pattern of first scattering optic layer 103 and/or second scattering optic layer 106 of the present invention. In the preferred embodiment, scattering optics of scattering optic pattern 201 are embossed in a hexagonal pattern.
First protective layer 102 and second protective layer 107 comprise a plastic, or other infrared transparent protective film, that acts as an infrared transparent protective film.
First scattering optic layer 103 and second scattering optic layer 106 comprise a film with an embossed pattern on a polymer foam. This layer provides reflective insulation. The film with an embossed pattern of first scattering optic layer 103 and second scattering optic layer 106 are disposed on a polymer or copolymer foam. In an alternate embodiment of the present invention, the film with an embossed pattern of first scattering optic layer 103 and second scattering optic layer 106 is copper or copper-colored. In an alternate embodiment of the present invention, the film with an embossed pattern of first scattering optic layer 103 and second scattering optic layer 106 is aluminum or aluminum-colored. Aluminum is preferred for visible light, while copper is preferred for infrared light. First scattering optic layer 103 and second scattering optic layer 106 reflect heat. The multi-layered reflective insulation system 101 keeps warm or cold air in an enclosure or structure insulated with multi-layered reflective insulation system 101 , while reflecting warm or cold air from the outside. The first scattering optic layer 103 and second scattering optic layer 106 act as a first barrier to reflect visible and infrared light. Any combination of copper, aluminum, or any metal that aids in reflectance of IR energy can be used on first scattering optic layer 103 and second scattering optic layer 106.
In an alternate embodiment of the present invention, the embossed pattern of first scattering optic layer 103 and/or second scattering optic layer 106 comprise a hexagonal pattern.
In an alternate embodiment of the present invention, the embossed pattern of first scattering optic layer 103 and/or second scattering optic layer 106 comprise a tiled pattern.
In an alternate embodiment of the present invention, the embossed pattern of first scattering optic layer 103 and/or second scattering optic layer 106 comprise a polygon pattern.
In an alternate embodiment of the present invention, the pattern of first scattering optic layer 103 and/or second scattering optic layer 106 comprise a non-embossed pattern.
In an alternate embodiment of the present invention, first scattering optic layer 103 and/or second scattering optic layer 106 comprise no embossed or non-embossed pattern.
First scattering optic layer 103 and second scattering optic layer 106 can compromise any combination of the aforementioned embodiments.
In an alternate embodiment of the present invention, the reflective film of first scattering optic layer 103 and second scattering optic layer 106 comprise Tyvek or other water-resistant, but vapor permeable, polymer textile. This reflective film may or may not be disposed on the film with an embossed pattern, which may or may not be disposed on a polymer or copolymer foam. Infrared transparent materials for retro-reflective microspheres, including, but not limited to, glass or plastic, boost reflectivity of a first reflective surface or use of multi-layer infrared reflective films with infrared transparent scrims in a reflective insulation.
Microsphere film layers 104 and 104' comprise a plurality of polymers as a manufacturing adhesive and/or particle carrier of microspheres. The microspheres reflect IR energy, thus aiding in overall performance and improved R-value of the multi-layered reflective insulation system 101. Microsphere film layers 104 and 104' further comprise a plurality of phase-change material microspheres for temperature management or polymer microspheres that serve as conductive and radiative insulation. Microsphere film layers 104 and 104' further comprise ceramic or glass microspheres that serve as conductive and radiative insulation.
In an alternate embodiment of the present invention, the microspheres acting as infrared retroreflectors of microsphere film layers 104 and 104' are disposed directly onto polyblend foam layer 105.
In an alternate embodiment of the present invention, the microspheres acting as infrared retroreflectors of microsphere film layers 104 and 104' are made of germanium.
In an alternate embodiment of the present invention, the microspheres acting as infrared retroreflectors of microsphere film layers 104 and 104' are any microspheres that aid in IR reflective energy and that improve the overall R-value of the multi-layered reflective insulation system 101.
In an alternate embodiment of the present invention, microsphere film layers 104 and 104' comprise a syntactic foam.
Polyblend foam layer 105 comprises a polymer or copolymer with or without a fire retardant. In an alternate embodiment of the present invention, the copolymer of the polyblend foam layer 105 comprises ethylene-vinyl acetate, low-density polyethylene, or any combination of the two.
In an alternate embodiment of the present invention, the copolymer of the polyblend foam layer 105 comprises, at least in part, polyethylene-vinyl acetate.
In an alternate embodiment of the present invention, the copolymer of the polyblend foam layer 105 comprises a polymer alloy foam. In an alternate embodiment of the present invention, the polymer or copolymer of polyblend foam layer 105 comprises, at least in part, microspheres. The polymer or copolymer is melted and then the microspheres are added. The mixture is then cooled and may be extruded and turned into pellets. The pellets are then turned into polyblend foam layer 105.
In alternate embodiments of the present invention, multi-layered reflective insulation system 101 comprises a plurality of layers. The layers of the multi-layered reflective insulation system 101 are disposed on each other and securably attached using a glue, resin, or other attaching material or process.
In an alternate embodiment of the present invention, holes are displaced through multi-layered reflective insulation system 101. The addition of the holes allows for air permeability. In the preferred embodiment of the present invention, the holes are formed by insertion of heated piercing means through multi-layered reflective insulation system 101. This ensures the holes have closed edges and will not close with the change of the environmental temperature. The holes can be arranged in any pattern or randomly. In an alternate embodiment of the present invention, the holes are formed by punching means, with or without the addition of heat to the punching means. In an alternate embodiment of the present invention, the holes are formed by piercing means, without the addition of heat to the piercing means.
Prior art insulation systems do not include melted holes, copper/aluminum scattering optics layers, and/or microspheres as used in the present invention. The present invention provides the following improvements over prior art insulation systems, including, but not limited to, cost and increased R-value.
While the invention has been described in conjunction with a specific best mode, it is to be understood that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications, and variations that fall within the scope of the included claims. All matters previously set forth herein or shown in the accompanying drawings are to be interpreted in an illustrative and non- limiting sense.

Claims

CLAIMS What is claimed is:
1 . A low density, thermally insulating composite comprising:
a first protective layer;
a first scattering optic layer;
microsphere film layers;
a polyblend foam layer;
a second scattering optic layer; and
a second protective layer.
2. A low density, thermally insulating composite according to claim 1 , whereby said polyblend foam layer includes microspheres.
3. A low density, thermally insulating composite according to claim 1 , whereby said first scattering optic layer and second scattering optic layer comprise metal that aids in reflectance of IR energy.
4. A low density, thermally insulating composite according to claim 1 , whereby said first scattering optic layer and second scattering optic layer each comprise a different metal that aids in reflectance of IR energy.
5. A low density, thermally insulating composite according to claim 1 , whereby said first scattering optic layer and second scattering optic layer include a pattern.
6. A low density, thermally insulating composite according to claim 1 , comprising any combination of one or more of the layers in any order.
7. A method of fabricating a low density, thermally insulating composite comprising: a first protective layer;
a first scattering optic layer;
microsphere film layers;
a polyblend foam layer;
a second scattering optic layer;
a second protective layer;
securably disposing the layers on top of each other; and
securably attaching the layers.
8. A method of fabricating a low density, thermally insulating composite according to claim 7, whereby holes are displaced throughout.
9. A method of fabricating a low density, thermally insulating composite according to claim 7, whereby any combination of one or more of the layers in any order are securably disposed on top of each other and securably attached.
EP16842919.9A 2015-08-31 2016-08-31 Multi-layered reflective insulation system Withdrawn EP3344452A4 (en)

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PCT/US2016/049725 WO2017040683A1 (en) 2015-08-31 2016-08-31 Multi-layered reflective insulation system

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US3619340A (en) * 1969-01-21 1971-11-09 Peter Jones Multilayered thermal insulation material
US4303729A (en) * 1979-07-20 1981-12-01 Torobin Leonard B Hollow plastic microspheres
US4442165A (en) * 1981-03-26 1984-04-10 General Electric Co. Low-density thermally insulating carbon-carbon syntactic foam composite
DE19914105A1 (en) * 1999-03-23 2000-09-28 Wolfgang Reimann Heat insulating plates, comprises expanded and extruded polystyrol or PUR with a thin coating of ceramic or glass ceramic hollow spheres embedded in a carrier
US6284809B1 (en) * 1999-12-07 2001-09-04 Emerson & Cuming Composite Materials Inc. Thermally insulating syntactic foam composition
US6797356B2 (en) * 2001-02-27 2004-09-28 Cgi Silvercote Inc. Reflective insulation
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