JP2015505921A - Wall insulation panel - Google Patents

Abstract

Comprising at least a continuous layer of a first protective panel having a wall meeting surface and a vacuum insulation panel (VIP) contact surface, an intermediate VIP panel, and a second protection panel having a VIP contact surface and a circumscribed surface; In order to enable expansion of the VIP panel without deforming the circumscribed surface of the protection panel, an extension region is provided between at least one of the first and second protection panels and the VIP panel. Wall insulation panel for use on walls. In this way, the expansion region allows expansion of the VIP panel without deformation of the VIP facing surface of the second existing panel, and thus without deformation of the circumscribed surface. This maintains the integrity and aesthetic appearance of the circumscribing surface and any additional surfaces or layers thereon, such as the rendering layer.

Description

(Cross-reference of related applications)
This application claims priority to US Provisional Patent Application No. 61 / 566,747, filed Dec. 5, 2011, and all its advantages, the contents of which are incorporated herein by reference. It is.

(Field of Invention)
The present invention relates to a wall comprising a series of said wall insulation panels for use on a wall and to provide a wall insulation panel including a vacuum insulation panel (VIP) and, in particular, a continuous VIP plane. Related to thermal insulation cladding.

  Vacuum insulation panels (VIPs), often referred to as “VIP panels”, are highly efficient and highly sophisticated, with at least 3-7 times more effective insulation capacity than conventional plastic foam or fibrous insulation It is a simple heat insulation technology. VIP panels are increasingly being used to improve performance in static items such as refrigerators and refrigerated vehicles.

  VIP panels are increasingly being used or proposed to be used in building insulation, especially for the purpose of further building thermal efficiency. VIP panels are generally smaller (by being thinner) than existing thermal insulation panels and reliably save both space and energy. While insulation within “cavity” walls is well known, it is also desirable to improve insulation on the exterior walls of buildings.

  Traditionally, building exterior insulation is provided by solid panels formed of conventional foam or fibrous insulation. Such panels can withstand handling during the construction and installation process, and can be cut and shaped to any size, and can be used intentionally or without significantly affecting thermal insulation. It provides a robust product that can be secured to a wall by an easy fastening method, including nails and other fasteners that can pass accidentally.

  After adding thermal insulation panels during the construction of the wall, the final layer, generally the “rendering” layer, is usually smooth and external to the building, for weather shielding and as the final circumscribing layer that defines the “view” of the building. Added to provide a uniform finish.

  VIP panels are generally not very robust due to the vacuum, and require at least some protection during installation and fixing so that they can withstand the required handling. Thus, traditionally, VIP panels for buildings are completely encased on all sides in one or more foam protection layers to form a thermal insulation panel.

  However, such a fully protected and encased VIP panel has two problems. First, although the vacuum technology has improved, the presence of vacuum in the VIP panel still allows gas to move from the atmosphere into the panel through the panel membrane, ie “leak” the vacuum To. However, any leakage will affect the overall size of the encased VIP panel and expand the entire insulation panel, thus distorting any weather shielding or rendered finish on it. The rendering is cracked and allows moisture ingress, not only affecting the integrity of the panel, but also aesthetically unsightly.

  Second, the overall effectiveness of vacuum insulation is reduced when several such panels are combined to form the entire surface or cladding. This is because foam protection surrounds the VIP panel from all sides and isolates the VIP panel, so providing several such panels together is the “vacuum insulation of separate VIP panels. "No continuation of properties. Thus, a “thermal highway” for heat transfer, ie an easier path, is created for the passage of heat from one side of such insulation panel to the other, generally from the outside to the inside. Is done. Thermal highways are formed between VIP panels, where foam protection breaks the association of the actual vacuum insulation portion of each panel, despite the insulation panel association.

  It is an object of the present invention to provide an improved wall insulation panel that has a VIP panel for use in wall insulation and can accommodate VIP leakage, and / or a thermal highway across such a series of panels ( to reduce the number of heat highways).

According to one aspect of the present invention, a wall insulation panel for use on a wall is provided, the panel comprising:
A first protective panel having a wall meeting surface and a vacuum insulation panel (VIP) contact surface; an intermediate VIP panel;
A first protective panel comprising at least a continuous layer of a VIP protective surface and a second protective panel having a circumscribed surface, wherein the first and An extended region exists between at least one of the second protective panels and the VIP panel.

  In this way, the extension region allows the VIP panel to be expanded without deformation of the VIP contact surface of the second panel and thus without deformation of the outer contact surface. This maintains the integrity and aesthetic appearance of the circumscribed surface and any additional surfaces or layers thereon, such as the rendering layer.

  The wall insulation panels of the present invention can be used on any type, form and range of walls, for example, interior walls, exterior walls, ceilings, roofs, floors, doors, or any other surface that provides a similar structure. However, it is not limited to these. The nature, extent, design, and shape of the walls are not limiting elements to the present invention.

  Preferably, the wall insulation panel is usable on the outer wall of the building.

  Typical but not limited dimensions of wall insulation panels are “width” 0.3 meters to 2.5 meters, “height” 0.3 meters to 4 meters, and “thickness” 50 millimeters to 500 millimeters. It can be a range.

  The nature, size, shape, and design of the first protective panel are not limited to the present invention. This can be formed of any suitable material, preferably a durable plastic foam, more preferably expanded polystyrene (EPS), extruded polystyrene (XPS), polyurethane (PU), PIR (polyisocyanate). Nurate foam), aluminum, or any hard plastic.

  Similarly, the nature, size, shape, and design of the second protective panel are not limited to the present invention and may be the same as or different from those of the first protective panel. Preferably, the second protective panel is also more preferably a durable plastic foam, even more preferably polystyrene (EPS), extruded polystyrene (XPS), polyurethane (PU), PIR (polyisocyanurate foam). May be formed from any suitable material selected from the group consisting of aluminum, or any hard plastic.

  The second protective panel has a circumscribed surface. As used herein, the term “outside” is used to mean the opposite of “wall meeting surface”, and similarly, most building walls have an inscribed surface and an outer or circumscribed surface. Generally, the “outer” tangent of the panel is the surface of the panel that is still visible after the panel is applied to the wall.

  The intermediate VIP panel can have any suitable nature, size, shape, and design that can be accommodated between the first and second protective panels. A VIP panel may be formed from any suitable external film, membrane, wall, coating, etc., commonly referred to as “membrane material” with a vacuum inside. The vacuum is generally from “ambient” or “atmospheric” pressure, such as a fumed silica filled VIP of less than 0.5 kilopascal (5 mbar), a mineral wool filled VIP of less than 0.1 kilopascal (1 mbar). Can be any suitable pressure. The vacuum pressure may be related to the size of the VIP panel and other structural characteristics.

  The wall insulation panel can include one or more intermediate VIP panels, the same or different, optionally having the same or similar dimensions and other characteristics, and further to “intermediate VIP panel” herein. The reference includes a single intermediate VIP panel or a plurality of intermediate VIP panels that overlap between the first and second protection panels.

  As mentioned above, the membrane or covering of the VIP panel is intended to resist the movement of gas from the atmosphere into the panel, which clearly reduces the vacuum insulation performance of the panel, and Increase the panel size. Film materials such as aluminum foil not only have good vacuum heat resistance, but are also easily “sealable” in the VIP panel manufacturing method. One or more additional layers or coatings may be present inside or outside the membrane material. However, creating a complete vacuum layer is not possible, especially with the vacuum pressures used to form VIP panels, and it can be used for building changes such as temperature changes, long-term exposure, any impact, etc. It is subject to wall "conditions" and the realization of long product life and effectiveness generally desired by builders.

  The VIP panel may include one or more internal media. The internal medium includes materials such as airgel, silica, in particular fumed silica, fiberglass and microfiberglass.

  According to one embodiment of the present invention, the VIP panel used in the present invention is a fumed silica VIP panel available from Dow Coming Corporation in Midland, Michigan, USA.

  The expansion area between at least one of the first and second protective panels and the VIP panel of the present invention allows expansion of the VIP panel without deformation of the circumscribed surface of the second panel. Therefore, the consistency of the circumscribed surface can be maintained. This integrity includes, but is not limited to, the aesthetic appearance of the material, as well as being a barrier to the environment, such as the weather, as well as any additional layers or surfaces that are added on or circumscribed. . For example, any deformation in the circumscribing surface will not only crack the rendered layer added on top of it, allowing moisture ingress with its known associated problems, but also permanently making it unsightly. Let's go.

  The expansion region can include any region or space that can accommodate the expansion of the vacuum insulation panel within the dimensions of the wall insulation panel without affecting the shape or surface of the circumscribed surface of the second protective panel.

  The extended region can extend partially, substantially, or completely across one or more faces of the VIP panel. Specifically, it may be the same dimensions as at least one of the VIP contact surfaces of the first and second protective panels, partially, substantially, or completely.

  According to one embodiment of the present invention, the length and width of the extension region completely or substantially matches the length and width of the VIP panel.

  According to another embodiment of the invention, the extension region has a fully or substantially constant depth, the “depth” being its dimension extending laterally from one side of the VIP panel. .

  According to another embodiment of the present invention, the extended region includes a correction layer. The correction layer can optionally include one or more layers and / or materials to correct any expansion in the size of the VIP panel.

  Preferably, the correction layer comprises one or more solid or semi-solid materials, at least a portion of which is deformable to accommodate expansion of the VIP panel. Optionally, the correction layer may be formed from one or more materials that are the same or different, at least one of the materials being deformable, and at least one of the materials being deformed by deformation or expansion of the VIP panel. Is impossible.

  The “different” material of the correction layer has the same chemical or material composition as the one or more plastics, but may include materials having different properties, such as different densities, molecular weights, and the like. Plastics such as EPS are available in different densities, molecular weights, etc., providing the same kind of plastics with different properties, especially different mechanical properties such as strength.

  Optionally, the expansion region is formed from one or more deformable materials as defined above and one or more gas regions or spaces, such as one or more airspaces or cavities.

  The deformable material can extend over the extended region, either regularly or irregularly, and can extend partially, substantially, or completely over the extended region.

  According to another embodiment of the invention, the expansion region or correction layer comprises one or more of the group comprising ribs, tubes, springs, flexible and / or compressible foams, for example very soft foams.

  Optionally, the extension region includes a series of ribs or tubes extending between the VIP interface and the VIP panel, at least a portion of the ribs or tubes being deformable. Such ribs or tubes may be formed from a low density PU soft foam, or another low density soft foam, or a flexible foam, or a flexible tube, extruded or molded foam, or silicone foam, or an acrylic material. Can do. Optionally, the ribs or tubes provide a corrugated surface between the VIP interface and the VIP panel. Also, optionally, ribs or tubes extend from the VIP interface to meet with the VIP panel.

  In another embodiment of the invention, the correction layer is a sheet-like material that is shaped to fit directly into the expansion layer. The sheet material may include a first surface having a deformable material, such as a number of ribs or pleats, extending laterally from the first sheet. Optionally, the sheet has a second opposing surface that forms a “sandwich” effect between the deformable materials. Such sheet-like material is formed as an extruded material and can be cut into a desired shape for easy insertion into the extended area during the manufacture of the wall insulation panel. Alternatively, a correction layer can be formed.

  Preferably, the extended area is between the VIP contact surface of the second panel and the VIP panel. Optionally, the extended region provides a similar tolerance for VIP panel expansion without deformation of the circumscribed surface of the second protective panel, and the VIP of the first protective panel and the VIP of the first protective panel. It is arranged between the contact surface. Alternatively, the extension region can be arranged on each side of the VIP panel so that it can accommodate expansion of the VIP panel from one or both sides of the VIP panel.

  As mentioned above, VIP panels are completely covered by one or more protective layers in conventional thermal insulation panels to protect the integrity of the more fragile VIP panels while being used in the construction industry and the like. Used only when surrounded by Go. However, because the protection surrounds the VIP panel on all sides, the provision of several such panels for coating the walls together is isolated within each of the insulation panels, and thus separate It does not allow the "vacuum insulation" property of the VIP panel to continue. In other words, the thermal highway is formed between the VIP panel and the thermal panel.

  Accordingly, in another embodiment of the present invention, the wall insulation panel of the present invention comprises a VIP panel that extends to two opposing sides of the wall insulation panel. In this way, such a side of the VIP panel provides a continuation of the vacuum insulation effect over the wall insulation panels of the present invention that are two or more adjacent, abutting, joining or otherwise joining. To the VIP side of other such panels that are placed opposite each other. Thus, there are no possible thermal highways in between, and the reduction in the number of “thermal highways” in the insulation wall cladding increases the effectiveness of the overall insulation effect across several panels.

  As used herein, the term “directly associates” relates to the association or abutment of VIP panels in a method for providing continuation of the vacuum insulation effect. That is, if there is any intermediate layer between the two VIP panels, it has a slight effect on the vacuum insulation properties. Preferably, the two VIP panels in this embodiment of the present invention are in contact with each other without an intermediate layer.

  According to another embodiment of the invention, the outer surface of the outer panel has a rendered finish thereon.

  Optionally, the outer panel includes a lateral warning line that is parallel to the circumscribing surface to indicate the cutting zone. Presented cutting zones for building panels are known in the art and are generally one or more formed on the outer surface by visual or tangible two-dimensional or three-dimensional additions or changes. Includes a line, which generally cuts off any area of the wall insulation panel to form the final required or desired shape of the wall insulation panel to match the corresponding space on the wall. This is to show the user what it can do, without affecting the VIP panel, more specifically without cutting the VIP panel and thus without negating the vacuum insulation effect. Such warning lines include continuous or discontinuous red lines or indented lines.

  According to another aspect of the present invention, a wall insulation cladding is provided comprising a series of abutting wall panels as defined herein. Wall insulation cladding can generally extend in two or three dimensions as a flat outer wall of a building, such as, but not limited to, a commercial building or facility.

  Preferably, the wall insulation cladding of the present invention provides a continuous VIP plane in at least one dimension based on the use of two or more abutting wall insulation panels of the present invention, each panel comprising a wall insulation cladding. In order to enhance the overall vacuum insulation effect, a VIP panel extending on two opposite sides of the wall insulation panel is included.

Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings.
FIG. 2 is a side view and a perspective view, respectively, of a wall insulation panel according to an embodiment of the present invention in an expanded form. FIG. 2 is a side view and a perspective view, respectively, of a wall insulation panel according to an embodiment of the present invention in an expanded form. FIG. 2 is a side view and a perspective view, respectively, of the wall insulation panel of FIGS. 1a and 1b in the formed form. FIG. 2 is a side view and a perspective view, respectively, of the wall insulation panel of FIGS. 1a and 1b in the formed form. 2b is a side view of the wall insulation panel of FIG. 2a after expansion of the VIP panel. FIG. 3 is a schematic front view of two abutting wall insulation panels in FIGS. 1 and 2. FIG. 3 is a schematic perspective view of several abutting wall insulation panels of FIGS. 1 and 2 forming a wall insulation cladding according to another embodiment of the present invention.

  Referring to the drawings, FIGS. 1 a, 1 b, 2 a, and 2 b show a wall insulation panel 2 according to an embodiment of the present invention, the wall insulation panel 2 comprising a wall assembly surface 6 and a vacuum insulation panel (VIP) contact surface 8. A first protective panel 4 having an intermediate VIP panel 10 and a second protective panel 12 having a VIP contact surface 14 and an outer contact surface 16.

  FIGS. 1 a and 1 b show an expanded form of the wall insulation panel 2 prior to combining the panels in the manufacturing method for providing the formed or completed wall insulation panel 2 shown in FIGS. 2 a and 2 b.

  The first protective panel 4 and the second protective panel 12 are each formed of expanded polystyrene (EPS). The EPS can be easily extruded into a suitable shape, or indeed any other similar shape that can achieve a protective effect, so as to surround the VIP panel 10 in a protective or clamshell manner.

  Although the present invention is not limited thereto, FIGS. 1 and 2 show a first protective panel 4 forming a “base channel”, the first protective panel 4 comprising a rear wall 18 and two projecting shoulders. And has internal dimensions of the three side surfaces of the VIP panel 10 so as to accommodate and protect the VIP panel 10 on the three side surfaces. The shoulder 19 of the first protective panel 4 also accommodates the corresponding protruding top and bottom walls 20 of the second protective panel 12 that overlap when formed together, as shown in FIGS. 2a and 2b. To be molded.

  The VIP panel 10 is formed from an aluminum film and a fumed silica internal medium available from Dow Coming Corporation, Midland, Michigan, USA.

  Without being limited thereto, the dimensions of the wall insulation panel 2 may range from 1.5 meters x 1.5 meters x 0.5 meters.

  The second protective panel 12 includes an extended region 22, which once the wall insulation panel 2 is formed as shown in FIGS. 2a and 2b, the VIP contact surface of the second protective panel 12. 14 and the opposite surface of the VIP panel 10.

  The extended region 22 extends from the VIP contact surface 14 of the second protective panel 12 to provide a corrugated pattern or surface between the VIP contact surface 14 and the VIP panel 10. A correction layer formed by the ribs 24 is provided. The ribs 24 are formed from a suitable material, such as a low density PU flexible foam that compresses / deforms when the VIP panel is damaged, as shown in FIG. 3 and described below.

  As shown in FIGS. 1 and 2, the rib 24 extends completely from the VIP contact surface 14 of the second protective panel 12 so as to meet with the VIP panel 10, and the rib 24 extends to the entire VIP contact surface 14. Extending over.

  The wall insulation panel 2 includes a lateral warning line 26 that is parallel to the circumscribing surface 16 to indicate a cutting zone. The warning line 26 is in the form of a groove or channel along the top of the second protective panel 12 and can be colored differently, such as red, as compared to the color of the second protective panel 12. The warning line 26 is formed to what extent the second protective panel 12 is cut or otherwise formed without cutting the VIP panel 10 and thus without destroying its integrity, Indicating indicators to the installer.

  1 and 2 also show two vertical sides 28 of the VIP panel 10 that extend to two opposite sides of the wall insulation panel 2. Such side faces are not limited to being “vertical” per se, but depend on the use and installation of the wall insulation panel 2. The vertical side surfaces 28 extend to the vertical side edges of the wall insulation panel 2 (ie they have the same “length” as the first protective panel 4 and the second protective panel 12).

  FIG. 3 shows the wall insulation panel 2 of FIG. 2 a formed after a vacuum leak in the VIP panel 10 that expands the size of the VIP panel 10, in particular the front wall 30 of the VIP panel 10. This expansion of the front wall 30 is shown in exaggerated form to best illustrate the advantages of the present invention.

  When the front wall 30 of the VIP panel is deformed outward in a generally convex shape, the additional space can be accommodated by deformation (i.e., crushing the opposing ribs 24, making the expansion region 22a smaller). ). The degree of deformation of the front wall 30 and the proximity of the second protective panel 12 to the VIP contact surface 14 is shown in an exaggerated form with respect to FIG. The deformation can be calculated in advance and provides wide tolerances for errors in the extended region to avoid any complete crushing of the ribs 24 during product life.

  FIG. 3 shows a response to expansion of the VIP panel 10 by crushing the opposing rib 24, and the expansion front wall 30 does not reach the VIP contact surface 14 of the second protective panel 12. Therefore, there is no deformation of the circumscribed surface 16 of the second panel 12.

  The extended region 22 is similarly provided with a VIP panel to provide similar tolerances in preparation for expansion of the opposing walls of the VIP panel 10 without deformation of the circumscribing surface 16 of the second protective panel 12. It can be seen that it can be arranged between 10 and the first protective panel 4. Alternatively, the extension region can be located on each side of the VIP panel 10 that can accommodate an extension of one or both VIP panel sidewalls.

  FIG. 4 is a front view of the circumscribed surface 16 of the two wall insulation panels 2 of the present invention that abuts along one vertical side 32. In this way, the vertical side surfaces 28 of the VIP panels 10 within each wall insulation panel 2 can abut directly so as to form a continuous VIP plane 34 over the range of the two wall insulation panels 2. , Providing a continuation of the vacuum insulation effect of the two VIP panels 10 across the abutment 32. The position of the other wall insulation panel along with the two wall insulation panels 2 shown in FIG. 4 extends the continuity of the vacuum insulation effect in the same direction over the entire range of the coating of the wall insulation panel 2.

  FIG. 5 is by way of example only and shows a 0.91 meter × 0.00 mm wall insulation panel 2 placed on a building wall 40 to form a wall insulation cladding 42 according to another embodiment of the present invention. The 91 meter (3 feet x 3 feet) series is shown. The wall insulation panels 2 abut along their vertical edges in the manner shown in FIG. 4 to provide a continuation of the vacuum insulation effect 34 as described above.

  After applying the wall insulation cladding 42, one or more rendering layers can then be added across the circumscribing surface 16 of the wall insulation panel 2 to provide the final rendered surface 44. The addition of one or more rendering layers provides shielding against the environment, particularly the weather, and in addition provides an aesthetically pleasing final finish on the outside of the building.

  It is well known that rendering is susceptible to cracking if there is any disturbance, especially deformation, on the surface on which it is laid. Accordingly, the ability of the present invention to maintain the exterior surface 16 of the wall insulation panel 2 over the life of the product without deformation is that the wall insulation panel 2 has a surface such as the exterior surface 16 and / or the rendering surface 44 thereon. It makes it possible to maintain the integrity and aesthetic appearance of any further surface or layer. Maintaining the integrity of the rendering surface 44 is not only aesthetically pleasing, but avoids or minimizes the possibility of moisture ingress through the rendering surface 44.

  Therefore, the present invention can enable expansion of the VIP panel in the wall heat insulation panel without deformation of the circumscribed surface of the second protective panel when such a thing occurs. In this way, the present invention maintains the integrity and aesthetic appearance of the circumscribing surface, or any further surface or layer thereon. The present invention can also provide a continuation of the vacuum insulation effect across two or more adjacent or abutting wall insulation panels.

Claims (14)

A wall insulation panel for use on a wall,
A first protective panel having a wall meeting surface and a vacuum insulation panel (VIP) interface;
Intermediate VIP panel,
At least a continuous layer with a second protective panel having a VIP-facing surface and a circumscribing surface;
In order to allow expansion of the VIP panel without deformation of the circumscribed surface of the second protection panel, at least one of the first protection panel and the second protection panel and the VIP Wall insulation panel, characterized in that there is an extended area between the panel.   The panel of claim 1, wherein the extended region includes a correction layer.   The panel of claim 2, wherein the correction layer comprises one or more solid or semi-solid materials, at least a portion of which is deformable to accommodate expansion of the VIP panel.   4. The expanded region includes one or more of the group comprising ribs, tubes, springs, low density flexible foam, deposited ribs or tubes, extruded ribs or tubes, silicone foam. Panel.   The panel of claim 4, wherein the extension region comprises a series of ribs or tubes extending between the VIP interface and the VIP panel, wherein at least a portion of the ribs or tubes is deformable. .   The panel according to claim 4 or 5, wherein the ribs or tubes provide a corrugated surface between the VIP interface and the VIP panel.   7. A panel according to any one of claims 4 to 6, wherein the rib or tube extends completely or substantially from the VIP interface so as to meet with the VIP panel.   The panel according to claim 1, wherein the extension region is between the VIP contact surface of the second panel and the VIP panel.   9. A panel according to any one of the preceding claims, wherein the VIP panel extends to two opposing sides of the wall insulation panel.   The panel according to any one of the preceding claims, wherein the circumscribing surface of the second protective panel has a rendered finish on its surface.   11. The panel according to any one of the preceding claims, wherein the VIP panel is a fumed silica VIP panel.   12. A panel according to any preceding claim, wherein the second panel includes a lateral warning line parallel to the circumscribing surface to indicate a cutting zone.   A wall insulation cladding comprising a wall insulation panel according to any one of the preceding claims, wherein the wall insulation cladding comprises a series of abutments.   The wall of claim 11, wherein each of the abutting wall insulation panels comprises a VIP panel that extends to two opposing sides of the wall insulation panel such that the cladding provides a continuous VIP plane. Insulation cladding.

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