JP2009540159A - Insulation - Google Patents

Abstract

  A heat insulating sheet (10) comprising two outer layers (11, 12) and a closed cell structure (13) joined between these outer layers. This sheet (10) is of a roll configuration and is of a thickness that allows it to be spread out to assume a substantially flat configuration. Each of the outer layers (11, 12) comprises a reinforced reflective aluminum foil. The closed cell foam structure (13) comprises a flexible lightweight foam such as a cross-linked LDPE foam. The outer surface of one of the outer layers (11, 12) is treated to provide some glare reduction while retaining heat reflective properties. Due to the closed cell structure (13), the insulation sheet (10) is compressible under a fixing load while providing a valuable insulation effect. For some applications, the insulating sheet (10) may be perforated for air and water vapor permeability.

Description

  The present invention relates to a heat insulating material, and more particularly to a heat insulating sheet.

  The present invention is specifically designed to insulate, but not necessarily, buildings and other structures. Accordingly, the present invention also relates to a building structure incorporating a heat insulating sheet.

  There are various types of insulation currently available for buildings, including heat reflective insulation sheets. An example of a heat-reflective heat-insulating sheet is disclosed in the applicant's Australian Innovation Patent No. 2003000663. Such a heat insulating sheet includes a single-layer closed cell structure sandwiched between two outer layers in which at least one of the two outer layers includes a reflective foil. This insulation sheet is a particularly effective barrier to reducing energy transfer, the closed cell structure functions to reduce the amount of heat transferred by convection and conduction, and the reflective foil layer provides heat transfer by radiation. It has been found that it works to reduce.

  This single-layer closed cell structure comprises a plurality of plastic films joined together to form a plurality of bubbles between the plastic films. These bubbles are generally cylindrical structures each having a diameter between 8 and 25 millimeters and a depth between about 3 and 10 millimeters.

  The cell size was chosen to give the necessary thermal insulation properties without having to rely on the double layer cell structure already used in the prior art.

  However, a thermal insulation sheet comprising a single layer cell structure defined by membranes joined together may have certain limitations.

  Accordingly, the present invention seeks to provide a thermal insulation sheet that does not require a closed cell structure defined by membranes joined together.

  According to a first aspect of the present invention, there is provided a cell structure including a closed cell foam structure, and a heat insulating sheet including the cell structure sandwiched between two outer layers.

  Preferably, the closed cell foam structure is flexible and elastically compressible.

  Preferably the closed cell foam structure comprises a polyethylene foam. More preferably, the closed cell foam structure comprises cross-linked low density polyethylene (LDPE) foam.

  This foam structure is advantageous because it provides moisture resistance and thereby increases resistance to mold formation.

  LDPE foam is advantageous because it provides the insulation sheet with improved insulation and soundproofing properties and greater heat and flame resistance.

  Preferably at least one of the two outer layers comprises a reflective foil. More preferably, both outer layers comprise a reflective foil.

  Preferably the reflective foil comprises an aluminum foil. The aluminum foil may comprise a 99.5 percent pure aluminum reflective foil.

  Preferably at least one of the outer layers is reinforced for tear resistance. This reinforcement can be provided by a scrim joined to the foil layer so that the reinforcement provides strength and tear resistance. Preferably the scrim comprises a high density polyethylene fabric laminated to an aluminum foil. Other types of scrims can also be used, one example being polypropylene fabric.

  Preferably, one of the reflective layers can be treated for glare reduction. This layer can be treated in any suitable manner such as applying a surface treatment such as coloring. Suitable colors for this surface treatment include red, blue, green or orange shades.

  The glare reduction process ideally provides greater comfort and dazzling appearance while providing sufficiently low radiation to provide thermal resistance through the upper reflective space in the range of E = 0.08 to E = 0.14. Designed to provide glare reduction that provides protection against.

  The closed cell foam structure is preferably flame retardant. This can be achieved by adding an appropriate amount of flame retardant material to the resin from which the foam structure is formed.

  Preferably, an antioxidant is added to the foam to provide durability. Preferably, this heat insulating sheet is also given UV protection.

  This insulation sheet is advantageous because it is compressible under a fixed load while providing a valuable insulation effect. This is due to the presence of the closed cell foam structure.

  In some applications, the outer layer may be perforated for air and water vapor permeability through the insulation sheet.

  Preferably, these perforations are sized, spaced and numbered to provide water vapor permeability by achieving a low grade for resistance to water vapor transmission under the Australian and New Zealand standard AS / NZS 4200.1. Such permeability allows the building to “breath” through the insulation sheet and minimizes the formation of condensation due to the barrier effect of the insulation sheet.

  Preferably these perforations are formed after the construction of the insulation sheet. In one configuration, these perforations can extend completely through not only the two outer layers, but also the closed cell foam structure disposed between the outer layers. In another configuration, the perforations can extend through the two outer layers and partially through the closed cell foam structure disposed between the outer layers. In the latter configuration, the perforations can extend from one outer layer into the closed cell foam structure and end inside the closed cell foam structure inside the other outer layer. In this configuration, the perforations may include holes extending through the one outer layer into the closed cell foam structure and ending inside the other outer layer, the holes being one of the one of the above. An opening in the outer layer opens on the one outer layer and a corresponding opening exists in the other outer layer.

  The perforations in the outer layer and the central closed cell foam structure are preferably aligned to aid the permeation of air and water vapor through the sheet. These perforations can be generated by perforating the sheet using a perforating device with a set of sharp tip projections designed to perforate the sheet at various predetermined intervals.

  According to a second aspect of the invention, a building comprising a frame, a cladding attached to the frame, and a thermal insulation comprising a thermal insulation sheet according to the first aspect of the invention between the frame and the cladding. A structure is provided.

  The invention will be better understood by reference to the above description of several specific embodiments of the invention as shown in the accompanying drawings.

1 is a schematic front view of a piece of a thermal insulation sheet according to a first embodiment with a portion of the outer layer of the thermal insulation sheet removed to reveal an internal closed cell foam structure. FIG. It is a side view of the fragment | piece of the heat insulation sheet | seat of FIG. It is a perspective view of the fragment | piece of the building structure in which the heat insulation sheet by 1st Embodiment was installed. It is sectional drawing of the fragment | piece of the building structure shown by FIG. FIG. 6 is a schematic front view of a fragment of a thermal insulation sheet according to a second embodiment with a portion of the outer layer of the thermal insulation sheet removed to reveal an internal closed cell foam structure. It is a side view of the fragment | piece of the heat insulation sheet | seat of FIG. It is a side view of the fragment | piece of the heat insulation sheet by 3rd Embodiment.

  1 and 2 of the drawings, a heat insulating sheet 10 according to a first embodiment is shown. The heat insulating sheet 10 includes two outer layers 11 and 12 and a closed cell structure 13 bonded between these layers. Each outer layer 11, 12 has an outer surface 14.

  Sheet 10 is of a thickness between outer surfaces 14 that allows the sheet to be rolled and unfolded to assume a substantially flat configuration. This thickness can be up to about 12 mm for typical applications. In one typical application, the thickness is about 4 mm, and in another typical application, the thickness is about 8-9 mm.

  Each of the outer layers 11, 12 comprises a reinforced reflective aluminum foil. The reflective aluminum foil comprises a 99.5% pure aluminum reflective foil reinforced with high density polyethylene scrim. This reinforcement improves the tensile strength of the insulation sheet 10 and allows the sheet to be installed over a long span in the building structure. This reinforcement also provides greater tear strength.

  The outer layers 11, 12 can be applied to the closed cell foam structure in any suitable manner. One particularly suitable method is related to the hot melt lamination process.

  The closed cell foam structure 13 comprises a flexible lightweight foam that is compressible with at least some elasticity. In this embodiment, the closed cell foam structure 13 comprises cross-bonded LDPE foam. Polyethylene foam incorporates UV protection, flame retardancy and antioxidants. Flame retardancy is what gives AS1530.2 compliance. Indeed, this flame retardancy can give a fire index of 5 or less under AS1530.2. Antioxidant protection is that it provides a product life of a minimum of 15 years when installed.

  The cross-linked structure of the closed cell foam structure 13 provides improved thermal and sound insulation properties as well as heat and flame resistance compared to the prior art thermal insulation sheets described above. In particular, the closed cell foam structure 13 made from cross-linked LDPE foam allows for the construction of a thermal insulation sheet that is thinner than the aforementioned prior art sheets due to the inherent stiffness of the foam resulting from the cross-bonding. Furthermore, closed cells in cross-linked LDPE foam are much smaller in size than bubbles in prior art sheets. Indeed, the closed cells in the foam structure 13 typically comprise microencapsulated bubbles with a cross-sectional size of less than 0.1 mm. With this configuration, the air bubbles are almost uniformly dispersed in the foam structure 13, thereby providing better fire resistance. This is because there are no relatively large bubbles to aid combustion, as is present in the prior art thermal insulation described above. The uniform distribution of microencapsulated bubbles also provides resistance to heat and acoustic energy transfer.

  In this embodiment, the reflective foil has a thickness of about 6.5 μm and the scrim comprises a high density polyethylene scrim having a 6 mm × 6 mm fabric.

  The outer surface 14 of one of the layers 11, 12 is treated to provide some glare reduction while retaining heat reflective properties. Glare reduction may be particularly desirable at construction sites where the sheet is exposed for some time, which can cause glare problems to nearby people. In the present embodiment, this process includes coloring. In this embodiment, the colorant contains an orange pigment.

Insulation sheet according to the first ^embodiment, has a material thermal resistance R0.20m 2 K / W (+/- 0.25m 2 K / W).

  In addition to providing a barrier to heat transfer, the sheet 10 according to the first embodiment also provides a barrier to air and water vapor.

  The insulation sheet 10 is advantageous because it can be compressed under a fixing load while providing a valuable insulation effect. This is due to the presence of the closed cell foam structure.

  The insulation sheet is suitable for use in a building structure that includes a frame and a cladding attached to the frame where the insulation sheet can be installed between the frame and the cladding. This cladding may include a wall cladding or a roof cladding.

  This thermal insulation sheet is especially needed when the thermal insulation layer between the steel frame and the wall cladding (cover) is required to reduce the thermal bridge and conductivity between the frame and the cladding. Suitable for installation of steel frame building structures. A typical example of such an installation is shown in FIGS. This installation includes a seat 10 installed between a wall frame 15 and a cladding (cover) 16 of a building structure 17. The wall frame 15 includes wall frame elements such as studs 18 and noggings 19. The cladding 16 is attached to the wall frame 15 by compressing the insulating sheet 10 between the cladding 16 and the wall frame 15 at an appropriate place 20. A cladding 23 is established between the cladding 16 and the insulation sheet 10 (at a place other than where the insulation sheet 10 is compressed between the cladding 16 and the wall frame element). Spacers 21 (known as spacer biscuits) are provided on the insulating sheet 10 to hold the insulating sheet at an interval with respect to the ding 16.

  The heat insulation sheet by this embodiment can function as a heat insulation layer, heat insulation, and a water vapor | steam barrier. This is waterproof in normal applications and is not affected by water. This is therefore particularly suitable for wet climates and may provide protection against flood damage. This does not promote fungal or bacterial growth, nor does it provide a nesting medium for rodents and insects.

  There are some situations where it is desirable for the insulation sheet to have some permeability to air and water vapor to reduce the risk of moisture loss due to condensation. The thermal insulation sheet according to the second embodiment seeks to provide such a thermal insulation sheet.

  Referring now to FIGS. 5 and 6, the insulation sheet according to the second embodiment is similar in many respects to the insulation sheet according to the first embodiment, and therefore the corresponding reference to identify corresponding parts. A sign is used.

  However, in the second embodiment, the heat insulating sheet is permeable to air and water vapor. In this regard, the insulating sheet has a plurality of perforations 25 extending through the sheet 10 between the two outer surfaces 14. The perforation 25 includes a hole 27 formed by perforating the sheet 10 using a perforation tool. Not only does the hole 27 extend through the outer layers 11, 12 to open at the outer surface 14 of the outer layer at the opening 28, but also extends through the closed cell foam structure 13. The perforations 25 are not clearly visible in the closed cell foam structure 13 due to the compressible nature of the foam. Even when crushed in the closed cell foam structure 13, the perforations 25 provide a permeation path through the sheet 10 for air and water vapor.

  Referring now to FIG. 7, the thermal insulation sheet according to the third embodiment is similar in many respects to the thermal insulation sheet according to the second embodiment, and therefore corresponding reference symbols are used to identify corresponding parts. ing.

  In the third embodiment, the perforations 25 extend through the two outer layers 11, 12 and partway through a closed cell foam structure 13 disposed between the two outer layers. In particular, these perforations comprise holes 27 extending from the outer layer 11 into the closed cell foam structure 13 and ending in the closed cell foam structure 13 inside the other outer layer 12. The perforations are provided with openings 28 in the two outer layers 11, 12 as in the second embodiment. The holes 27 extend from corresponding openings 28 in the outer layer 11 and terminate inside the openings 28 in the outer layer 12 to define a void 29 between the holes 27 and the outer layer 12.

  It should be understood that the scope of the present invention is not limited to the scope of the three embodiments described above. For example, it is not necessary for both outer layers 11 and 12 to be reflective foils. One of these outer layers can be a reflective foil (preferably treated for glare reduction) and the other layer can be any suitable type of film including, for example, a polyethylene film. Can be prepared.

  Modifications and changes can be made without departing from the scope of the invention.

Throughout this specification, unless the context requires anything else,
The terms “comprise” or “comprises” or “comprising” mean the inclusion of a specifically stated integer or group of integers, but any other integer or group of integers. It is understood that no exclusion is meant.

Claims (22)

  A cell structure sandwiched between two outer layers, the cell structure comprising a closed cell foam structure.   The thermal insulation sheet according to claim 1, wherein the closed cell foam structure comprises a polyethylene foam.   The thermal insulation sheet of claim 2, wherein the closed cell foam structure comprises cross-linked low density polyethylene (LDPE) foam.   The heat insulation sheet according to any one of claims 1 to 3, wherein at least one of the two outer layers includes a reflective foil.   The heat insulating sheet according to claim 4, wherein both outer layers include a reflective foil.   The heat insulating sheet according to claim 5, wherein the reflective foil comprises an aluminum foil.   The said aluminum foil is a heat insulation sheet of Claim 6 provided with the reflective foil of 99.5% pure aluminum.   The thermal insulation sheet according to any one of the preceding claims, wherein at least one of the outer layers is reinforced for tear resistance.   The heat insulation sheet according to claim 8, wherein the reinforcement includes a scrim joined to the outer layer.   The heat insulating sheet according to claim 9, wherein the scrim comprises a high density polyethylene fabric laminated to the outer layer.   The heat insulation sheet according to any one of claims 4 to 10, wherein at least one of the reflective layers is treated for reducing glare.   The heat insulation sheet according to any one of the preceding claims, wherein the closed cell foam structure has flame retardancy.   The thermal insulation sheet according to any one of the preceding claims, wherein the closed cell foam structure includes an antioxidant for durability.   The heat insulation sheet according to any one of the preceding claims, wherein the closed cell foam structure has UV protection.   The thermal insulation sheet according to any one of the preceding claims, wherein the outer layer is perforated for air and water vapor permeability through the thermal insulation sheet.   The heat insulating sheet according to claim 15, wherein the perforations are formed after the heat insulating sheet is constructed.   17. A thermal insulation sheet according to claim 15 or 16, wherein the perforations extend through the two outer layers and the closed cell foam structure disposed between the two outer layers.   17. A thermal insulating sheet according to claim 15 or 16, wherein the perforations comprise holes extending through one outer layer into the closed cell foam structure and ending inside the other outer layer.   The heat insulating sheet according to claim 18, wherein the hole opens on the one outer layer in an opening of the one outer layer, and a corresponding opening exists in the other outer layer.   20. A thermal insulation sheet according to any one of claims 17 to 19, wherein the perforations in the outer layer and the closed cell foam structure are aligned to assist in the permeation of air and water vapor through the sheet. .   A building structure comprising a frame, a cladding attached to the frame, and a heat insulating material between the frame and the cladding, wherein the heat insulating material precedes. Building structure with a thermal insulation sheet.   A thermal insulation sheet substantially as herein described with reference to the accompanying drawings.

Images