GB2501053A

GB2501053A - Insulating material comprising bubble layers between reflective layers

Info

Publication number: GB2501053A
Application number: GB201121877A
Authority: GB
Inventors: Geoffrey Peter Lyon; Russell William Harrison
Original assignee: Individual
Current assignee: Individual
Priority date: 2011-10-20
Filing date: 2011-12-20
Publication date: 2013-10-16
Also published as: GB201121878D0; GB201121877D0; GB2501863A; GB201118141D0

Abstract

An insulating thermal material comprises a heat bonded, 'crown to crown', double layer, air retention, barrier air sealed, circular bubble closed cell structure (1, 2). This structure (1,2) is preferably constructed of co-extruded plastic bubble film comprising [linear low density polyethylene (LLDPE) or low density polyethylene (LDPE)], high density polyethylene (HDPE) and nylon (polyarnide (PA)) laminated to and interposed between two outer reflective layers (3, 4). Both of the outer reflective layers (3, 4) comprise vacuum applied aluminium metallised co-extruded bioriented polypropylene (BOPP). The double layer barrier sealed circular bubble closed cell structure comprises a plurality of cells (5) which contain air.

Description

INSULATING MATERIAL

This invention relates to insulating material.

There are numerous and various types of insulation currently in use such as fibreglass, foam, wool, polystyrene and air cell bubble, These provide usefiul emissive thermal properties as a heat loss or gain barrier insofar as conduction is concerned but are Car less effective in relation to heat loss or gain by radiation unless they have a reflective outer layer. In the main these reflective insulation products have been proven to have excellent R and U values and are used extensively in the construction industry in commercial buildings and domestic dwellings to maintain a warm interior in winter and a cool interior in summer.

The present invention relates to an alternative insulating material.

According to the present invention there is provided an insulating material comprising at least two layers of sealed bubbles, the bubbles having a closed cell structure, the layers being provided between the outer layers of reflective material.

The invcntion has been devised particularly, but not solely, to afford an extremely high level of thennal protection, be it from either heating or cooling, for temperature sensitive goods, he they at ambient temperature, frozen or chilled, Ihe invention has application in providing thermal protection for a wide range of perishable products such as foodstuffs, cosmetics, chemicals and pharmaceuticals.

In various converted applicable applications the invention will have a truly dramatic energy reducing, fuel saving, carbon footprint lowering, cost saving impact on all manner of electrical, diesel, oil and petrol powcred mechanical refrigeration devices, machines and appliances, commercial and industrial builds and installations and other such huge fuel consumers and carbon producers as the road haulage industry and air cargo operators.

The relatively narrow gauge reflective, laminated air cell insulator of the invention exhibits excellent thermal, radiative and anti static properties, maintaining strict hot, cold and chill conditions for temperature sensitive goods, as outlined above. This being the case there is a cascade effect which reciprocally and drastically impacts on fuel consumption by reducing the normally applied loads on the energy sources required to maintain critical temperate conditions as these are now being extremely and sympathetically aided by the insulator. As thc gauge is relatively modest compared to conventional insulation, there is scope for cubic size and weight reduction in shipping and transport units and material may be applied as retro fit to already assembled structures dramatically increasing thermal properties whilst having little effect on internal volume capability of the installation, In new builds of say road trailers, axle weights may be reduced by over four tonnes.

In a preferred embodiment the invention comprises an insulating thermal material comprising a heat bonded, crown to crown, double layer, of air retention, barrier air sealed, circular bubble, closed cell structure constructed of co-extruded plastic bubble film comprising linear low density polyethylene (LDPE) and linear high density polyethylene (lIDPE) and nylon polyamide (PA), such as NYLON (trade mark) which is laminated to and interposed between two outer high brilliance reflective layers. Both of the reflective layers may comprise metallised OPP (orientated polypropylene) laminate co-extruded heat-sealable bi-oriented polypropylene film adhesive laminated to a one-side metaflised 20sm co-extruded heat-sealable bi-oriented polypropylene film with the metal layer sandwiched between the two polypropylene film layers. Each film is a 3-layer structure with a core layer of polypropylene and two outside layers of heat-sealable film made ftom two or more polymers. One surface is corona treated for print or adhesive lamination. Each film thickncsscs can vary from 15 micron to 50 micron or combinations thereof. The film is metallised by depositing aluminium on one surface of thc film using a vacuum metallisation process to an optical density of typically 2.0. Other optical densities are available as required, This may be made by one of a number of different techniques using solvent or solventless lamination systems and is generally a 2-component curing polyurethane adhesive. The insulation material of the invention works within the confines and controls of NDA directives, and has been developed, tested and proven to deliver dramatic and outstanding performance as follows: reduction in carbon emission with returns as low as zero in some applications, reduced fuel consumption by a huge percentage delivering massive cost savings and most importantly carving a huge chunk off carbon footprints where applied.

l'he present invention has been made with a view to reducing carbon emissions.

In order that the present invention may be more readily understood a specific embodiment thereof will now be described by way of example only with reference to the accompanying drawings in which:-Figure 1 is a schematic perspective view of the insulating material of the invention, including metalised reflective insulation, indicating the outer layers and cclluktr structure; Figure 2 is a schematic view of the insulating material's metalised reflective insulation with part of an exterior layer peeled back to reveal the cellular structure; Figurc 3 is a cross scction of the material along the line A-A of Figure 1; Figure 4 is a fragmentary cross section of the material along the line A-A of Figure 1.

Referring to the drawings an insulating thermal material in accordance with the invention comprises a heat bonded, crown to crown, double layer, of air retention barrier air sealed, circular bubble, closed cell structure constructed of co-extruded pla'tic bubble film 1, 2 comprising linear low density polyethylene (LDPE), linear high density polyethylene (HDPE) and polyamide (PA), such as NYLON (trade mark). The air retention barrier air sealed bubble material of the invcntion is a hundred times more resistant to the passage of air than a thielcer single layer of polythene bubble. Every bubble 5 is sealed against air loss and is resistant to compression degenerationlbursting. This heat bonded crown to crown' amalgamation of two layers of bubble ifim is laminated to and interposed between two outer high brilliance reflective layers 3, 4, both of which comprise metallised OPP Laminate co- extruded heat-sealable hi-oriented polypropylene film adhesive laminated to a one-side metallised 20sm co-extruded heat-sealable hi-oriented polypropylene film with the metal layer sandwiched between the two polypropylene film layers. Each film is a 3-layer structure with a core layer of polypropylene and two outside layers of heat-sealable film made from two or more polymers. One surface is corona treated for print or adhesive lamination. Each film thicknesses can vary from 15 micron to 50 micron or combinations thereof. The film is metallised by depositing aluminium on one surface of the film using a vacuum metallisation process to an optical density of typically 2.0, Other optical densities are available as required. This may be made by one of a number of different teelmiques using solvent or solventless lamination systems and is generally a 2-component curing polyurethane adhesive. The two outer layers of the laminated sandwich' may comprise a different co-extruded material such as, but not limited to, for example, aluminium foil with a bonded anti corrosion filmllaquer applied to the outer exposed face or polycarbonate sheet. Different materials may be provided on one side to the other dependent on application demands or frmnctional requirements. The double layer heat bonded barrier air sealed circular bubble closed cell structure comprises a plurality of cells which contain air. The dimensions of the width/diameter of the cell is related to the depth of the cell and will increase or decrease as applications dictate, but without adverse effect on the overall thermal capability except if the cells were of greater diameter than 32mm whereas there is a tendency for the exterior metallised layers to fall into each other' and to come into contact with each other between the cells forming a negative thermal abridgment.

Colourless barrier sealed closed cell double bubble; produced from film of low and high density polypropylene and polyamide (LDPE/HDPE & PA) laminated to a metallised OPP laminate, reflective, high brilliance, co-extruded, bioriented, (OPP) exterior film on both sides. This combination provides for a high degree of prevention of einissive heat or cold thermal transfer by conduction and extremely high degrees of prevention of radiative heat or cold thermal transfer from either side of the insulation material incorporating a high barrier to humidity and to the forming of condensation.

The high surface tension and inter-ply bond strength of the metallised exterior film affords enhanced tensile strength to the laminated sandwich'. The exterior metalliscd brilliant film can have a colour applied to tone down the reflective glare characteristic should applications dictate. The two outer layers of the laminated sandwich' may comprise a different co-extruded material such as but not limited to, for example, aluminium foil with a bonded anti corrosion filmllaquer applied to thc outer exposed face or polycarbonate sheet or differing materials on one side than the other dependent on application demands or functional requirements.

It is to be understood that the above described embodiment is by way of illustration only. Many modifications and variations are possible.

Claims

CLAIMSI. A thermal insulating material comprising at least two layers of sealed bubbles, the hubbies having a closed cell structure, the layers being provided between outer layers of reflective material.
2. An insulating material as claimed in claim I, comprising a crown to crown double layer of sealed bubbles.
3. An insulating material as claimed in claim 1 or claim 2, wherein the bubbles comprise air.
4. An insulating material as claimed in any preceding claim, wherein one layer of bubbles is heat bonded to another layer of bubbles.
5. An insulating material as claimed in any preceding claim, wherein the bubble layers are a heat bonded, crown to crown double layer of air retention barrier air sealed, circular bubble, closed cell structure.
6. An insulating material as claimed in claim 5, wherein the bubble layers are constructed of co-extruded plastic bubble film comprising linear low density polyethylene (LDPE) and linear high density polyethylene (HDPE) and polyamide (PA).
7. An insulating material as claimed in any preceding claim, wherein the bubble layers are laminated to and interposed between two outer optionally high brilliance, reflective layers.
8. An insulating material as claimed in claim 7, wherein the reflective layers comprise a laminated layer of vacuum applied, optionally high brilliance, aluminium metallised film co-extruded with two bioriented polypropylene (OPP) upper and lower adhesive films.
9. An insulating material as claimed in claim 8, wherein three laminated layers of film are co-extruded to form the OPP.
10. An insulating material as claimed in claim 1, wherein the heat bonded crown to crown' amalgamation of two layers of air retention barrier air sealed circular bubble closed cell structure comprises a plurality of cells which contain air.
11. An insulating material as claimed in claim 1, wherein at least one of the two outer layers of the laminated sandwich' comprises aluminium foil, optionally with a bonded anti corrosion film or polycarbonate sheet applied to the outer exposed face of the aluminium foil.
12. An insulating material as claimed in claim 1, wherein every bubble is sealed against air loss and is resistant to compression degeneration/bursting.
13. An insulating material as claimed in claim I, in which the matcrial is anti-stafic.
14, An insulating material as claimed in claim 1, in which the material is non toxic, irritant and CEC free.
15. An insulating material as claimed in claim 1, in which the material is 100% water resistant.
16. An insulating material as claimed in claim 1, in which the material is resistant to fungal attack such as mildew.
17. An insulating material as claimed in claim 1, in which the material is retardant to rodent attack.