GB2581819A

GB2581819A - Inflatable insulated vacuum panel

Info

Publication number: GB2581819A
Application number: GB1902696.2A
Authority: GB
Inventors: James Mellors Edward
Original assignee: Blue Planet Buildings UK Ltd
Current assignee: Blue Planet Buildings UK Ltd
Priority date: 2019-02-28
Filing date: 2019-02-28
Publication date: 2020-09-02
Also published as: GB201902696D0

Abstract

An inflatable panel (10) for forming a shelter comprises an inflatable first part (12) having an internal compartment (13); an inflatable second part (14) having an internal compartment (15); and a third part (16) connecting the first part (12) to the second part (14) at a periphery of the first and second parts (12, 14). The first, second, and third parts (12, 14, 16) together define a sealed enclosure (18) therebetween. At least one semi-rigid insulator (20) is positioned between the inflatable first part (12) and the inflatable second part (14). The inflatable panel (10) also includes means for evacuating air from the sealed enclosure. Said means for evacuating air from the sealed enclosure is operable to create a full or partial vacuum within said sealed enclosure, and said sealed enclosure is configured to increase thermal insulation between the first part (12) and the second part (14). In use a shelter may comprise a plurality of panels, the first and second parts of each panel may be in fluid communication, the first parts of a plurality of the panels may be in fluid communication and the enclosures of a plurality of the panels may be in fluid communication.

Description

INFLATABLE INSULATED VACUUM PANEL

Field of the Invention

[0001] The present invention relates to an inflatable insulated panel, in particular an inflatable insulated vacuum panel.

Background of the Invention

[0002] Inflatable panels are employed for a number of applications such as for the construction of inflatable tents, as an underlay for a sleeping bag or tent, or as part of an inflatable mattress or bed.

[0003] An advantage of inflatable panels when used as a shelter, part of a shelter, and/or item of furniture is that they can be easily inflated for deployment and rolled up when not in use for minimal transportation benefits. However, due to the nature of the construction of the panels, they are not thermally efficient and in hot or cold weather do not provide sufficient insulation, often requiring significant energy in the form of heating or cooling to maintain a habitable environment.

[0004] There is therefore a need for an inflatable panel which is both thermally efficient and provides adequate insulation from the heat or cold when used as part of a shelter or item of furniture.

Summary of the Invention

[0005] According to a first aspect there of the present invention, there is provided an inflatable panel comprising: an inflatable first part having an internal compartment; an inflatable second part having an internal compartment; a third part connecting the first part to the second part at a periphery of the first and second parts, the first, second, and third parts together defining a sealed enclosure therebetween; at least one semi-rigid insulator positioned between the inflatable first part and the inflatable second part; and means for evacuating air from the sealed enclosure, said means for evacuating air from the sealed enclosure operable to create a full or partial vacuum within said sealed enclosure; wherein, said sealed enclosure is configured to increase thermal insulation between the first part and the second part.

[0006] An inflatable insulated panel in accordance with the invention provides a thermally efficient, rigid, external structure that can be inflated for deployment and rolled up when not in use for minimal transportation benefits.

[0007] In exemplary embodiments, the inflatable panel comprises a plurality of semi-rigid insulators positioned between the inflatable first part and the inflatable second part.

[0008] Preferably, the third part is inflatable and includes an internal compartment.

[0009] Preferably, the first, second and/or third parts comprise a flexible 15 material.

[0010] Preferably, the first, second and/or third parts comprise a waterproof material.

[0011] Preferably, the first and/or second part comprises a drop-stitch structure.

[0012] In exemplary embodiments wherein the third part is inflatable, the third part may comprise a drop-stitch structure.

[0013] By having a drop-stitch structure, the first part, second part or third part will provide an inflatable structure that when inflated is very stable, uniform in shape when pressurised and is capable of withstanding significant loads without losing its prime shape. The drop-stitch structure also prevents the walls of the first and second parts from deforming and touching in a central void of the inflatable insulated panel. Having the walls of the first and second parts touching would decrease the thermal efficiency of the inflatable insulated panel in use.

[0014] In exemplary embodiments wherein the third part is not inflatable, the third part may comprise a rigid or semi-rigid material.

[0015] The first, second and third parts are made from any suitable material. Preferably the first, second and third parts each comprise a plastics or rubber material.

[0016] The plastics material may be in the form of a PVC or textile-reinforced urethane plastic material.

[0017] The rubber material may be in the form of a synthetic rubber for example Hypalon ®.

[0018] In exemplary embodiments, the first, second and/or third part is constructed from a fabric having a flexible and waterproof coating. Preferably the fabric is polyester and the coating is a PVC or synthetic rubber coating.

[0019] Such a construction provides added rigidity to the first, second and/or third panel while also increasing its resistance to stretching; tearing and/or tension.

[0020] Preferably, the inflatable panel further comprises means for introducing fluid into the first part and/or second part.

[0021] The means for introducing fluid into the first part and/or second part may be any suitable means known in the art, for example may be in the form of an inlet valve or an integrated fluid pump. The fluid pump may be an air pump or pressure pump.

[0022] Preferably, the first part and/or the second part are in fluid communication with each other.

[0023] In exemplary configurations, wherein the third part is inflatable, the first part, second part and third part may all be in fluid communication with each other. Having the first, second and third parts in fluid communication with each other allows all the inflatable parts of the inflatable panel to be inflated via a single point or means.

[0024] Preferably, the first part and/or second part and/or third part is inflatable to a pressure above atmospheric pressure.

[0025] The means for evacuating air from the sealed enclosure may be any 3 0 suitable means known in the art. For example, the means for evacuating air from the sealed enclosure may comprise a vacuum release valve or integrated vacuum pump.

[0026] In accordance with a second aspect of the present invention, there is provided an inflatable panel assembly comprising two or more inflatable panels connected together, each of the two or more inflatable panels comprising: an inflatable first part having an internal compartment; an inflatable second part having an internal compartment; a third part connecting the first part to the second part at a periphery of the first and second parts, the first, second, and third parts together defining an enclosure therebetween; and at least one semi-rigid insulator positioned between the inflatable first part and the inflatable second part; the first part, second part and third part being in fluid communication with each other and being sealed from said enclosure therebetween; wherein the first part of first inflatable panel of said two or more panels is in fluid communication with the first part of an adjacent inflatable panel connected thereto, and the enclosure of said first inflatable panel is in fluid communication with the enclosure of said adjacent inflatable panel; and wherein the inflatable panel assembly includes means for evacuating air from the enclosure of the first inflatable panel, said means for evacuating air from the sealed enclosure operable to create a full or partial vacuum within said sealed enclosure; and the enclosure of each of said two or more inflatable panels is configured to increase thermal insulation between the first part and the second part of a respective inflatable panel.

[0027] The panels forming the panel assembly of the second aspect may include one or more features of an inflatable panel in accordance with the first aspect.

[0028] According to a third aspect of the present invention, there is provided a floor comprising an inflatable panel in accordance with the first aspect, or an inflatable panel assembly in accordance with the second aspect.

[0029] According to a fourth aspect of the present invention, there is provided a ground sheet comprising an inflatable panel in accordance with the first aspect; or an inflatable panel assembly in accordance with the second aspect.

[0030] According to a fifth aspect of the present invention, there is provided a wall comprising an inflatable panel in accordance the first aspect, or an inflatable panel assembly in accordance with the second aspect.

[0031] According to a sixth aspect of the present invention, there is provided an inflatable shelter comprising an inflatable panel in accordance with the first aspect, or an inflatable panel assembly in accordance with the second aspect.

[0032] Other aspects are as set out in the claims herein.

Brief Description of the Drawings

[0033] For a better understanding of the invention and to show how the same may be carried into effect, there will now be described by way of example only, specific embodiments, methods and processes according to the present invention with reference to the accompanying drawings in which: [0034] Fig. 1 is a schematic representation of a first embodiment of an inflatable panel in accordance with the invention; [0035] Fig. 2 is a schematic representation of a second embodiment of an inflatable panel in accordance with the invention; [0036] Fig. 3 is a cross-sectional view of the inflatable panel of Fig. 2 taken 2 0 along line A-A; [0037] Fig. 4 is a schematic representation of a third embodiment of an inflatable panel in accordance with the invention; [0038] Fig. 5 is a cutaway view of the embodiment of figure 4; [0039] Fig. 6 is a cutaway view of the embodiment of figure 4 with the first part omitted; [0040] Fig. 7a is a schematic representation of an embodiment of panel assembly in accordance the invention; [0041] Fig. 7b shows the panel assembly of Fig. 7a in folded form; [0042] Fig. 7c shows an embodiment of a shelter in accordance with the 3 0 invention constructed from the panel assembly of Fig. 7a; and [0043] Fig. 8 shows another embodiment of a shelter in accordance with the invention formed from panel assemblies in accordance with the invention.

Details Description of the Embodiments

[0044] There will now be described by way of example a specific mode contemplated by the inventors. In the following description numerous specific details are set forth in order to provide a thorough understanding. It will be apparent however, to one skilled in the art, that the present invention may be practiced without limitation to these specific details. In other instances, well known methods and structures have not been described in detail so as not to unnecessarily obscure the description.

[0045] With reference to figure 1, a first embodiment of an inflatable vacuum panel 10 (herein after referred to as a "panel") in accordance with a first aspect of the invention is shown.

[0046] The panel 10 comprises a first part 12 having an internal compartment 13, a second part 14 having an internal compartment 15, and a third part 16 having an internal compartment 17.

[0047] The first, second and third parts 12, 14, 16 are each inflatable and the third part 16 is sandwiched between the first part 12 and the second part 14. The third part 16 connects the first part 12 to the second part 14 at a periphery of the first and second parts 12, 14. In the embodiment shown, the third part 16 partially surrounds a perimeter of the first part 12 and a perimeter of the second part 14.

[0048] The first, second and third parts 12, 14, 16 are made from a plastics or rubber material, for example from PVC or from a textile-reinforced urethane plastic or a fabric with a PVC or synthetic rubber coating.

[0049] The panel 10 further comprises a sealed enclosure 18 positioned between the first part 12, second part 14 and third part 16. The first, second and third parts 12, 14, 16 together define the sealed enclosure, that is to say an inner wall 23, 24, 25 of each of the first part 12, second part 14, and third part 16 substantially defines the perimeter of the sealed enclosure 18 and that the sealed enclosure is sealed from the first part 12, second part 14, and third part 16.

[0050] Means for evacuating air from the sealed enclosure (not shown) and means for introducing fluid into the first part 12, second part 14 and third part 16 (not shown) are incorporated into the panel 10. The means for evacuating air from the sealed enclosure may be in the form of a vacuum release valve or a vacuum pump integrated with or temporarily attached to the panel 10.

[0051] When air from the sealed enclosure 18 is evacuated, a vacuum chamber in the panel 10 is created via the evacuated sealed enclosure 18. The vacuum chamber facilitates an increase in thermal insulation between the first part 12 and the second part 14.

[0052] The means for evacuating air from the sealed enclosure is used to create a partial vacuum or a full vacuum within the vacuum chamber.

[0053] The first pad 12, second pad 14 and third part 16 are each formed from a drop-stitch structure, for example a constructed of a drop-stitch inflatable member.

[0054] Drop-stitch is a widely known technique incorporating fibres that tie the external faces of the form together. This creates inflatable structures with very stable, uniform shapes when pressurised and are capable of withstanding significant loads without losing their prime shape.

[0055] The incorporation of a drop-stitch structure allows the first, second and third parts 12, 14, 16 to acts as rigid layers once inflated, preserving the integrity of the sealed enclosure 18 when a negative (near absolute zero) pressure is generated in the sealed enclosure 18.

[0056] The third part 16 provides lateral stability to the panel 10 and prevents edge collapse of the vacuum chamber formed by the sealed enclosure 18.

[0057] In the embodiment shown, the first part 12, second part 14, and third part 16 are all in fluid communication with each other. This allows the parts of the panel 10 to be inflated by a single means from a single point. It would be understood that it is possible for fluid communication between the parts of the panel to be restricted such that each part would need to be separately inflated.

[0058] The first part 12, second part 14 and third part 16 are each configured to be inflatable to a pressure above atmospheric pressure.

[0059] The inside of the panel 10 includes a plurality of hollow pillar-like structures 20. The pillar-like structures are inflatable and define semi-rigid insulators within the sealed enclosure 18.

[0060] An inner wall 22 of the pillar-like structures 20 is impermeable, while an outer wall of the pillar-like structures 20 is permeable. The outer wall of the pillar-like structures 20 being permeable allows for the equalizing of pressure within the sealed enclosure 18 on either side of a pillar-like structure.

[0061] The pillar-like structures/semi-rigid insulators 20 are formed from a material having a very low thermal conductivity.

[0062] The pillar-like structures/semi-rigid insulators 20 provide a physical connection between the first part 12 and the second part 14 in order to maintain the stand-off and preserve the vacuum chamber integrity. The pillar-like structures/semi-rigid insulators 20 prevent a direct fluid connection or direct physical connection between the first part 12 and the second part 14. A direct fluid connection or direct physical connection between the first part 12 and the second part 14 would constitute a thermal bridge between the first part 12 and the second part 14, allowing temperatures of the internal compartments of the first and second parts 12, 14 to match one another at a faster rate than without such a thermal bridge.

[0063] Since the mechanical joint between the first part 12 and the second part is thermally broken by the pillar-like structures/semi-rigid insulators 20, the physical properties required for separation of the parts of the panel 10 whilst maintaining a low thermal conductivity for the panel 10 is achieved.

[0064] In use, the first, second and third parts 12, 14, 16 of the panel 10, as well as the pillar-like structures are inflated to a pressure above atmosphere.

The air within the sealed enclosure 18 is then extracted from the sealed enclosure 18 via a vacuum pump (either via a vacuum release valve or integrated with the panel). The extraction of air from the sealed enclosure 18, as mentioned above, creates a vacuum chamber which forms a barrier to thermal transfer between the first and second parts 12, 14.

[0065] The pressure in the first and second parts 12, 14 is sufficient to overcome both the tendency of the vacuum chamber 18 to collapse and provide net external pressure to allow the structure of the panel 10 to be self-supporting and withstand loads applied from the outside of the panel 10.

[0066] Referring to figures 2 and 3, a second embodiment of an inflatable vacuum panel 100 (herein after referred to as a "panel") in accordance with a first aspect of the invention is shown.

[0067] As in the first embodiment, the panel 100 in accordance with the second embodiment comprises a first part 112 having an internal compartment and a second part 114 having an internal compartment.

[0068] The panel also includes a third part 116, however, unlike in the first embodiment, the third part 116 does not comprise an internal compartment.

[0069] The first and second parts 112, 114 are each inflatable in a similar manner to the first and second parts of the first embodiment. The first and second parts are arranged parallel to one another and the third part is configured to provide a boundary around the periphery of the first and second parts 112, 114.

[0070] The first, second and third parts 112, 114, 116 are made from a plastics or rubber material, for example from PVC or from a textile-reinforced urethane plastic or a fabric with a PVC or synthetic rubber coating.

[0071] As in the previously described embodiment, the panel 100 further comprises a sealed enclosure 118 positioned between the first part 12, the second part 114 and the third part 116. The first, second and third parts 112, 114, 116 together define the sealed enclosure, that is to say an inner wall 123, 124, 125 of each of the first part 112, second part 114, and third part 116 substantially defines the perimeter of the sealed enclosure 118, and that the sealed enclosure is sealed from the first part 112, second part 114, and third part 116.

[0072] Means for evacuating air from the sealed enclosure 130 and means for introducing fluid into the first part 112 and second part 114 (not shown) are incorporated into the panel 100. In the embodiment shown, the means for evacuating air from the sealed enclosure 130 is in the form of a vacuum release valve, however it would be understood that it may be in a different form for example the mean for evacuating air from the sealed enclosure 118 may be in the form of a vacuum pump.

[0073] When air from the sealed enclosure 118 is evacuated, a vacuum chamber in the panel 100 is created via the evacuated sealed enclosure 118. 5 The means for evacuating air from the sealed enclosure 130 is used to create a partial vacuum or a full vacuum within the vacuum chamber.

[0074] The vacuum chamber facilitates an increase in thermal insulation between the first part 112 and the second part 114. Like in the first embodiment, the first part 112 and second part 114 are each formed from a drop-stitch structure, and the first part 112 and second part 114 are in fluid communication with each other to facilitate inflation of the parts by a single means from a single point. It would be understood that fluid communication between the parts of the panel 100 may be restricted such that each part would need to be separately inflated.

[0075] The first part 112 and second part 114 are each configured to be inflatable to a pressure above atmospheric pressure.

[0076] In the embodiment shown, the third part 116 is formed from a solid membrane structure, however, it would be understood that it may be formed in a different manner.

[0077] Semi-rigid insulators 121 are positioned between the first part 112 and the second pad 114. The semi-rigid insulators 121 are formed of a material having a very low thermal conductivity.

[0078] Similar to the first embodiment, the semi-rigid insulators are inflatable, and in the embodiment shown, the semi-rigid insulators 121 are substantially cuboid in shape and act like pillars between the first part 112 and the second part 114. It would be understood that the semi-rigid insulators 121 may take any suitable shape.

[0079] The semi-rigid insulators 121 provide a physical connection between the first part 112 and the second part 114 in order to maintain the stand-off between the two parts and preserve the vacuum chamber integrity.

The semi-rigid insulators 121 prevent a direct fluid connection or direct physical connection between the first part 112 and the second part 114.

[0080] In the configurations of inflatable vacuum panels 10,100 in accordance with the first and second embodiment of the invention depicted in figures 1 to 3, the semi-rigid insulators 20, 121 are arranged in parallel rows. Having the semi-rigid insulators arranged in parallel rows, facilitates the folding or rolling of the inflatable vacuum panel into a compact size for storage and/or transportation.

[0081] The number of rows will be determined by the size of the inflatable vacuum panels. It is envisaged that three rows of semi-rigid insulators would be sufficient but more or less rows may be utilized.

[0082] In certain configurations, the inflatable vacuum panels 10, 100 further comprise a filling in the form of a thermal insulator within their respective sealed enclosures 18, 118. The thermal insulator filling facilitates the thermal insulation between the first part and the second part of the panels 10, 100. In addition, the thermal insulator filing allows sufficient thermal efficiency to be achieved after only a small amount of air has been evacuated from the sealed enclosure.

[0083] The filling is preferably in the form of a compressible filling where the inflatable vacuum panel is intended to be folded or rolled into a compact size for storage and/or transportation, so as not to adversely effect the panel's storage and/or transportation capabilities.

[0084] In certain configurations, the inflatable vacuum panels 10, 100 further comprise a reflective layer on the inner surface of the first part and on the inner surface of the second part. The reflective layers will advantageously reflect radiated heat back into or out of the panel.

[0085] Referring to figures 4 to 6, a third embodiment of an inflatable panel 200 in accordance with a first aspect is shown.

[0086] The panel 200, like the above described embodiments, comprises a first part 212 having an internal compartment, a second part 214 having an internal compartment, and a third part 216.

[0087] The first part 212, second part 214, and third part 216 of the panel 200 are of a similar construction to the equivalent parts of the panel 100 of the second embodiment. While the third part 216 is shown having a similar construction to the third part 116 of the second embodiment, it would be understood that it may be of a similar construction to the third part 16 of the first embodiment.

[0088] As in the previously described embodiments, an inner wall 223, 224, 225 of each of the first part 212, second part 214, and third part 216 substantially defines the perimeter of the sealed enclosure 218.

[0089] Means for evacuating air from the sealed enclosure 230 and means for introducing fluid into the first part 212 and second part 214 (not shown) are incorporated into the panel 200. In the embodiment shown, the means for evacuating air from the sealed enclosure 230 is in the form of a vacuum release valve 230, however it would be understood that it may be in a different form for example the mean for evacuating air from the sealed enclosure 230 may be in the form of a vacuum pump.

[0090] The means for evacuating air from the sealed enclosure 230 is used to create a partial vacuum or a full vacuum within the vacuum chamber.

[0091] The panel 200 differs from the panels of the first and second embodiment 10, 100 in that rather than having a plurality of inflatable pillar-like structures positioned within the sealed enclosure 218, a single semi-rigid insulator 220 is positioned within the sealed enclosure 218.

[0092] The semi-rigid insulator 220 is formed of a similar material to the semi-rigid insulators of the previously described embodiments.

[0093] The semi-rigid insulator 220 comprises an open end 221 through which the semi-rigid insulator is inflated and a sealed end 222. The sealed end 222 is positioned within the sealed enclosure while the open end 221 is accessible from outside the panel 200.

[0094] In the embodiment shown, the semi-rigid insulator 220 is arranged within the sealed enclosure in a square spiral formation, although it would be understood that the semi-rigid insulator 220 may be arranged in a different configuration, for example in a serpentine formation, circular spiral formation etc. [0095] Apart from the sealed enclosure and semi-rigid insulator construction/arrangement, all other components of the panel are identical to that of the previously described embodiments (depending on whether of similar construction to the first or second described embodiment) and arranged in a similar fashion as already described so further detail would not be provided. [0096] In accordance with a third aspect of the invention, two or more panels of similar construction to the panels described above in accordance with the first, second or third embodiments, are tied together to form an inflatable panel assembly. This allows the production of a continuous structure of varied length and/or width.

[0097] The first part of each panel of the inflatable panel assembly is in fluid communication with the first part of an adjacent or adjacent panels connected thereto.

[0098] Likewise, the enclosure of each panel of the inflatable panel assembly is in fluid communication with the enclosure of an adjacent or adjacent panels.

[0099] Having the first parts of each panel in fluid communication with the first part of an adjacent or adjacent panels and the enclosures of each panel in fluid communication with the enclosure of an adjacent or adjacent panels means that only one pressure pump and one vacuum pump is required for any size of structure of the panel assembly.

[0100] The panel or panel assembly in accordance with the invention can be utilized for numerous applications wherever a degree of thermal insulation is required. It can be utilized as part of a floor, a ground sheet, a wall or an inflatable shelter.

[0101] When used as a floor, it addresses the combined elements of thermal effectiveness and comfort. The drop-stitch structure of the first part and second part, and the third part if inflatable, can be inflated to a higher pressure than traditional air mattresses so can provide a walk-able surface.

[0102] As a ground sheet for a tent or sleeping bag, it can help mitigate the effects of cold/damp/heat and as well as provide a firm but comfortable surface for sleeping on.

[0103] When incorporated as part of an inflatable shelter, an outer surface of the shelter may be provided with a flexible solar film. This is advantageous as it gives a potential for integral power and increased self-sufficiency when the shelter is used in remote operation.

[0104] Referring to figures 7a to c, an inflatable shelter 1000 constructed from a panel assembly 300 in accordance with the invention is shown.

[0105] The panel assembly 300 comprises four panels 301, 302, 303, 304 joined together in series. The inflatable parts of each panel of the inflatable panel assembly are in fluid communication with the same inflatable parts of an adjacent or adjacent panels connected thereto. Likewise, the enclosure of each panel of the inflatable panel assembly is in fluid communication with the enclosure of an adjacent or adjacent panels.

[0106] The panels 301, 302, 303, 304 are of similar construction to a panel in accordance with one of the previously described embodiments.

[0107] The panel assembly 300 is configured to fold into a wall-roof-wallfloor segment of the shelter.

[0108] In preferred arrangements, the panels 301, 302, 303, 304 are substantially rectangular in plan and each have a width of around 1.2-1.4m. [0109] In the embodiment shown, the length of each of the first, second and fourth panel 301, 302, 304 is approximately 2400mm, and the length of the third panel is approximately 2300mm, giving the panel assembly a total length 20 of approximately 9500mm.

[0110] Each panel 301-304 comprises a beveled edge along its width, which is configured to abut against a beveled edge of an adjacent panel when the panel assembly 300 is folded (see figure 7b).

[0111] End or door panels 310 can be added to the folded structure to cover openings as required (see figure 7c).

[0112] The end/door panels 301 are attached to the folded panel assembly 310 by suitable attachment means, for example by means of a sliding attachment, a weatherproof zipper configuration, hook-and-loop flaps etc or a combination thereof.

[0113] The panels 301, 302, 303, 304 provide the inflatable shelter 1000 with a robust structure which is able to withstand environmental conditions and/or factors such as wind; rain, and snow without the need for additional supports such as tent frames, guy ropes, air beams etc. as would be required to maintain structural integrity in other temporary structures.

[0114] Referring to figure 8, two or more panel assemblies 300,400 may be connected to each other to provide a shelter 2000 with an increased the floor print compared to the shelter 1000 utilizing a single panel assembly. The adjacent panel assemblies may be joined to one another in the same way that the end/door panels are attached.

[0115] Each panel assembly 300,400 includes an air and a vacuum interconnection to plug into a manifold tube. This means that only one air input or vacuum output would be required per shelter structure.