GB2507325A - Composite insulation including gas filled pockets - Google Patents

Composite insulation including gas filled pockets Download PDF

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Publication number
GB2507325A
GB2507325A GB1219304.1A GB201219304A GB2507325A GB 2507325 A GB2507325 A GB 2507325A GB 201219304 A GB201219304 A GB 201219304A GB 2507325 A GB2507325 A GB 2507325A
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GB
United Kingdom
Prior art keywords
layer
insulation member
gas
pockets
skins
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Withdrawn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
GB1219304.1A
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GB201219304D0 (en
Inventor
Paul Mitton
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Euroform Products Ltd
Original Assignee
Euroform Products Ltd
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Filing date
Publication date
Application filed by Euroform Products Ltd filed Critical Euroform Products Ltd
Priority to GB1219304.1A priority Critical patent/GB2507325A/en
Publication of GB201219304D0 publication Critical patent/GB201219304D0/en
Publication of GB2507325A publication Critical patent/GB2507325A/en
Withdrawn legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/28—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • 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
    • 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
    • E04B1/78—Heat insulating elements
    • E04B1/80—Heat insulating elements slab-shaped
    • E04B1/806—Heat insulating elements slab-shaped with air or gas pockets included in the slab
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • 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
    • B32B15/08—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 of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/10—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/42—Alternating layers, e.g. ABAB(C), AABBAABB(C)
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/10—Fibres of continuous length
    • B32B2305/18—Fabrics, textiles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B32B2307/102—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2311/00—Metals, their alloys or their compounds
    • B32B2311/24—Aluminium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2315/00—Other materials containing non-metallic inorganic compounds not provided for in groups B32B2311/00 - B32B2313/04
    • B32B2315/08—Glass
    • B32B2315/085—Glass fiber cloth or fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2317/00—Animal or vegetable based
    • B32B2317/12—Paper, e.g. cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2323/00—Polyalkenes
    • B32B2323/04—Polyethylene
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • 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
    • E04B1/88—Insulating elements for both heat and sound
    • E04B1/90—Insulating elements for both heat and sound slab-shaped
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • 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
    • E04B2001/742—Use of special materials; Materials having special structures or shape
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • 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
    • E04B2001/742—Use of special materials; Materials having special structures or shape
    • E04B2001/747—Corrugated materials
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • 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
    • E04B1/82—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 sound only
    • E04B1/84—Sound-absorbing elements
    • E04B2001/8457—Solid slabs or blocks
    • E04B2001/8461—Solid slabs or blocks layered
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A30/00—Adapting or protecting infrastructure or their operation
    • Y02A30/24—Structural elements or technologies for improving thermal insulation
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B80/00—Architectural or constructional elements improving the thermal performance of buildings
    • Y02B80/10—Insulation, e.g. vacuum or aerogel insulation

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  • Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Acoustics & Sound (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

The insulation sheet or panel comprises sealed gas filled pockets 103 between a polymeric layer 102 and another layer 101, 106; fluid flow between the pockets 103 is prevented. The insulating gas has a lower thermal conductivity than air, and is preferably argon (Ar), sulphur hexafluoride (SF6), krypton (Kr), carbon dioxide (CO2) or sulphur dioxide (SO2). The preferred insulation includes opposed outer, metallic (especially reflective, aluminium) foil (105, 108, figure 1). The preferred polymeric layer 102 is polyethylene. The preferred other layer 101, 106 is aluminium foil, paper, cloth, tissue material or glass fibre. Preferably, the gaps 113 between the pockets 103 are filled with a matrix material, especially aerogel. The preferred sheet or panel includes rubber (polyisocyanurate and polyurethane disclosed) or foam acoustic insulation 302. The preferred sheet or panel comprises multiple layers containing pockets of gas, bonded together.

Description

Composite Insulation Member The present invention relates to a composite insulation member and in particular, although not exclusively, to a insulation panel or sheet having an array of gas filled pockets extending between first and second opposed out skins.
In most jurisdictions, thermal insulation of both domestic and commercial buildings is a necessity to satisfy building regulations and to achieve a desired energy efficiency.
Fibrous materials such as fibreglass or rockwool contain a large proportion of trapped air and are well known heat insulation materials widely used for insulation of walls and roofs of buildings.
The success of fibreglass is due largely to its low production cost and the fact that it may be compressed to a small percentage of its normal bulk for storage and transport.
However, fibreglass exhibits sponge like properties and therefore readily absorbs water, particularly water vapour, from inside the heated building. This water absorption decreases the insulation effectiveness of the fibreglass.
As gases generally have a very low thermal conductivity, compared to solids and liquids, gas filled insulation sheets and panels have more recently been developed as thermal insulation materials particularly for roofs spaces, Example inflatable or gas filled insulation sheets are described in GB 2273722; WO 91/1 7326; US 3,619,340; US 4,262,045 and WO 2009/032763.
The gas filled laminate blankets are typically formed from outer sheets that are sealed along their edges with internal polymer films creating an internal labyrinth of passages within which the gas is trapped. These passages are interconnected in fluid communication via baffles that allow the gas to entirely fill and flow within the inner space of the blanket.
However, a problem with this type of construction is the complete or significant insulation loss due to puncture. Where the insulation sheet is installed within a wall, puncture may occur due to contact with a sharp wall tie or an individual nailing or drilling into the wall cavity space. In a loft or roof environment, puncture may result from contact with similar objects and subsequent constructional steps of the roof such as the fixing of plaster boards and supportjoists. In the majority of situations, it is unknown that puncture has occurred and the thermal insulation characteristics destroyed. The may go unnoticed for many years if detected at all resulting in considerable energy wastage. Accordingly, great care must be taken during installation of gas filled insulation sheeting and this can be both time inefficient and require additional specifically adapted fixings.
What is required therefore is a gas filled insulation sheet or panel that is effective to provide optimised thermal insulation that addresses the above problems.
It is an objective of the present invention to provide an insulation member that provides enhanced thermal insulation characteristics with regard to fibrous insulation materials such as fibreglass sheeting and the like. It is a further objective to provide a gas filled insulation sheet or panel configured to maintain its thermal insulation properties with only very minimal decrease in performance due to undesired puncture.
The objective is achieved by trapping a gas phase medium within a plurality of individual pockets within the insulation member. Each pocket is sealed independently so as to be self contained such that the gas is not capable of flowing in a fluid communication between pockets and is therefore effectively isolated. Should one of the pockets be ruptured due to puncture, the surrounding pockets will remain unaffected with only a very small percentage reduction in insulation performance incurred, effectively due to the loss of one pocket. By sizing the pockets with relatively small cross sectional dimensions each pocket provides a very small contribution to the collective insulation performance. The present insulation member therefore comprises a very large number of gas filled pockets.
According to a first aspect of the present invention there is provided a composite insulation member comprising: a polymer first layer; a second layer laminated or bonded to the first layer; a plurality of gas filled pockets formed in a region between the first and the second layer to form a pocketed gas layer; wherein the pockets are sealed such that the gas in each pocket is isolated and prevented from fluid flow between the pockets; wherein the gas comprises a thermal conductivity less than air at the same respective temperature.
Preferably, the insulation member further comprises first and second opposed outer skins, the pocketed gas layer positioned between the first and second outer skins.
Preferably, the polymer layer is bonded to at least one of the first and second skins.
Preferably the bonding is such that discrete regions of the polymer layer, that are spaced at regular intervals in the plane of the outer skins, are free to extend away from the skin to which the polymer layer is bonded to form the pocketed structure. Preferably each of the plurality of individual pockets is substantially circular in shape at the bonding region with the respective outer skin.
Optionally, the insulation member comprises a matrix material at a region around the gas filed pockets and between the first and second skins. Optionally, the matrix material comprises at least one aerogel having a thermal conductivity less than air at the same respective temperature.
Preferably, the insulation member comprises at least one aerogel layer, the aerogel having a thermal conductivity less than air at the same respective temperature.
Optionally, the insulation member further comprises an acoustic insulating membrane.
Preferably, the acoustic insulating membrane is positioned intermediate between the first and second skins. Preferably, the insulating membrane comprises polyisocyanurate (PIR); polyurethane (PUR); a rubber material andlor a foam material.
Optionally, each gas filled pocket comprises a diameter in the range of any one of a combination of the following set of: * 20 to 30 mm and preferably 25 mm; * 45 to 55 mm and preferably 50 mm; * 70 to 80 mm and preferably 75 mm; * 95 to 105 mm and preferably 100 mm, Preferably, the first and second skins comprise aluminium foil. Optionally, the first and second opposed outer skins comprise any one or a combination of the following set of: a metallic foil; a fibrous material; a tissue material; paper; a glass fiber; cloth.
Optionally at least one surface of at least one of the first and seconds skins is reflective.
Optionally, the first and second skins comprise a material having an emissivity of less than 0,1 and preferably between 0.02 to 0.1. Where the insulation member comprises additional and/or intermediate insulating layers or membranes, such layers and membranes may also comprise a reflective characteristic having an emissivity of less than 0.1 and preferably between 0.02 to 0.1.
Optionally, the first and second outer skins comprise a thickness in the range 5 to 1 Sjim.
Optionally, the polymer layer comprises polyethylene. Optionally, the polymer layer may comprise any suitable thermoplastic polymer and in particular a thermoplastic polymer material comprising a polyalkylene repeat unit, Optionally, the insulation member ftirther comprises a polymer third layer and a fourth layer laminated or bonded to the third layer to form a second pocketed gas layer in which the gas is sealed in each pocket and isolated from fluid flow between the pockets.
Optionally, the polymer first layer is bonded to the first outer skin and the polymer third layer is bonded to the second outer skin.
Preferably, the acoustic membrane is positioned intermediate between the first and second pocketed gas layers.
Optionally, the insulation member comprises a plurality of pocketed gas layers formed from a plurality of flexible polymer layers arranged to form a multilayer structure with each layer comprising isolated gas filled pockets.
Optionally, the gas comprises any one or a combination of the following set of: argon; sulphur hexafluoride; krypton; carbon dioxide; sulphur dioxide.
According to a second aspect of the present invention there is provided a composite insulation member comprising: first and second opposed outer skins, each skin comprising a metallic foil material; a first flexible polymer layer positioned between the first and second skins; a plurality of gas filled pockets formed by the polymer layer to form a pocketed gas layer between the first and second skins; wherein the pockets are sealed such that the gas in each pocket is isolated and prevented from fluid flow between the pockets; wherein the gas comprises a thermal conductivity less than air at the same respective temperature.
According to a third aspect of the present invention there is provided a composite insulation sheet comprising an insulation member described herein.
Optionally, regions of the insulation sheet are devoid of the gas filled pockets between the first and second skins.
According to a fourth aspect of the present invention there is provided a composite insulation panel comprising an insulation member described herein.
Brief description of drawings
One embodiment of the present invention will now be described, by way of example only, and with reference to the accompanying drawings in which: Figure 1 is a partially exploded view of an insulation member having first and second opposed outer skins with a plurality of individual gas filled pockets extending between the outer skins according to a specific implementation; Figure 2 is a cross sectional view of the insulation member of figure through A-A; Figure 3 is a ftirther embodiment of the present invention having two layers of gas filled pockets extending between first and second opposed outer skins with an intermediate membrane positioned between the layers of gas filled pockets.
Detailed description of preferred embodiment of the invention The composite insulation member 100 comprises a laminate structure having a first outer foil skin 101, an opposed second outer foil skin 106 and an intermediate layer 109 form from a plurality of gas filled pockets 103. According to the specific implementation, the first and second outer foil layers 101, 106 are formed from aluminium foil having an approximate thickness of 9 to 12 jim. The first foil layer 101 comprises an outer facing surface 105 and an internal facing surface 104. Similarly, second foil layer 106 comprises an internal facing surface 104 and an outward facing surface 108. An intermediate flexible polymer film 102 is at least partially bonded to internal facing surface 104 at circular regions 110 of foil layer 101 to form the individual pockets 103. An area of film 102 encapsulated by each bonding region 110 is therefore capable of being separated from surface 104.
According to the specific implementation, each pocket 103 is defined, in part, by surface 104 of foil layer 101 and surface 111 of intermediate polymer film 102. In particular a bonding region 110 comprises a substantially circular shape profile at its innermost edge to define the pocket or bubble base. Bonding region 110 seals individually each of the plurality of pockets 103 such that an internal volume 112 of each pocket 103 is isolated from adjacent volumes 112 of neighbouring pockets 103.
The bonding at region 110 may be provided by a bonding agent. Alternatively or in addition, intermediate layer 102 comprises a thermoplastic polymer (in particular polyethylene) and is formed as a thin film of a similar thickness to that of foil layers 101, 106. According to this embodiment, the thermoplastic film may be bonded to surface 104 via heat treatment and a partial melting of the film 102 onto surface 104.
Each internal volume 112 of each pocket 103 is filled with a gas to provide the gas filled pocketed layer 109 extending co-planar between the outer foil sheets 101, 106.
To optimise the thermal insulation characteristics of member 100, the gas chosen to occupy each pocket 103 is selected based on its thermal conductivity/thermal insulating properties.
In particular the gas may comprise air. However, improved thermal conductivity is achieved by a gas having a thermal conductivity of less than air, being less than approximately 26.2 rnW/mK at 300K. In particular the gas may comprise argon (17.9 mW/mK); sulphur hexafluoride (13.0 mW/mK); krypton (9,5 mW/mK); carbon dioxide (16.8 mW/mK); sulphur dioxide (9.6 mW/mK); or exenon (5.5 mW!mK).
Each pocket 103 is formed as a semi-spherical dome with the base end of each dome defined by surface 104 of foil skin 101. According to one embodiment, the dome apex may be bonded to the internal facing surface 107 of the opposed second skin 106 at each region 114 using the same or a different bonding method to that of bonding region 110.
According to one embodiment, the region 113 intermediate the gas filled pockets 103 may be occupied by air. Alternatively, a matrix material may be accommodated within region 113. In one embodiment, the matrix material comprises an aerogel having a thermal conductivity less than that of air at the same relative temperature, for example 300K. The aerogel may be powdered or may comprise a porous or honeycomb type structure, Alternatively, a fibrous material may surround each gas filled pocket 103 at region 113.
According to one method of construction, the domed pockets are formed by layering the polyethylene film onto a dye having a shape profile corresponding to that of the final gas filled pocketed layer 109. Heat, pressure and/or a partial vacuum may be applied to either or both faces of the polyethylene film 102 to retain it in the desired shape at the dye. The low thermal conductivity gas is then introduce into pocket volume 112 and the first foil skin 101 bonded directly on top of the layer 109 with contact being made and retained at bonding regions 110. At the same time or subsequently, the second foil layer 106 is laminated onto layer 109 to provide the composite structure of figures 1 and 2.
According to the specific implementation, a diameter of each gas filled pocket 103 is 25 mm. According to further embodiments, the diameter at the base region of each pocket (corresponding to the area within the perimeter bonding region 110) is 50, 75 or 100 mm.
According to the preferred embodiment, at least the first foil layer 101 and optionally the second foil layer 106 is reflective to further enhance the thermal insulation characteristics of the composite sheet 100. Accordingly, at least one or a plurality of surfaces 104, 105, 107, 108 maybe reflective.
Figure 3 illustrates a further embodiment of the present invention comprising a plurality of gas filled pocketed layers 300, 301 positioned intermediate between first and second outer foil layers 101, 106. In particular, a first polyethylene film 102 is partially bonded to foil layer 101 and a second polyethylene film 102 is bonded to second foil layer 106. The gas filled pockets 103 therefore project internally from first respective surfaces 104 and 107.
An intermediate acoustic insulating membrane 302 is positioned between pocketed gas filled layers 300, 301 and is orientated substantially co-planar with foil films 101, 106.
Intermediate membrane 302 comprises a material optimised to enhance the sound insulating characteristics of the composite structure 303 relative to the embodiment of figures 1 and 2. The intermediate insulating membrane 302 may or may not be bonded at the apex regions 112 of each domed pocket 103. According to one embodiment, layer 302 may be bonded to each layer 102 via the same bonding materials and/or processing employed at bonding regions 110. The sound insulating membrane 302 may comprise a polyisocyanurate (PIR) andlor polyurethane (PUR).
The region 113 intermediate pockets 103 may comprise air or another gas phase medium.
Alternatively, a matrix material as described with reference to the embodiment of figures 1 to 2 maybe incorporated at regions 113.
According to further specific embodiments, the composite member 303 may comprise a plurality of pocketed layers 300, 301 without an intermediate insulating membrane 302.
According to further embodiments, a plurality of intermediate membranes 302 may be provided separating a plurality of additional gas filled pocketed layers 300, 301 extending between outer foil skins 101, 106 to provide a multilayer structure. Each gas filled pocket is sealed at respective bonding regions 110 at each surface 104, 107 of the outer foil layers 101, 106 and are optionally bonded to the intermediate insulating membrane(s) 302.
According to a further specific implementation the insulation member comprises a first polymer film 102 and a second polymer film positioned opposed to the first polymer film 102 at a position corresponding to that of skin 101 as described with reference to figures 1 to 3. According to the further embodiment, outer skins 101, 106 may or may not be provided. In any event, the internal volume 112 of each pocket 103 is defined by polymer layer 102 and the adjacent polymer layer that is bonded to layer 102 at regions 110 as described with reference to the embodiment of figure 2. The lower thermal conductivity gas is then entrapped within volume 112 to create the pocketed gas layer 109. As indicated, optionally outer skins 101, 106 may be positioned either side of the gas layer 109 and the materials and construction of the outer skins is as described with reference to the embodiment of figures 1 to 3, According to a further embodiment, a second polymer layer is positioned adjacent to first polymer layer 102 and a first foil layer 101. In this embodiment, the gas tight seal of each pocket 103 is created by the bonding contact between layer 102 and the polymer layer positioned intermediate foil layer 101 and polymer layer 102. A further polymer layer may optionally be provided to surface 107 of second foil layer 106.

Claims (23)

  1. Claims 1. A composite insulation member comprising: a polymer first layer; a second layer laminated or bonded to the first layer; a plurality of gas filled pockets formed in a region between the first and the second layer to form a pocketed gas layer; wherein the pockets are sealed such that the gas in each pocket is isolated and prevented from fluid flow between the pockets; wherein the gas comprises a thermal conductivity less than air at the same respective temperature.
  2. 2. The insulation member as claimed in claim I further comprising first and second opposed outer skins, the pocketed gas layer positioned between the first and second outer skins.
  3. 3. The insulation member as claimed in claim 2 wherein the polymer layer is bonded to at least one of the first and second skins.
  4. 4. The insulation member as claimed in claims 2 or 3 ftirther comprising a matrix material at a region around the gas filed pockets and between the first and second skins.
  5. 5. The insulation member as claimed in claim 4 wherein the matrix material comprises at least one aerogel having a thermal conductivity less than air at the same respective temperature.
  6. 6. The insulation member as claimed in any one of claims Ito 3 comprising at least one aerogel layer, the aerogel having a thermal conductivity less than air at the same respective temperature.
  7. 7. The insulation member as claimed in any one of claims 1 to 5 further comprising an acoustic insulating membrane positioned intermediate between the first and second skins.
  8. 8. The insulation member as claimed in claim 7 wherein the insulating membrane comprises a rubber material and/or a foam material.
  9. 9. The insulation member as claimed in any preceding claim wherein each gas filled pocket comprises a diameter in the range of any one of a combination of the following set of: * 2Oto3Omm * 45to55mm * 7OtoSOmm * 9StolOSmrn.
  10. 10. The insulation member as claimed in any preceding claim when dependent on any one of claim 2 to 5 wherein the first and second skins comprise aluminium foil.
  11. 11. The insulation member as claimed in claim 10 wherein at least one of the first and seconds outer skins is reflective.
  12. 12. The insulation member as claimed in claims 10 or 11 wherein the first and second outer skins comprise a thickness in the range 5 to 1 Sjzm.
  13. 13. The insulation member as claimed in any preceding claim wherein the polymer layer comprises polyethylene.
  14. 14. The insulation member as claimed in any preceding claim comprising a polymer third layer and a fourth layer laminated or bonded to the third layer to form a second pocketed gas layer in which the gas is sealed in each pocket and isolated from fluid flow between the pockets.
  15. 15. The insulation member as claimed in claim 14 when dependent on claim 2 wherein the polymer first layer is bonded to the first outer skin and the polymer third layer is bonded to the second outer skin,
  16. 16. The insulation member as claimed in claim 15 when dependent upon claim 7 wherein the acoustic membrane is positioned intennediate between the first and second pocketed gas layers.
  17. 17. The insulation member as claimed in any preceding claim comprising a plurality of pocketed gas layers formed from a plurality of flexible polymer layers arranged to form a multilayer structure with each layer comprising isolated gas filled pockets sandwiched between the first and second outer skins.
  18. 18. The insulation member as claimed in any preceding claim wherein the gas comprises any one or a combination of the following set of: * argon * sulphur hexafluoride * krypton * carbon dioxide * sulphur dioxide.
  19. 19. The insulation member as claimed in claim 2 wherein the first and second opposed outer skins comprise any one or a combination of the following set of: * a metallic foil * aluminium foil * a fibrous materiai * a tissue material * paper * a glass fiber * cloth.
  20. 20. A composite insulation member comprising: first and second opposed outer skins, each skin comprising a metallic foil material; a first flexible polymer layer positioned between the first and second skins; a plurality of gas filled pockets formed by the polymer layer to form a pocketed gas layer between the first and second skins; wherein the pockets are sealed such that the gas in each pocket is isolated and prevented from fluid flow between the pockets; wherein the gas comprises a thermal conductivity less than air at the same respective temperature.
  21. 21. A composite insulation sheet comprising an insulation member as claimed in any preceding claim.
  22. 22. The insulation sheet as claimed in claim 21 wherein regions of the sheet are devoid of the gas filled pockets between the first and second skins,
  23. 23. A composite insulation panel comprising an insulation member as claimed in any one of claims 1 to 20.
GB1219304.1A 2012-10-26 2012-10-26 Composite insulation including gas filled pockets Withdrawn GB2507325A (en)

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WO2017016831A1 (en) * 2015-07-27 2017-02-02 Basf Se Foam as adhesive for composites for thermal insulation
CN106436940A (en) * 2016-10-14 2017-02-22 重庆方浩建筑保温材料有限公司万盛分公司 Light thermal insulation board with matrix core holes
CN106436939A (en) * 2016-10-14 2017-02-22 重庆方浩建筑保温材料有限公司万盛分公司 Staggered meshed light insulation board with matrix core holes
CN107100288A (en) * 2017-06-22 2017-08-29 厦门派探特环保科技有限公司 A kind of environment-friendly type energy-saving warming plate and its installation method
CN107311013A (en) * 2017-06-05 2017-11-03 上海华美电梯装饰有限公司 A kind of elevator thermal insulation noise insulation decorative plate
US10272634B2 (en) * 2015-05-12 2019-04-30 Sang Geun Lee Cloth having gas sheet
WO2021129488A1 (en) * 2019-12-24 2021-07-01 青岛海尔电冰箱有限公司 Thermal insulating assembly

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US10272634B2 (en) * 2015-05-12 2019-04-30 Sang Geun Lee Cloth having gas sheet
WO2017016831A1 (en) * 2015-07-27 2017-02-02 Basf Se Foam as adhesive for composites for thermal insulation
US10987910B2 (en) 2015-07-27 2021-04-27 Basf Se Foam as adhesive for composites for thermal insulation
CN106436940A (en) * 2016-10-14 2017-02-22 重庆方浩建筑保温材料有限公司万盛分公司 Light thermal insulation board with matrix core holes
CN106436939A (en) * 2016-10-14 2017-02-22 重庆方浩建筑保温材料有限公司万盛分公司 Staggered meshed light insulation board with matrix core holes
CN106436939B (en) * 2016-10-14 2019-04-19 重庆方浩建筑保温材料有限公司万盛分公司 A kind of light insulation board with matrix core bore of staggeredly engagement
CN106436940B (en) * 2016-10-14 2019-04-19 重庆方浩建筑保温材料有限公司万盛分公司 A kind of light insulation board with matrix core bore
CN107311013A (en) * 2017-06-05 2017-11-03 上海华美电梯装饰有限公司 A kind of elevator thermal insulation noise insulation decorative plate
CN107100288A (en) * 2017-06-22 2017-08-29 厦门派探特环保科技有限公司 A kind of environment-friendly type energy-saving warming plate and its installation method
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WO2021129488A1 (en) * 2019-12-24 2021-07-01 青岛海尔电冰箱有限公司 Thermal insulating assembly

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