KR20140107336A - Wall insulation panel - Google Patents

Abstract

A second VIP panel having a VIP-facing surface and a second protective panel having a VIP-facing surface and an outward-facing surface, the first VIP panel having a wall-contacting surface and a vacuum insulation panel (VIP) facing surface, Characterized in that there is an extended region between at least one of the first and second protective panels and the VIP panel to allow expansion of the VIP panel without deformation of the outward facing surface of the second protective panel, A wall insulating panel is disclosed. In this way, the extension area allows expansion of the VIP panel without deformation of the VIP facing surface of the second panel, thus without deformation of the outward facing surface. This maintains the integrity and aesthetic appearance of the outward facing surface, and any additional surfaces or layers on the outward facing surface such as the rendered layer.

Description

{WALL INSULATION PANEL}

Cross-reference to related application

This application claims priority to U.S. Provisional Patent Application No. 61 / 566,747, filed December 5, 2011, the contents of which are incorporated herein by reference, and all the advantages of this application.

The present invention includes a wall insulation panel for use on a wall and including a vacuum insulation panel (VIP), as well as a series of said wall insulation panels to provide a continuous VIP plane Lt; RTI ID = 0.0 > cladding. ≪ / RTI >

Vacuum insulation panels (VIP), also often referred to as 'VIP panels', are highly efficient and advanced insulation techniques with insulation capacity three to seven times more effective than conventional plastic foam or fibrous insulation. VIP panels are increasingly being used to improve the performance of stationary products such as refrigerators and refrigerated vehicles.

VIP panels are being used or are increasingly being used for building insulation, especially for the purpose of making buildings more efficient. VIP panels are generally more compact (by being thinner) than conventional insulation panels, thus ensuring both space and energy savings. Although the insulation in the cavity wall is well known, it is also required to improve the insulation on the exterior wall of the building.

Conventionally, the external wall insulation for a building is provided by a solid panel formed of conventional foam or fibrous insulation. Such a panel is not only capable of withstanding handling during construction and installation processes, but also can be cut and shaped to any size, and can be used to remove the nails which can intentionally or accidentally pass through the panel without significantly affecting the adiabatic properties of such panels. nail, and other fastening brackets to provide a robust product that can be secured to the wall.

As a final outward layer for weather shielding and after the addition of an insulating panel during wall construction and defining a 'view' of the building, the final layer, typically a 'rendered' layer, To provide a smooth, uniform finish on the exterior of the building.

The VIP panel is generally less robust by involving vacuum, and requires at least some degree of protection to withstand the associated handling during installation and fastening. Thus, conventionally, a VIP panel for architectural purposes is completely enclosed in one or more foam-protective layers on all sides to form a heat-insulating panel.

However, such fully protected and encapsulated VIP panels have two problems. First, although the vacuum technology is improving, the presence of vacuum in the VIP panel still allows gas to move from the atmosphere through the panel membrane into the interior of the panel, i.e., to 'leak' the vacuum. However, any leakage will affect the overall size of the enclosed VIP panel, expanding the entire adiabatic panel and thus deforming any weather shielding or rendered finish on the adiabatic panel. Rendering will crack and allow water ingress, which will not only affect the completeness of the panel, but will also make it aesthetically unsightly.

Second, the overall effectiveness of vacuum insulation is reduced when many such panels are combined to form the entire surface or cladding. This is because the foam baffle surrounds the VIP panels on all sides to isolate the VIP panels so that providing multiple such panels together will not produce any continuity of the 'vacuum insulation' properties of the individual VIP panels. Thus, a " heat highway ", i.e., a path that is easier for heat to travel, is created for the passage of heat from one side of the insulating panel to the other, generally from outside to inside. The thermal highway is formed between the VIP panels which, despite the adherence of the insulating panels, cause the foam barrier to break the contact of the actual vacuum insulation part of each panel.

It is an object of the present invention to provide an improved wall insulation panel having a VIP panel for use in wall insulation and capable of reducing the number of thermal highways that accept VIP leaks and / or traverse a series of such panels.

According to one aspect of the present invention,

A first protective panel having a wall-contacting surface and a vacuum insulation panel (VIP) facing surface,

Intermediate VIP panel, and

A second protective panel having a VIP facing surface and an outward facing surface

Wherein the wall comprises at least continuous layers of wall,

Characterized in that there is an extended area between the VIP panel and at least one of the first and second protective panels to allow expansion of the VIP panel without deformation of the outward facing surface of the second protective panel.

In this way, the extension area allows expansion of the VIP panel without deformation of the VIP facing surface of the second panel, thus without deformation of the outward facing surface. This maintains the integrity and aesthetic appearance of the outward facing surface, and any additional surfaces or layers on the outward facing surface such as the rendered layer.

The wall insulation panels of the present invention may be of any type, shape, and size, including, but not limited to, inner wall, outer wall, ceiling, roof, floor, door, or any other surface intended to provide a similar structure It is available on the wall. The nature, size, design and shape of the wall are not limiting factors of the present invention.

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

Typical but non-limiting dimensions of the wall insulation panel may be in the range of 0.3 m to 2.5 m 'wide', 0.3 m to 4 m 'high', and 50 mm to 500 mm 'thick'.

The characteristics, size, shape, and design of the first protective panel are not limited to the present invention. It may be any suitable material, preferably a durable plastic foam, more preferably expanded polystyrene (EPS), extruded polystyrene (XPS), polyurethane (PU), polyisocyanurate foam (PIR) , Aluminum, or any rigid plastic.

Similarly, the characteristics, size, shape, and design of the second protective panel are not limited to the same invention, and may be the same as or different from those of the first protective panel. Preferably, the second protective panel may also comprise any suitable material, more preferably a durable plastic foam, even more preferably an expanded polystyrene (EPS), extruded polystyrene (XPS), polyurethane (PU), PIR Sisanurate foam), aluminum, or any rigid plastic.

The second protection panel has an outward facing surface. The term "outward" is used herein to mean the opposite of a "wall-contacting surface ", in the same manner as most building walls have an inner facing surface and an outer or outward facing surface. Generally, the "outward" facing surface 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 may have any suitable characteristics, size, shape, and design acceptable between the first and second protective panels. The VIP panel can be formed of any suitable outer film, membrane, wall, covering or the like, generally referred to as a " membrane material " The vacuum is lower than generally 'ambient' or 'atmospheric' pressures, such as less than 0.5 mbar (5 mbar) for dry silica filled VIP and less than 0.1 mbar (1 mbar) for mineral wool filled VIP It may be of any suitable pressure. The vacuum pressure may be related to the size of the VIP panel and other configuration parameters.

The wall insulation panel may include one or more intermediate VIP panels having the same or different, optionally the same or similar dimensions and other parameters, and reference herein to a "intermediate VIP panel" A single intermediate VIP panel or a number of intermediate VIP panels that are layered between them.

As discussed above, the membrane or covering material of the VIP panel is intended to resist movement of gas from the atmosphere into the interior of the panel, which obviously reduces the vacuum insulation performance of the panel and also enlarges the size of the panel. Membrane materials such as aluminum foils not only have good vacuum-resistance properties, but are also easily " sealable " during the manufacturing process of VIP panels. One or more additional layers or coverslips can be internal or external to the membrane material. However, not only is it possible to produce a complete vacuum layer at vacuum pressures that are particularly susceptible to 'conditions' of building walls such as temperature changes, long term exposure, random impacts, and used to form VIP panels, It is not possible to achieve the long product life and effectiveness required.

The VIP panel may include one or more internal media. The internal medium includes materials such as airgel, silica, especially dry silica, glass fibers and micro glass fibers.

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

The extended area between at least one of the first and second protective panels of the present invention and the VIP panel allows for expansion of the VIP panel without deformation of the outward facing surface of the second panel. Thus, the integrity of the outward facing surface can be maintained. This completeness includes, but is not limited to, an aesthetic appearance of any additional layer or surface or material added on the outward facing surface or outward facing surface, as well as being a barrier to the environment, particularly weather. For example, any deformation at the outward facing surface will crack the added rendered layer on top of it, allowing water ingress with known related problems as well as making it permanently unsightly.

The extension area may include any area or space that can accommodate the expansion of the vacuum insulated panel within the dimensions of the wall insulation panel without affecting the shape or planar surface of the outward facing surface of the second protective panel have.

The extension area may extend partially, substantially or completely across one or more surfaces of the VIP panel. In particular, the extension area may be partially, substantially or completely the same dimensions as at least one of the VIP facing surfaces of the first and second protective panels.

According to one embodiment of the present invention, the length and width of the extension area are completely or substantially coincident with the length and width of the VIP panel.

According to another embodiment of the present invention, the extension area has a full or substantially constant depth, wherein the 'depth' is a dimension extending transversely from one side of the VIP panel.

According to another embodiment of the present invention, the extended area comprises a compensation layer. The compensation layer optionally includes one or more layers and / or materials and can compensate for any expansion of the size of the VIP panel.

Preferably, the compensation layer comprises one or more solid or semi-solid materials which are at least partially deformable to accommodate expansion of the VIP panel. Optionally, the compensation layer may be formed from one or more of the same or different materials, wherein by modification or expansion of the VIP panel, at least one of the materials is deformable and at least one of the materials is unmodifiable .

The 'different' materials of the compensation layer may include materials having different chemical, or material compositions such as one or more plastics, but different properties such as different densities, molecular weights, and the like. Plastics such as EPS are available in different densities, molecular weights, etc. to provide the same type of plastic with different properties, particularly different mechanical properties such as strength.

Optionally, the extension region is formed of one or more deformable materials as defined above, and one or more gas regions or spaces, such as one or more air spaces or pockets.

The deformable materials may extend regularly or irregularly over the extended area and may extend partially, substantially or completely over the extended area.

According to another embodiment of the present invention, the extension region or compensation layer may comprise one or more of ribs, tubes, springs, and / or groups comprising a soft and / or compressible foam, for example a very soft foam .

Optionally, the extension region comprises a series of ribs or tubes extending between the VIP facing surface and the VIP panel, and at least some of the ribs or tubes are deformable. Such ribs or tubes may be formed from low density PU flexible foam, or other low density flexible foam, or flexible foam, or flexible tubes, extruded or molded foam, or even silicone foam or acrylic materials. Optionally, the ribs or tubes provide a pleated surface between the VIP facing surface and the VIP panel. Optionally, ribs or tubes are also extended from the VIP facing surface to meet the VIP panel.

In another embodiment of the present invention, the compensation layer is a sheeted material shaped to fit directly into the extension layer. The sheet-like material may include a first surface having a deformable material such as a plurality of ribs or wraps extending transversely from the first sheet. Optionally, the sheet has a second opposing surface that forms a 'sandwich' effect between the deformable material. Such a sheet-like material can be formed as an extruded material and can be cut into a desired shape for easy insertion into the expanded area during manufacture of the wall insulation panels. Alternatively, the compensation layer can be formed.

Preferably, the extension area is between the VIP facing surface of the second panel and the VIP panel. Optionally, the extension area is positioned between the VIP panel and the VIP facing surface of the first protective panel to provide the same tolerance for expansion of the VIP panel without deformation of the outward facing surface of the second protective panel. Alternatively, an extension area may be located on each side of the VIP panel to accommodate the expansion of the VIP panel from one or both sides of the VIP panel.

As mentioned above, VIP panels have generally only been used when fully enclosed by one or more protective layers in conventional insulating panels to protect the integrity of the more fragile VIP panels during use in the construction industry, and the like. However, providing a plurality of such panels to cover the wall, as the blanket surrounds the VIP panels on all sides, permits a series of " vacuum insulation " properties of the isolated and thus separated VIP panels in each of the insulating panels I never do that. That is, despite the contact of the insulating panels, a thermal highway is formed between the VIP panels.

Thus, in another embodiment of the present invention, the wall insulation panel of the present invention comprises a VIP panel extending to two opposite sides of the wall insulation panel. In this way, to provide a continuum of vacuum insulation effects across two or more adjacent, abutting, bonded, or otherwise tangent wall insulation panels of the present invention, such aspects of the VIP panel It can be in direct contact with the sides. Thus, there is no thermal highway possible between them, and the reduction in the number of "thermal highways" in the insulating wall cladding increases the effectiveness of the overall insulation effect across multiple panels.

The term 'direct contact' as used herein relates to contact or abutment of VIP panels in a manner that provides a continuum of vacuum insulation effects. That is, if there is an intermediate layer between the two VIP panels, this will have a minimal effect on the vacuum insulation properties. Preferably, the two VIP panels of this embodiment of the present invention abut without any intermediate layer.

According to another embodiment of the present invention, the outward facing surface of the outer panel has a rendered finish on top.

Optionally, the outer panel includes a lateral warning line parallel to the outward facing surface to indicate the cutting area. The marked cut areas on the building panels are known in the art and can generally be achieved without affecting the VIP panel, in particular without cutting through the VIP panel and thus without overcoming the vacuum insulation effect. In order to inform the user of what area of the wall insulation panel can be cut so as to form the final necessary or desired shape of the wall insulation panel to substantially conform to the space in which the wall or wall is made, ≪ / RTI > and one or more lines formed by adducts or modifications. Such warning lines include continuous or discontinuous red or serrated lines.

According to another aspect of the present invention, a wall insulation cladding is provided that includes a series of abutting wall panels as defined herein. The wall insulation cladding may extend in two or three dimensions and is generally, but not exclusively, a flat outer wall of a building such as a commercial building or building.

Preferably, the wall insulation cladding of the present invention comprises two or more contacts of the present invention, each comprising a VIP panel extending to two opposite sides of the wall insulation panel to increase the overall vacuum insulation effect of the wall insulation cladding. Based on the use of wall insulation panels, it provides a continuous VIP plane in at least one dimension.

Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings.
1A and 1B,
Figures 1a and 1b are side and perspective views, respectively, of an open type wall insulation panel according to one embodiment of the present invention.
2A and 2B,
Figures 2a and 2b are side and perspective views, respectively, of the wall insulation panel of Figures 1a and 1b, in the form of formed;
3,
Figure 3 is a side view of the wall insulation panel of Figure 2a after expansion of the VIP panel;
<Fig. 4>
Fig. 4 is a schematic front view of the two mating wall insulation panels of Figs. 1 and 2;
5,
Figure 5 is a schematic perspective view of a plurality of abutting wall insulation panels of Figures 1 and 2 forming a wall insulation cladding in accordance with another embodiment of the present invention;

1A, 1B, 2A and 2B illustrate a first protective panel 4 having a wall-contacting surface 6 and a vacuum-adiabatic panel (VIP) facing surface 8, a middle VIP panel 10 ) And a second protective panel 12 having a VIP facing surface 14 and an outward facing surface 16, as shown in Fig.

Figures 1a and 1b show the wall insulation panels 2 in an open form before combining the panels in a manufacturing method for providing the formed or finished wall insulation panel 2 shown in Figures 2a and 2b.

Each of the first and second protective panels 4, 12 is made of expanded polystyrene (EPS). EPS can be easily extruded with related shapes to protect or clam-shell the VIP panel 10, or other similar shapes that can actually achieve a protective effect.

Although the present invention is not limited in this regard, Figures 1 and 2 illustrate a preferred embodiment of the VIP panel 10 having a rear wall portion 18 and two protruded shoulder portions 19 to receive and protect the VIP panel 10 on three sides Showing a first protective panel 4 forming a &quot; base channel &quot; having inner dimensions of three sides of the VIP panel 10. The shoulder portions 19 of the first protective panel 4 also have a corresponding protruded top and bottom wall 20 of the second protective panel 12 which overlaps when formed together as shown in Figures 2A and 2B. Lt; / RTI &gt;

The VIP panel 10 is formed from an internal dry silica media and an aluminum membrane available from Dow Corning Corporation of Midland, Mich., USA.

Although not limited thereto, the dimension of the wall insulating panel 2 may be in the range of 1.5 m x 1.5 m x 0.5 m.

The second protection panel 12 is configured such that once the wall insulation panel 2 is formed as shown in Figures 2A and 2B, the VIP facing surface 14 of the second protection panel 12 and the VIP panel 10, And an extended region 22 extending between the opposed surfaces of the first and second regions.

The extension area 22 extends from the VIP facing surface 14 of the second protective panel 12 to provide a pleated pattern or surface between the VIP facing surface 14 and the VIP panel 10, And a compensating layer formed by the parallel ribs 24. The ribs 24 are formed from a suitable material, such as a low density PU flexible foam, to be deformed / compressed when the VIP panel is damaged as shown in FIG. 3 and as discussed below.

1 and 2, the ribs 24 extend completely from the VIP facing surface 14 of the second protective panel 12 to meet the VIP panel 10, And extends across the entire facing surface 14.

The wall insulation panels (2) include a transverse warning line (26) parallel to the outward facing surface (16) to indicate the cutting area. The warning line 26 is in the form of a groove or channel along the top of the second protective panel 12 and may be a different color such as red compared to the color of the second protective panel 12. [ The warning line 26 indicates to the installer how far the second protective panel 12 can be cut or otherwise shaped without cutting into the VIP panel 10 and thereby destroying the integrity of the panel.

Figs. 1 and 2 also show two vertical sides 28 of the VIP panel 10 extending to two opposite sides of the wall insulation panel 2. Fig. Such aspects are not limited to being "vertical" as such, depending on the use and installation of the wall insulation panel 2. [ The vertical sides 28 extend to the vertical side edges of the wall insulation panel 2, that is to say they have the same "length" as the first and second protection panels 4, 12.

Figure 3 shows the formed wall insulation panel 2 of Figure 2a after the leakage of the vacuum in the VIP panel 10, which enlarges the size of the VIP panel 10, in particular the front wall 30 of the VIP panel 10 . The extension of this front wall 30 is shown in exaggerated form to best illustrate the advantages of the present invention.

When the VIP panel front wall 30 is deformed outwardly, generally in a convex manner, its additional space is received by deformation, or crushing, of the opposing ribs 24, Can be made smaller. The degree of deformation of the front wall 30 and the proximity of the front wall to the VIP facing surface 14 of the second protective panel 12 are shown in exaggerated form in Figure 3, The expected deformation over the product life of the wall insulation panel 2 can be precomputed so as to leave a wide margin of error in the expansion area to avoid any complete squeezing.

3 shows the accommodating of the expansion of the VIP panel 10 by the compression of the opposing ribs 24 but the extended front wall 30 reaches the VIP facing surface 14 of the second protection panel 12 I do not. Thus, there is no deformation of the outward facing surface 16 of the second panel 12. [

The enlarged area 22 is likewise connected to the VIP panel 10 so as to provide the same tolerance for the expansion of the opposed wall of the VIP panel 10 without the deformation of the outward facing surface 16 of the second protective panel 12. [ Can be located between the first protective panel (4). Alternatively, an extension area may be located on each side of the VIP panel 10 to accommodate the expansion of one or both VIP panel sidewalls.

4 is a front view of the outwardly facing surfaces 16 of the two wall thermal insulation panels 2 of the present invention abutting along one vertical side 32. Fig. In this way the vertical sides 28 of the VIP panels 10 in each wall insulation panel 2 are in direct contact to form a continuous VIP plane 34 over the size of the two wall insulation panels 2 Thus providing a continuity of the vacuum insulation effect of the two VIP panels 10 across the abutment portion 32. The position of the other wall insulation panels lined up with the two wall insulation panels 2 shown in Fig. 4 will extend the continuity of the vacuum insulation effect in the same direction throughout the entire coverage of the wall insulation panels 2.

Figure 5 shows a series of wall insulation panels 0.91 m x 0.91 m ('3 x 3') positioned on the building wall 40 to form the wall insulation cladding 42 according to another embodiment of the present invention 2) are shown as an example only. The wall insulation panels 2 are abutted along the vertical edges of the panels in the manner shown in Figure 4 to provide a continuity 34 of vacuum insulation effects as described above.

After the application of the wall insulation cladding 42, one or more render layers may be added over the outward facing surfaces 16 of the wall insulation panels 2 to provide the final rendered surface 44. The addition of one or more rendered layers not only provides shielding for the environment, particularly weather, but also provides a more aesthetically pleasing final finish on the exterior of the building.

It is well known that rendering is susceptible to cracking if there is any disturbance, especially deformation, of the surface on which the rendering is placed. The ability of the present invention to retain the outwardly facing surfaces 16 of the wall insulation panels 2 without deforming over the life of the product thus ensures that the wall insulation panels 2 are protected against the outward facing surfaces 16 and the rendered surface 44 To maintain the integrity and aesthetic appearance of any additional surface or layer on the outward facing surface. Maintaining the integrity of the rendered surface 44 is not only aesthetically pleasing, but also avoids or minimizes the possibility of influx of moisture through the rendered surface 44.

Thus, the present invention can allow expansion of the VIP panel without deformation of the outwardly facing surface of the second protective panel when expansion of the VIP panel occurs within the wall insulation panel. In this manner, the present invention maintains the integrity and aesthetic appearance of any additional surface or layer on the outward facing surface or the outward facing surface. The present invention can also provide a continuum of vacuum insulation effects across two or more adjacent or abutting wall insulating panels.

Claims (14)

A first protective panel having a wall-meeting surface and a vacuum insulating panel (VIP) facing surface,
Intermediate VIP panel, and
A second protective panel having a VIP facing surface and an outward facing surface
A wall insulation panel for use on a wall, the wall insulation panel comprising at least a continuous layer of continuous walls,
Characterized in that there is an extended area between at least one of said first and second protective panels and said VIP panel to allow expansion of said VIP panel without deformation of said outward facing surface of said second protective panel. panel. 2. The panel of claim 1, wherein the expanded region comprises a compensation layer. 3. The panel of claim 2, wherein the compensation layer comprises one or more solid or semi-solid materials that are at least partially deformable to accommodate expansion of the VIP panel. 4. The apparatus of claim 3, wherein the extension region comprises ribs, tubes, springs, low density flexible foam, attached ribs or tubes, extruded ribs or tubes, Wherein the wall comprises one or more of the following groups: 5. The panel of claim 4, wherein the extension comprises a series of ribs or tubes extending between the VIP facing surface and the VIP panel, wherein at least a portion of the ribs or tubes are deformable. 6. The panel of claim 4 or 5, wherein the ribs or tubes provide a pleated surface between the VIP facing surface and the VIP panel. 7. A panel according to any one of claims 4 to 6, wherein the ribs or tubes extend completely or substantially from the VIP facing surface to meet the VIP panel. 8. A panel according to any one of claims 1 to 7, wherein the extension area is between the VIP facing surface of the second panel and the VIP panel. 9. A panel according to any one of claims 1 to 8, wherein the VIP panel extends to two opposite sides of the wall insulation panel. 10. A panel according to any one of the preceding claims, wherein the outward facing surface of the second protective panel comprises a rendered finish at the top. 11. A wall insulation panel according to any one of claims 1 to 10, wherein the VIP panel is a dry silica VIP panel. 12. A panel according to any one of the preceding claims, wherein the second panel comprises a lateral warning line parallel to the outward facing surface to indicate a cutting area. A wall insulation cladding comprising a series of abutting wall insulation panels according to any one of the preceding claims. 12. The closure of claim 11, wherein each of the abutting wall insulation panels comprises a VIP panel extending to two opposite sides of the wall insulation panel such that the cladding provides a continuous VIP plane.

Images