ITMO20110298A1 - PROCEDURE FOR CONSTRUCTION OF AN INSULATING PANEL AND RELATIVE INSULATING PANEL OBTAINED. - Google Patents

Description

"PROCEDURE FOR MAKING AN INSULATING PANEL AND RELATIVE OBTAINABLE INSULATING PANEL"

DESCRIPTION

The present invention relates to a process for making an insulating panel and relative insulating panel that can be obtained.

It is known to use insulating materials that can be applied perimeter to a compartment in order to minimize the heat exchange between the inside and the outside of the compartment itself. It is also known to use insulating materials comprising airgel composed of amorphous silica with a nano-porous structure, that is characterized by a distance between the particles that make it up of about 0.01 micrometers. Thanks to their nanotechnological structure, the airgel allows to obtain, with reduced thickness, much higher insulating performances compared to other known types of insulators. These airgels are reinforced, by known manufacturing processes, with fibrous fabrics, such as for example felted fiberglass, polypropylene fiber or polyethylene terephthalate fiber, giving the final product a shape similar to a layer of soft and flexible wadding such to be adapted to any surface. These reinforced aerogels, such as the products marketed under the names Spaceloft®, Crygel® and Pyrogel® made by Aspen Aerogels Inc., are available in rolls of flexible fabric. These insulating materials are joined by a rigid cover plate in order to increase the speed of installation, as illustrated in the international patent application n. PCT / 2011/000264 filed by the same applicant of this application.

These known types of insulating panels are not free from drawbacks, including the fact of releasing dust deriving from the movement of the fibrous fabric reinforcing the airgel. In fact, during the movement of the insulating panel, the fibers collide with each other, breaking and releasing dust on the ground resulting from this break. There is an excessive accumulation of dust in the storage areas of the panels, as well as an excessive presence of dust in the installation areas, requiring the use of suitable protection by the operators in order to avoid excessive inhalation of this dust.

Another drawback of these known types of insulating panels consists in the fact that they require fixing screws or dowels in case of wall installation, since the adhesive surface of the adhesives placed between the wall and the panel is soiled by the dust generated by the fibers, not allowing good adhesion of the insulating panel to the wall, requiring the use of specific adhesives with consequent high installation costs.

These known panels are produced by means of a manufacturing process requiring a vertical press which, by means of a punch and a matrix, suitably sized, press the various layers that make up the panel together.

This known type of manufacturing process is not free from drawbacks, including the fact of producing a single insulating panel at a time, considerably increasing the manufacturing times of a plurality of panels.

A further drawback of this known type of manufacturing process consists in the fact that it is inefficient, as it requires an extremely long opening phase of the press in which the newly formed insulating panel is removed and the multilayer defining the subsequent insulating panel is placed. in which the press does not produce any insulating panel, increasing the production cycle times and consequently the production costs.

Another drawback of this known type of manufacturing process consists in the fact of producing insulating panels shaped according to the geometry of the punch and of the die, requiring their replacement in order to produce them in different geometric shapes. The replacement of the punch and the die requires a high investment cost, resulting in almost prohibitive manufacturing costs for small production batches of insulating panels with customized shapes.

The aim of the present invention is to carry out a process for manufacturing an insulating panel which obviates the drawbacks and overcomes the limits of the known art, allowing production times to be reduced.

Within the scope of this aim and of the objects illustrated, an object of the present invention is to carry out a manufacturing method which is more efficient than known methods, reducing production costs.

A further object of the invention consists in carrying out a manufacturing process which allows a modeling step of the insulating panel subsequent to the production step, drastically reducing the costs for small production batches.

Another object of the invention is to provide an insulating panel which drastically reduces the release of dust during its handling.

A further object of the invention consists in providing an insulating panel which allows its installation by means of common adhesives of the known type.

The aforementioned task, as well as the aforementioned purposes and others which will appear better later, are achieved by a process for making an insulating panel comprising at least one covering layer, at least one base layer of insulating material, at least one covering layer lower, at least a first layer of adhesive film and a second layer of adhesive film, characterized in that it comprises:

-a first phase of drafting said base layer;

-a second heating step of said first layer of adhesive film;

-a third step of juxtaposition and adhesion of said first layer of heated adhesive film on a first face of said base layer;

-a fourth heating step of said second layer of adhesive film;

-a fifth step of juxtaposition and adhesion of a second first layer of adhesive film heated on a second face, opposite to said first face, of said base layer;

-a sixth step of juxtaposition and adhesion of said covering layer on said first layer of heated adhesive film;

-a seventh step of juxtaposition and adhesion of said lower coating on said second layer of heated adhesive film;

- an eighth step of laminating said layers adhering to each other.

Furthermore, this task, as well as these and other purposes which will appear better later, are achieved by an insulating panel comprising at least one covering layer, at least one base layer of insulating material, at least one lower covering layer, at least one first layer of adhesive film, interposed between a first face of said base layer and said covering layer, and a second layer of adhesive film, interposed between a second face, opposite to said first face, of said base layer and said covering layer lower, characterized in that said lower covering layer is made of a material called "non-woven fabric" and said covering layer is a sheet chosen between a metal sheet and a composite material sheet.

Further characteristics and advantages will become clearer from the description of a preferred but not exclusive embodiment of a process for making an insulating panel and the relative insulating panel that can be obtained, illustrated by way of non-limiting example with the aid of the attached drawings in which:

figure 1 is a schematic section of an insulating panel made according to a transversal plane;

Figure 2 is a schematic representation of a process for making the insulating panel illustrated in Figure 1;

Figures 3 and 4 are a perspective view of variants of a first roller used in the lamination stage and of the relative insulating panel that can be obtained.

With reference to the aforementioned figures, the process for making an insulating panel comprises the supply of at least one covering layer 2, at least one base layer 3 of insulating material, at least one lower covering layer 4, at least one first layer of adhesive film 5 and a second layer of adhesive film 6.

According to the invention, the manufacturing process comprises a first step of spreading the base layer 3, which can take place by resting it on a work surface or by tensioning defined by at least two gripping means. Subsequently, a second stage of heating the first layer of adhesive film 5 is carried out so as to activate the adhesives present on the film itself and a third stage of juxtaposition and adhesion of the first layer of adhesive film 5 heated to a first face 7 of the layer. base 3 so that the adhesive sticks firmly to the insulating material. Identically also the second layer of adhesive film 6 undergoes a fourth heating phase and a subsequent fifth phase of juxtaposition and adhesion on a second face 8, opposite to the first face 7, of the base layer 3. When the two layers of adhesive film 5 and 6 are active anchors, i.e. in temperature, in order to cling with the free face opposite to the one adhering to the base layer 3, a sixth step of juxtaposition and adhesion of the covering layer 2 on the first layer of adhesive film 5 is performed and a seventh step of juxtaposition and adhesion of the lower coating 4 on the second layer of heated adhesive film 6. All the superimposed layers undergo an eighth stage of lamination in order to be compressed and adhere perfectly to each other.

Conveniently, a subsequent ninth cutting phase is envisaged in which the laminate obtained is sectioned into the required dimensions, suitably calibrating the insulating panel obtained; this cutting phase can be performed mechanically through the use of appropriately sized blades, such as punches or shears, but the possibility of performing this phase with other devices, such as cutters, or through hydraulic systems, such as cutting, is not excluded with water.

Advantageously, some of the steps described above can occur simultaneously, reducing production times, ie the second and fourth phase, the third and fifth phase or the sixth and seventh phase can be simultaneous. Furthermore, thanks to the possibility of using all components available in rolls and consequently supplying material for continuous production, as illustrated schematically in figure 2, all production phases can take place almost simultaneously or in close succession.

In particular, the second and fourth heating phases take place at a temperature substantially between 30 ° C and 200 ° C, adjustable heat according to the type of glue used, while the eighth phase takes place at a pressure which substantially varies between 0.5 bar. and 5 bar, depending on the type of materials used. This eighth phase is obtained by means of the tangential compression defined by at least a first roller 9 and a second roller 10, counter rotating each other. The first roller 9 has on its radial surface a plurality of protrusions 11 which, acting on the covering layer 2 during the rolling step, plastically deforms an upper face 13 thereof, impressing a respective plurality of protrusions 12. These protrusions 11 can have shapes different according to the optimal geometry to be impressed on the panel 1, as illustrated for example in figures 3 and 4.

In other embodiments, the possibility of having a plurality of protrusions also on the radial surface of the second roller 10 is not excluded.

Further, at least one of the two rollers 9 and 10 or both can be heated.

The manufacturing process just described allows to obtain an insulating panel 1 comprising at least one covering layer 2, at least one base layer 3 of insulating material, at least one lower covering layer 4, at least a first layer of adhesive film 5, interposed between said between a first face 7 of the base layer 3 and of the covering layer 3, and a second layer of adhesive film 6, interposed between a second face 8 opposite to the first face 7 of the base layer 3 and of the lower coating layer 4 . The peculiarity of the insulating panel 1 is defined by the fact that the lower covering 4 is of a material called "non-woven fabric" and the covering layer 2 is, depending on the requirements, a metal plate or a plate of material composite.

The "non-woven fabric" is typically obtained by joining fibers arranged in layers or crossed with adhesives or thermal processes; chemical additives can be added to this material in order to give fireproof characteristics to the insulating panel 1.

On the opposite face of the insulating panel 1 with respect to the position of the lower covering layer 4 there is the covering layer 2, which gives stiffness to the whole panel. Specifically, this layer can be a metal plate or a composite material comprising a resinous matrix and reinforcing fibers. In the first case, the metal plate, such as aluminum, steel, copper or other metals, allows you to define a plastic deformation according to the needs of the end user by applying a pressure (of an entity related to the thickness of the plate) at certain points of the plate itself so as to conform the plate to the compartment to be insulated. Advantageously, depending on the thickness of the metal plate, this deformation can be carried out manually without the use of specifically manufactured pads. In the second case, the composite material can include reinforcement fibers selected from glass fibers, carbon fibers and aramid fibers, such as Kevlar® fibers, impregnated in matrices comprising epoxy, vinyl or other types of resins suitable for amalgamating the various fibers between them. The use of this composite material confers to the insulating panel 1 a high impact resistance and a high lightness.

Advantageously, thanks to the use of the first roller 9 comprising superficially a plurality of protrusions 11, the covering layer 2 has a plurality of reliefs 12 on an upper face 13, opposite to a lower face 14 in direct contact with the first layer of film adhesive 5, which facilitates the adhesion of mortar or other building agglomerates in case of installation of the insulating panel 1 on walls or ceilings on which an additional finishing layer is required, such as plaster. Between the covering layer 2 and the lower covering layer 4 there is the base layer 3 comprising an airgel with an amorphous microporous structure associated with a flexible fabric. The base layer 3, based on silicon dioxide, has a nanoporous structure with a pore size of about 0.01 micrometers. Advantageously, the base plate 4 can be replaced with a layer of insulating material of the type commercially known with the names Spaceloft®, Crygel® and Pyrogel®, aerogel, produced and marketed by Aspen Aerogels Ine.

Furthermore, in other embodiments, the possibility of using further insulating materials deriving from nano technology is not excluded.

In order to allow the transpiration of the insulating panel 1, the two layers of adhesive film 5 and 6 have a plurality of through holes.

In practice it has been found that the process for making an insulating panel, according to the present invention, accomplishes the task as well as the intended purposes as it allows to reduce production times and costs, defining a more efficient production process if compared to the prior art thanks to continuous production. In fact, the lamination phase does not require loading or unloading times of the machinery for the production of each single panel, allowing a rapid production of a plurality of insulating panels. Furthermore, thanks to the use of materials in layers that can be rolled up one on top of the other, it is possible to define a continuous production of a considerable number of insulating panels without requiring the stop of the production line for the loading and unloading of the basic materials, as happens in the vertical presses of known type.

A further advantage of the manufacturing process, according to the invention, consists in making insulating panels of variable length according to requirements. In fact, these insulating panels can define insulating strips having a length substantially equal to the height of an external wall of a house, drastically reducing the installation time of an insulating coat.

Another advantage of the manufacturing process, according to the invention, consists in allowing a modeling step subsequent to the production step, giving an economic customization of the panel thanks to the plastic deformation which can also be obtained manually. In fact, the use of a sufficiently thin metal sheet allows the end user to model the insulating panel directly on the surface of the compartment to be insulated, applying slight pressure on the sheet due to its plastic deformation. This plastic deformation insulating panel can be advantageously used in applications where the space intended for insulation is limited in size, such as the lining of household appliances, air conditioning and heating systems, storage tanks, the automotive sector or pipe lining. In particular, the panel can have a semicircular conformation and, by fitting with a respective semicircular panel, embrace a pipe in order to isolate it from the external environment and be inspectable in the event of an accidental leak.

A further advantage of the insulating panel, according to the invention, consists in the fact of drastically reducing the release of dust, since the presence of the lower coating contains possible releases of dust, preventing the latter from soiling the surrounding surfaces or being inhaled by operators during handling of the insulating panel.

Another advantage of the insulating panel, according to the invention, consists in the fact that it adheres better to the walls of the compartment to be protected as common glues placed between the surface of the compartment and the panel are not soiled by dust, allowing good adhesion between a continuous layer. firmly anchored to the panel and the compartment to be insulated. Furthermore, this adhesion allows to eliminate any fixing means such as fixing screws or dowels, reducing both the cost and the installation time.

The process for making an insulating panel and the relative panel obtainable thus conceived are susceptible of numerous modifications and variations, all of which are within the scope of the inventive concept.

Furthermore, all the details can be replaced by other technically equivalent elements.

In practice, the materials employed, so long as compatible with the specific use, as well as the contingent shapes and dimensions, may be any according to requirements.

Claims (14)

CLAIMS 1.Procedure for making an insulating panel (1) comprising at least one covering layer (2), at least one base layer (3) of insulating material, at least one lower covering layer (4), at least one first layer of film adhesive (5) and a second layer of adhesive film (6), characterized in that it comprises a first step of spreading said base layer (3); -a second heating step of said first layer of adhesive film (5); -a third step of juxtaposition and adhesion of said first layer of adhesive film (5) heated to a first face (7) of said base layer (3); -a fourth heating step of said second layer of adhesive film (6); -a fifth step of juxtaposition and adhesion of a second first layer of adhesive film (7) heated on a second face (8), opposite to said first face (7), of said base layer (3); -a sixth step of juxtaposition and adhesion of said covering layer (2) on said first layer of heated adhesive film (5); -a seventh step of juxtaposition and adhesion of said lower coating (4) on said second layer of heated adhesive film (6); -an eighth lamination step of said layers (2,5,3,6,4) adhering to each other. 2. Process according to the preceding claim, characterized in that it comprises a ninth cutting step subsequent to said eighth step for the calibration of said panel (1). 3. Process according to claim 1, characterized in that said second and second phase are simultaneous. 4. Process according to one or more of the preceding claims, characterized in that said third and fifth phases are simultaneous. 5. Process according to one or more of the preceding claims, characterized in that said sixth and seventh phases are simultaneous. 6. Process according to one or more of the preceding claims, characterized in that said second and said fourth phase take place at a heating temperature which varies substantially between 30 ° C and 200 ° C. 7. Process (1) according to one or more of the preceding claims, characterized in that said eighth phase occurs at a pressure which varies substantially between 0.5 bar and 5 bar. 8. Process according to the preceding claim, characterized in that said eighth phase is obtained by means of at least a first roller (9) and a second counter-rotating roller (10) and at least one between said first roller (9) and said second roller (10) has a plurality of projections (11) on its radial surface. 9. Process according to claim 8, characterized in that at least one of said first roller (9) and said second roller (10) is heated. 10.Insulating panel (1) which can be produced with a method according to one or more of the preceding claims, comprising at least one covering layer (2), at least one base layer (3) of insulating material, at least one lower covering layer (4) , at least a first layer of adhesive film (5), interposed between a first face (7) of said base layer (3) and said covering layer (3), and a second layer of adhesive film (6), interposed between a second face (8) opposite to said first face (7), of said base layer (3) and said lower covering layer (4), characterized in that said lower covering layer (4) is of a material called "non-woven fabric" and said covering layer (2) is a sheet chosen between a metal sheet and a sheet of composite material. 11.Insulating panel (1) according to claim 10, characterized in that said composite material comprises a resinous matrix and reinforcing fibers of the type selected from glass fibers, carbon fibers and aramid fibers. 12. Insulating panel (1) according to one or more of claims 10 to 11, characterized in that said covering layer (2) has a plurality of reliefs (12) on an upper face (13), said upper face (13) ) being opposite to a lower face (14) in direct contact with said first layer of adhesive film (5). 13.Insulating panel (1) according to one or more of claims 10 to 12, characterized in that said base layer (3) is an airgel with an amorphous microporous structure associated with a flexible fabric. 14.Insulating panel (1) according to one or more of claims 10 to 13, characterized in that at least one of said first layer of adhesive film (5) and said second layer of adhesive film (6) has a plurality of through holes .