IE20100784A1

IE20100784A1 - An insulating panel

Info

Publication number: IE20100784A1
Application number: IE20100784A
Authority: IE
Inventors: Malcolm Rochefort; Adrian Pargeter
Original assignee: Kingspan Holdings Irl Ltd
Priority date: 2009-12-21
Filing date: 2010-12-16
Publication date: 2011-06-22
Also published as: WO2011077418A2; GB2476382A; WO2011077418A3; GB201021348D0

Abstract

A vacuum insulating panel comprises a first panel part 2 and a second panel part 3. The first panel part 2 comprises a plurality of first insulation bodies 5 encased in an evacuated first casing 6. The first insulation bodies 5 are spaced-apart to define gaps 7 between the insulation bodies 5. Similarly, the second panel part 3 comprises a plurality of second insulation bodies 10 encased in an evacuated second casing 11. The second insulation bodies 10 are spaced-apart to define gaps 12 between the insulation bodies 10. The second insulation bodies 10 are recieved in the first gaps 7 and the first insulation bodies 5 are recieved in the second gaps 12 to form an assembled vacuum insulating panel 1. <Figure 3>

Description

“An Insulation Panel” Introduction This invention relates to vacuum insulation panels (VIP).

Current VIP technology used in refrigeration units and the like generally comprises a single panel of insulation material formed typically of fumed silica, fibre or other microporous material core, which may or may not contain infra red opacifiers, the core wrapped in a flexible, gas-tight envelope and a vacuum applied before sealing. The vacuum is essential to the panel’s thermal insulating performance. Thermal conductivity properties of VIPs are typically of the order of 0.005 W/mK. If the vacuum is lost the panel loses a large proportion of its effectiveness as a thermal insulator, with the thermal conductivity reverting to that of the core material, which is typically above 0.020 W/m.K The use of VIP technology in construction is not widespread but could enable improved insulation properties and allow a significant reduction in thickness of insulation materials required to meet ever increasing requirements for thermal efficiency of buildings. However, in considering the use of VIP for insulation in building’s floor, wall or roof there is a need to create robustness against various threats to piercing due to one or more of handing damage; cutting to size on site; fixing of panels to building substrate; and damage caused by drilling of holes for wiring, shelf fixing and the like.

It has been suggested to provide VIPs with compartments and sealed regions around the compartments. However, such sealed regions between compartments have poor thermal insulation properties and lead to a reduction in the overall thermal performance of the panel.

Statements of Invention According to the invention there is provided a vacuum insulating panel comprising:30 a first panel part and a second panel part; the first panel part comprising a plurality of first insulation bodies encased in an evacuated first casing, the first insulation bodies being spaced apart to define first gaps between the first bodies; IE 1 0 07 84 a second panel part comprising a plurality of second insulation bodies encased in an evacuated second casing, the second insulating bodies being spaced - apart to define second gaps between the second insulating bodies, the second insulating bodies being received in the first gaps and the first insulating bodies being received in the second gaps to form an assembled insulating panel. The first and second panel parts are interfitted.

In one embodiment the first and second panel parts comprise sections of a similar vacuum insulating system.

In one case the first and second panel parts comprise sections of the same vacuum insulating system.

The vacuum insulating system may comprise a first flexible sheet and a second flexible sheet between which the insulating bodies are encased. In one case the first sheet is a base sheet and the second sheet is a top sheet, the top sheet extending around the profile of the spaced-apart insulating bodies and the base sheet defining gap regions between the spaced-apart insulating bodies.

There may be indicia at the gap regions to indicate the location of the gaps.

The first and second sheets may be of a metal or metallised material. The first and second sheets may be of aluminium foil. The first and second sheets may be of stainless steel foil.

In one embodiment the first and second sheets are of metallised polymeric film The first and second sheets may be of the same material.

In one embodiment the insulating bodies are self supporting.

The insulating bodies may comprise a plurality of insulation pieces and a binder. The insulating bodies may be of an insulating foam material.

IE 1 0 07 84 In one case the insulating bodies are of generally dovetail shape. Alternatively the insulating bodies are of generally rectilinear shape. The insulating bodies may be of generally trapezoidal shape. Alternatively the insulating bodies are of generally triangular shape.

In one embodiment the vacuum insulating panel comprises reception spaces to receive fixings. The vacuum insulating panel as claimed may comprise insulating fillers for filling the spaces adjacent to fixings.

In one embodiment the gaps between the insulation bodies of one of the panel parts defines the reception spaces.

In one case the first panel part is adapted for fixing to a substrate and the second panel part is adapted for fixing to the first panel part. There may be means for fixing the second panel part to the first panel part. The means for fixing may comprise a bonding means. The bonding means may comprise an adhesive. The adhesive may be applied to at least part of the faces of at least one of the panel parts which are contacted by the other panel parts. The first panel part may be fixed to a substrate and adhesive is applied to at least part of the faces of the first panel part which are contacted by the second panel part.

In one case the insulation bodies are spaced-apart longitudinally. Alternatively or additionally there are a plurality of insulation bodies which are spaced-apart transversely.

The invention also provides a vacuum insulating system comprising a plurality of first bodies of insulating material each encased in an evacuated casing, the first insulating bodies being spaced - apart to define gaps therebetween for reception of second insulating bodies to form a vacuum insulating panel.

The gaps are preferably of complementary size and shape to that of the second insulating bodies.

The vacuum insulating system may comprise a first sheet and a second sheet encasing the plurality of first insulating bodies therebetween.

The gaps may be of complementary size and shape to the insulating bodies.

. IE 1 0 07 84 In one case the insulating bodies comprise a base, a top, and side wall means extending between the base and the top. In one embodiment the side wall means are inclined between the base and the top.

The insulating bodies may be of generally square shape in cross section, or of generally trapezoidal shape in cross section, or of generally triangular shape in cross section.

In one embodiment one of the sheets has indicia thereon.

In a preferred embodiment the vacuum insulating system is wound up to form a reel.

Brief Description of the Drawings The invention will be more clearly understood from the following description of an embodiment thereof, given by way of example only, with reference to the accompanying drawings, in which: Fig. 1 is a perspective view of one part of a vacuum insulating panel according to the invention; Fig. 2 is a perspective view of the insulating panel part of Fig. 1 being interfitted with another like panel part; Fig. 3 is a cross sectional view of the interfitted panel parts; Fig. 4 is an enlarged cross sectional view of a detail of Fig. 3; Fig. 5 is a cross sectional view of part of another vacuum insulating panel of the invention; Fig. 6 is a cross sectional view of part of a further vacuum insulating panel of the invention; Fig. 7 is a cross sectional view of part of a still further vacuum insulating panel of the invention; IE 1 0 07 84 Fig. 8 is a perspective view of a still further panel part of a vacuum insulating panel of the invention; Fig. 9 is an isometric, partially cross sectional view of a panel of Fig. 8 and an associated 5 fixing; Fig, 10 is a cross sectional view of a panel and fixing of Fig. 9; Fig. 11 is a view similar to Fig. 9 illustrating the insertion of fillers in the region of the 10 fixing; Fig. 12 is a cross sectional view similar to Fig. 10 with fillers in the region of the fixing; Fig. 13 is a cross sectional view similar to Fig. 10 with another fixing; Fig. 14 is a cross sectional view of another insulating panel part being interfitted with another like panel part; Fig. 15 is a cross sectional view ofthe panel parts of Fig. 14 interfitted together; Fig. 16 is a perspective view of an insulating panel part of the invention wound into a roll; Fig. 17 is a perspective view of an insulating panel part wound into a roil; Fig. 18 is a perspective view of another insulating panel part wound into a roll; Fig. 19 is a perspective view of a further insulating panel part wound into a roll; Fig. 20 is a plan view of a further insulating panel part according to the invention; Fig. 21 is a perspective view of the panel part of Fig. 20 being interfitted with another like panel part; IE 1 0 07 84 Fig, 22 is a plan view of the panel parts of Fig. 21 interfitted together; and Fig. 23 is a cross sectional view of the panel parts of Fig, 21 interfitted together.

Detailed Description The invention provides a compartmentalised vacuum insulation panel which combines two panel parts to provide a greater area of vacuumed insulation per square metre, avoiding the poor thermal insulation performance between compartments. The compartmentalisation is segmented i 0 with one or both of vertical and horizontal separation.

The insulation material in both panel parts is covered top and bottom in a foil/film, this foil/film seals around the compartments and holds the vacuum applied to the insulation materials. The foil/film construction can be made of several layers designed to resist water vapour, oxygen and/or nitrogen transmission, all of which threaten the integrity of the vacuum over time.

The insulation material may be of any suitable shape and configuration. For example:1. Tapered section (this can allow for interlocking when two sheets are slid together if the wider cross-section is away from the foil base, or ease of fitting together if the wider cross-section is attached to the base); 2. Rectilinear / squared section allows easy interlaying when fitted. Both sheets are then fixed to a building substrate; and 3. Triangular section which allows easy interlaying when fitted. Both sheets are then fixed to a building substrate.

The pattern at which the insulating bodies are laid out on a sheet is selected to suit thermal performance, application, and manufacturing techniques.

There are several advantages of the vacuum insulated panels of the invention. The various panels 30 ofthe invention have at least some of the following advantages: • They can be produced and delivered in a roll form o Allowing for continuous production o Assisting in protection during transportation • Easily cut to required length between compartments without breaching the vacuum.

IE 1 0 07 84 • Fixings can go through one side and then be covered by second panel.

• Second panel part can be interlocked using tapered section.

• Second panel part can be adhered to first panel • System flexibility will allow for curved applications Referring to the drawings and initially to Figs. 1 to 4 thereof there is illustrated a vacuum insulating panel 1 which comprises a first panel part 2 and a second panel part 3.

The first panel part 2 comprises a plurality of first insulation bodies 5 encased in an evacuated first casing 6, The first insulation bodies 5 are spaced apart to define gaps 7 between the insulation bodies 5.

Similarly, the second panel part 3 comprises a plurality of second insulation bodies 10 encased in an evacuated second casing 11. The second insulation bodies 10 are spaced - apart to define gaps 12 between the insulation bodies 10. The second insulation bodies 10 are received in the first gaps 7 and the first insulation bodies 5 are received in the second gaps 12 to form an assembled vacuum insulating panel 1.

The first casing 6 is formed by a first flexible sheet 20 and a second flexible sheet 21 between which the insulating bodies 5 are encased. The first sheet 20 is in this case a base or flat sheet and the second sheet 21 is wrapped around the insulation bodies to conform to the profile of the insulation bodies 5 when a vacuum is applied between the sheets 20,21, Similarly, the second casing 11 comprises a base sheet 23 and a profiled sheet 24 which conforms to the profile of the second insulation 10 when a vacuum is applied between the sheets 23,24.

The sheets 20, 21 may be of the same or different materials to provide desired insulation properties whilst conforming to the profile of the insulating bodies 5. The sheets 20, 21 may for example comprise a foil or film material such as a metal or metallised material. One example of such sheet material is an aluminium foil. The sheets 22,23 are similar to the sheets 20,21.

In one embodiment of the invention, for ease of manufacture, transport, storage, and use the first and second panel parts 2, 3 comprise sections of the same vacuum insulating system. For IE 1 0 07 84 example, they may comprise lengths cut from a single stock of a vacuum insulating system which may be provided in the form of a roll 25 as illustrated in Figs. 16 to 19.

In this case marks or indicia 30 are provided in the gap regions 7, 12 to indicate the location of 5 the gaps. The indicia 30 may be provided on the outer and/or inner face of the base sheets 20,23 to provide cut area guidelines.

The insulation bodies 5, 10 may comprise any suitable insulating material such as pressed fumed silica. If the insulating material is in the form of particulates, the particulates may be bound together to facilitate forming into a described shape, for example using a suitable binder.

In Figs. 1 to 4 the insulated bodies are of generally trapezoidal shape which facilitates interlocking, on interfitting of the first and second parts 2,3.

Fig. 2 illustrates the interfitting of two like parts to form an assembled vacuum insulation panel. The first part is laid with the flat sheet facing down and the inverted sheet is slid into position in the direction of the arrows.

Fig 3 is a perspective cross sectional view of a portion of the tapered panel 1 when two panel parts 2, 3 are combined together. The upper part 3 is interlocked to the lower part 2 by sliding together in the direction of the arrows. In this arrangement only the part 2 in contact with a building structure 29 would need to be fixed either by means of mechanical screw type fix or by adhesive. The outer part 3 is held in place by the engagement of the tapered sides, similar to a tongue and groove joint, Referring to Fig. 5 there is illustrated one panel part 30 according to another embodiment of the invention. The panel part 30 is similar to the panel part 2 described above and like parts are assigned the same reference numerals. There will be a second panel part identical to the first panel part in the same manner as described above. In this case the insulating foam body is of generally rectilinear, in this case square shape. This shape facilitates ease of interlaying when first and second panel parts are being assembled. In this case both panel parts are fixed to the associated building structure.

IE 1 0 07 84 Referring to Fig. 6 there is illustrated one panel part 40 which is similar to the panel part 30 and the same comments apply. In this case the insulating foam body is of generally triangular shape which facilitates ease of interlaying when first and second panel parts are being assembled. In this instance, both panel parts are fixed to the associated building structure.

Referring to Fig. 7 there is illustrated another panel part 45 which is similar to that described with reference to Figs. 1 to 4 and like parts are assigned the same reference numerals. In this case the panel part is tapered inwardly from the base towards the top. This facilitates ease of fitting ofthe panel parts on assembly.

Fig. 8 illustrates another panel part 50 in which there are both horizontal gaps 51 and vertical gaps 52. The gaps 51, 52 facilitate fixing to a building substrate.

The same principle can be applied to any insulation material shapes.

Fig 9 is a perspective view of the tapered sheet assembly showing insulation material in dashed lines under the top foil layer. The horizontal gap provides an area for a fixing 55 through a hole 56 through to the building substrate 57. This can be done on site using conventional fixing methods. The fixing can be repeated as required across the panel using the horizontal gap.

Fig 10 is a sectional view through the centre line of the horizontal gap of Fig. 9 and shows the fixing 55 passing through the gap into the building substrate 57, A head 59 of the fixing 55 is enlarged to engage against the insulation material.

Fig. 11 is a view similar to Fig. 9 showing filler pieces such as PIR or phenolic foam pieces 45 laid in the gap around the fixing 55. Fig. 12 is a view similar to Fig. 10 illustrating filler pieces 45 in the gap around the fixing 55.

Referring to Fig. 13 in an alternative arrangement a first panel part 4 is fixed to a building substrate by a fixing 70. The second panel part, on fitting covers the fixing 70.

Referring to Figs. 14 and 15 there is illustrated the assembly of two like panel parts 75, 76 together. The panel parts 75, 76 are similar to those described above and like parts are assigned the same reference numerals. The panel part 76 is first fixed by suitable fixings such as screws IE 1 0 07 84 or nails 77 to a support substrate 78. The fixings 77 are inserted in the gaps between adjacent insulation bodies of the panel part 76. In this way the insulation bodies are not penetrated. An inner panel part fixing means such as an adhesive which may for example be pre-applied or applied on site to at least some and in this case substantially all of the exposed faces of one or both of the panel parts 75, 76. In this case illustrated a layer of adhesive 79 is applied over the exposed faces of the panel part 76 and the counter faces of the other panel part 75 are bonded to the faces of the panel part 76, on assembly. This is a particularly efficient way of applying the panel parts on site and fixing them to a substrate without penetrating the insulation medium. The adhesive 79 may be of any suitable type such as a two part epoxy, polyurethane, acrylic or polyester based adhesive in either liquid or tape format. The particular advantage of such a system is that the panel is readily installed whilst ensuring that insulation bodies are not penetrated by fixings and without a necessity for fillers.

In embodiments in which the fixings are covered by a layer of insulation the effects of thermal bridging are negated.

Fig 16 is a perspective view of the panel parts in roll form 25 with insulation material compartments laid out on the foil/film sheet. A cutting tolerance band 30 may be marked on the centre horizontal gap and/or on the vertical gap on the foil/film.

Fig. 17 illustrates another insulating panel part wound into a roll 80. This is similar to Fig. 16 except that in this case there are only transverse and not longitudinally extending gaps.

Fig. 18 illustrates yet another insulating panel part wound into a roll 85. This panel is similar to that of Fig. 16 except that in this case there are three insulating bodies rather than two across the width of the sheet.

Referring to Fig. 19 there is illustrated a further insulating panel part according to the invention wound onto a roll 90. This panel is similar to that of Fig. 18 except that in this case there are four insulating bodies rather than two across the width of the sheet.

It will be appreciated that the panel parts 25, 80, 85, 90 illustrated in Figs. 16 to 19 are fully interchangeable with one another. For example, the full width version of Fig. 18 can be fitted IE 1 0 07 84 with the double version of Fig. 16 or the triple version of Fig. 19 to form an insulating panel. This provides flexibility in fitting.

Referring to Figs. 20 to 23 there is illustrated a panel part 60 with a plurality of offset insulation 5 bodies 61. In this case the insulation bodies are substantially rectilinear in plan view and are arranged to leave gaps 62 between adjacent insulation bodies 61. The gaps 62 are of a size and shape to accommodate insulation bodies 63 of another like panel part 65 as illustrated in Fig. 21 and 22. The panel part 65 also has gap 64 to accommodate the insulation bodies 61 of the panel part 60. This chequer board-like arrangement is particularly advantageous because there are a large number of individual insulating bodies per unit area and the gaps 62 between the bodies accommodate fixings as described above which do not damage the insulation bodies. Further, the insulation bodies of like panel parts closely interengage / interfit for enhanced insulation performance and enhanced strength. The panel parts 60, 61 are identical and may be cut from a common stock length. Further, the squareness of the core shapes may facilitate ease of manufacture.

It will be appreciated that the insulation bodies in such an offset arrangement may be of any suitable size and shape.

Modifications and additions can be made to the embodiments of the invention described herein without deporting from the scope of the invention. For example, while the embodiments described herein refer to particular features, the invention includes embodiments having different combinations of features. The invention also includes embodiments that do not include all of the specific features described.

The invention is not limited to the embodiments hereinbefore described, with reference to the accompanying drawings, which may be varied in construction and detail.

Claims

1. A vacuum insulating panel comprising:a first panel part and a second panel part; the first panel part comprising a plurality of first insulation bodies encased in an evacuated first casing, the first insulation bodies being spaced - apart to define first gaps between the first bodies; a second panel part comprising a plurality of second insulation bodies encased in an evacuated second casing, the second insulating bodies being spaced - apart to define second gaps between the second insulating bodies, the second insulating bodies being received in the first gaps and the first insulating bodies being received in the second gaps to form an assembled insulating panel in which the first and second panel parts are interfitted.

2. A vacuum insulating panel as claimed in claim 1 wherein the first and second panel parts comprise sections of a similar vacuum insulating system.

3. A vacuum insulating panel as claimed in claim 1 or 2 wherein the first and second panel parts comprise sections of the same vacuum insulating system.

4. A vacuum insulating panel as claimed in claim 2 or 3 wherein the vacuum insulating system comprises a first flexible sheet and a second flexible sheet between which the insulating bodies are encased, 5. Sheets has indicia thereon, 5 plurality of insulation bodies which are spa ced-apart transversely. 5 of stainless steel foil 5 bodies of one of the panel parts defines the reception spaces.

5. A vacuum insulating panel as claimed in claim 4 wherein the first sheet is a base sheet and the second sheet is a top sheet, the top sheet extending around the profile of the spaced-apart insulating bodies and the base sheet defining gap regions between the spaced-apart insulating bodies.

6. A vacuum insulating panel as claimed in claim 5 comprising indicia at the gap regions to indicate the location of the gaps. JE 1 0 07 84

7. A vacuum insulating panel as claimed in any of claims 1 to 6 comprising reception spaces to receive fixings.

8. A vacuum insulating panel as claimed in claim 7 wherein the gaps between the insulation

9. A vacuum insulating panel as claims in any of claims 1 to 8 wherein the first panel part is adapted for fixing to a substrate and the second panel part is adapted for fixing to the first panel part. 10. Insulating panel. 10 20. A vacuum insulating panel as claimed in any of claims 1 to 19 wherein the first and second sheets are of the same material.

10. A vacuum insulating panel as claimed in claim 9 comprising means for fixing the second panel part to the first panel part.

11. A vacuum insulating panel as claimed in claim 10 wherein the means for fixing

12. A vacuum insulating panel as claimed in claim 11 wherein the bonding means comprises an adhesive. 20

13. , A vacuum insulating panel as claimed in claim 12 wherein the adhesive is applied to at least part of the faces of at least one of the panel parts which are contacted by the other panel parts.

14. A vacuum insulating panel as claimed in claim 13 wherein the first panel part is fixed to a

15. A vacuum insulating panel as claimed in claim 7 or 8 comprising insulating fillers for filling the spaces adjacent to fixings. 15 comprises a bonding means.

16. A vacuum insulating panel as claimed in any of claims 1 to 15 wherein the first and second sheets are of a metal or metallised material. IE 1 0 07 84

17. A vacuum insulating panel as claimed in claim 16 wherein the first and second sheets are of aluminium foil.

18. A vacuum insulating panel as claimed in claim 16 wherein the first and second sheets are

19. A vacuum insulating panel as claimed in claim 16 wherein the first and second sheets are of metallised polymeric film

20. Bodies are of an insulating foam material.

21. A vacuum insulating panel as claimed in any of claims 1 to 20 wherein insulating bodies are self supporting.

22. A vacuum insulating panel as claimed in any of claims 1 to 21 wherein the insulating bodies comprise a plurality of insulation pieces and a binder.

23. A vacuum insulating panel as claimed in any of claims 1 to 21 wherein the insulating

24. A vacuum insulating as claimed in any of claims 1 to 23 wherein the insulating bodies are of generally dovetail shape.

25. 25. A vacuum insulating panel as claimed in any of claims 1 to 23 wherein the insulating bodies are of generally rectilinear shape. 25 substrate and adhesive is applied to at least part of the faces of the first panel part which are contacted by the second panel part.

26. A vacuum insulating panel as claimed in any of claims 1 to 23 wherein the insulating bodies are of generally trapezoidal shape.

27. A vacuum insulating panel as claimed in any of claims 1 to 26 wherein the insulating bodies are of generally triangular shape. IE 1 0 07 84

28. A vacuum insulating panel as claimed in any of claims 1 to 27 wherein the insulation bodies are spaced-apart longitudinally.

29. A vacuum insulating panel as ciaimed in any of claims 1 to 28 wherein there are a

30. A vacuum insulating system comprising a plurality of first bodies of insulating material each encased in an evacuated casing, the first insulating bodies being spaced - apart to define gaps therebetween for reception of second insulating bodies to form a vacuum

31. A vacuum insulating system as claimed in claim 30 wherein the gaps are of complementary size and shape to that of the second insulating bodies. 15

32. A vacuum insulating system as claimed in claim 29 or 31 comprising a first sheet and a second sheet encasing the plurality of first insulating bodies therebetween.

33. A vacuum insulating system as claimed in any of claims 29 to 32 wherein the gaps are of complementary size and shape to the insulating bodies.

34. A vacuum insulating system as claimed in any of claims 29 to 33 wherein the insulating bodies comprise a base, a top, and side wall means extending between the base and the top. 25

35. A vacuum insulating system as claimed in claim 34 wherein the side wall means are inclined between the base and the top.

36. A vacuum insulating system as claimed in claim 35 wherein the insulating bodies are of generally square shape in cross section.

37. A vacuum insulating system as claimed in claim 35 wherein the insulating bodies are of generally trapezoidal shape in cross section. IE 1 00784

38. A vacuum insulating system as claimed in claim 35 wherein the insulating bodies are of generally triangular shape in cross section.

39. A vacuum insulating system as claimed in any of claims 29 to 38 wherein one of the

40. A vacuum insulating system as claimed in any of claims 23 to 32 which is wound up to form a reel. 10

41. A vacuum insulating system substantially as hereinbefore described with reference to the accompanying drawings.

42. A vacuum insulating panel comprising a vacuum insulating system as claimed in any of claims 23 to 34.

43. A vacuum insulating panel substantially as hereinbefore described with reference to the accompanying drawings.