WO2008141689A1

WO2008141689A1 - Vacuum insulation panel and method for the production thereof

Info

Publication number: WO2008141689A1
Application number: PCT/EP2008/002039
Authority: WO
Inventors: Gerd NIEMÖLLER
Original assignee: The Wall Ag
Priority date: 2007-01-13
Filing date: 2008-03-13
Publication date: 2008-11-27
Also published as: DE102007035851A1; CA2674479A1; ZA200904777B; US20100095622A1; RU2009130807A; EP2126233A1

Abstract

The present invention relates to a vacuum insulation panel (1) having a core (5) having insulating hollow spaces and cover layers (11) closing off the core (5) from the environment, the hollow spaces of the core (5) being formed by two chambers (3) sealed off from each other in a gas-tight fashion, extending together with the walls (4) or intermediate walls thereof from one cover layer (11) to the other cover layer (11) and being formed from the walls (4) or intermediate walls and the cover layers (11). The present invention further relates to a method for producing such a vacuum insulation panel (1), wherein a) plates (7) are produced having the shape and arrangement in cross section of walls (4) of the half chamber (3) connecting to each other, but being substantially longer than the height of the walls (4) of the chambers (3), then b) a composite (9) then being produced, in that a further such plate (7) is laid on a first such plate (7) such that the entire chambers (3) are formed, c) the plates (7) are then connected to each other, in a gas-tight and permanent fashion, at the contact points (8) thereof, d) further plates (7) are then laid on the uppermost plate (7) of the composite (9) according to step b) and connected, in a gas-tight and permanent fashion, to the uppermost plate (7)of the composite (9) according to step c), e) the composite (9) is further cut transverse to the plates (7) into chamber discs (17) having the desired thickness corresponding to the intended chamber height, and f) the chamber discs (17) are connected, in a gas-tight and permanent fashion, to the cover layers (11) on the open sides of the chambers (3).

Description

Vacuum insulation panel and manufacturing method therefor

description

The present invention relates to a vacuum insulation panel according to the preamble of claim 1 and a manufacturing method thereof.

Such vacuum insulation panels are known in practice. They are thermally and acoustically highly insulating and are therefore used e.g. used as Dämmpaneele. The known vacuum insulation panels consist of a core of an open-pore material, such as a pressure-resistant foam and sealing outer layers or skins.

The previously known vacuum insulation panels have the disadvantage, inter alia, that the vacuum is lost even with a slight damage to the outer skin. If, for example, a hole penetrating the cover layers is drilled in the panel, the core draws air and the insulation effect is reduced or significantly worsened. Another disadvantage is that the known vacuum insulation panels can not be reworked, but from the outset in the production in the factory before the evacuation of the core already have the form in which they are subsequently installed or otherwise used. Subsequent reworking is not possible without loss or drastic deterioration of the insulation properties. Furthermore, the mechanical strength of the known vacuum insulation panels is inadequate for many applications. These vacuum insulation panels can not be used as load-bearing elements, but serve only for isolation. The present invention aims to provide a reworkable vacuum insulation panel, and achieves this object with a vacuum insulation panel according to claim 1 and a manufacturing method for a vacuum insulation panel according to claim 18.

According to the invention, a vacuum insulation panel is thus provided with a core with cavities and the core to the environment towards tight cover layers, the cavities of the core are formed by tightly sealed against each other chambers, which extend together with their partitions from one cover to another cover layer ,

Such a vacuum insulation panel according to the invention has numerous advantages. It can serve both as a high insulation panel, which can be cut to any size, even after evacuation, and which also largely in the partial infringement of the surface gets its function, as well as a static device from the load-bearing walls can be built.

Preferably, the walls or partitions of the chambers form a honeycomb structure. It may further be provided with preference that the honeycomb structure is quadrangular, hexagonal or octagonal, contains circular shapes or is regular or irregular.

Another preferred embodiment is that each cover layer consists of a gas-tight material or is coated with a gas-tight material. Alternatively or additionally, it can be provided that each cover layer contains a layer or plate of in particular reinforced epoxy, melamine or phenolic resin or the like in direct contact with the walls or partitions of the chambers, more preferably the reinforcement of the cover layer of glass fiber material, kraft paper or sisal or the like. Yet another preferred embodiment is that each cover layer has on its side facing away from the walls or partitions of the chambers side a protective layer, wherein in particular the protective layer may contain a mirrored high barrier or aluminum foil or a high barrier or aluminum coating or the like.

Preferably, each cover layer has a thickness greater than about 0.5 mm, preferably greater than about 1 mm, and most preferably about 1 mm.

Another preferred embodiment is that the walls or partitions of the chambers are made of a gas-tight material or coated with a gas-tight material.

It can also be provided with preference that the walls or partitions of the chambers contain paper or cellulose, and / or that the walls or intermediate walls of the chambers have a coating with melamine resin, phenolic resin or a melamine resin-phenolic resin derivative, and / or the walls or intermediate walls of the chambers contain kraft or hard paper, in particular with a reinforcement. Alternatively or additionally, it is preferred if the walls or intermediate walls of the chambers contain a metallic foil or are vapor-deposited with a metallic layer.

Yet another preferred embodiment is that the walls or partitions of the chambers based on a cubic meter, a thermal conductivity of less than about 0.3 W / mK, preferably less than about 0.2 W / mK, and more preferably less than about 0.1 W / mK have. Corresponding values are also influenced by the choice of material pairing. Furthermore, the walls or partitions of the chambers may preferably have a thickness of about 0.5 mm.

A vacuum of about 98% is preferably present in the chambers, or the chambers contain a heat-insulating gas, such as argon or another noble gas or a corresponding gas mixture.

In yet another preferred embodiment, it is provided that the core is sealed at its free edges between the cover layers with synthetic resin or the like.

In a special embodiment, the invention further relates to a vacuum insulation panel with an evacuated or provided with a insulating gas filling core and the core on both sides sealing, consisting of a gas-tight material or coated with a gas-tight material cover layers. In this case, the core consists of a plurality of individual vacuum chambers which are formed by, for example, at right angles to the cover layers extending, in particular regularly arranged, gas-tightly connected to the cover layers walls or partitions, which consist of a gas-tight material or coated with a gas-tight material , In this case, the walls can form a honeycomb pattern or circular tubes in the cross section, or have other geometries. The walls or intermediate walls of the vacuum chambers or generally chambers may in particular consist of a pulp coated with a phenolic resin, alternatively the formation of a metallic foil or of a metal vapor-deposited material or another material having a similar effect. The walls or partitions thus form a plurality of individual vacuum chambers, which are covered on both sides with a cover layer and thus sealed. At least one of the cover layers is applied, for example, under vacuum conditions, so that the chambers are evacuated. The vacuum insulation panel according to the invention can be produced over a large area or endless and then cut to the required size: By cutting is - unlike the previously known from practice vacuum insulation panels - only the insulation effect of the actually cut chambers lost, as this yes compared the adjacent chambers are gas-tight. Even when a hammer, for example, a nail in one of the outer layers, the insulating effect is lost only the respective chamber, but not that of the vacuum insulation panel as a whole.

The preferably regularly formed walls and the sandwich construction of the honeycomb structure between the two cover layers give the vacuum insulation panel a high strength, in particular also against forces which are applied to the vacuum insulation panel in the plane of the cover layers. The vacuum insulation panel can be used as a structural element of a building and other applications. In principle, the chambers can also be filled, for example, with an open-pored foam, as known from the prior art as a sheet-like continuous core material, or else a closed-cell foam.

The honeycomb body can absorb high mechanical loads in conjunction with the cover layers - much higher than wood panels - and yet the honeycomb core weighs only 33 to 60 kg / m ³ , in particular, for example, only about 44 kg / m ³ .

It is again pointed out that instead of the vacuum in the chambers and heat-insulating gases can be used. It is especially thought of the possibility for special applications e.g. Argon or other noble gases to use.

An inventive vacuum insulation panel can be used for the following uses (whereby at the same time as to the invention further inventive idea these uses for the design of the vacuum insulation panel is shown):

Gates (of any kind, such as garage doors, industrial doors, etc.

Doors of any kind swimming pool insulation

Cool boxes, refrigerators, freezers, refrigerated rooms, cold storage or cold storage

Warming boxes for keeping food warm (eg airplanes in airplanes, etc.)

Pipe insulation of any kind

Ship insulation, container container construction, etc. Container construction in general, e.g. Refrigerated containers, sanitary containers, office containers, magazine containers, living containers, etc. Floor coverings of any kind, such as Laminate floor, cold storage floor in aluminum, Riffeloptik, etc. false ceilings, house ceilings of any kind

Rooftop, hall roof (flat roof, etc.) with the corresponding, different optics

Walls as building element (substitute for stones) and as additional insulation incorporated into the stones (bricks, concrete blocks, sandstones, etc.)

Door, gate and window frame insulation of any kind Roller blind boxes of any kind can be manufactured or at least insulated with vacuum insulation panels Heating systems (the system itself can be isolated) Caravan construction Floating house construction Prefabricated construction of any kind Truck trailer construction (cooling trailer construction, etc.)

Prefabricated garage construction (for example car automatically heats the garage with the last waste heat)

Passive hall and passive house construction of any kind furniture industry, etc. Chipboard replacement plasterboard replacement in see-through optics as window pane replacement or as a bridge plate replacement

Paving stone (any type of floor covering, does not let the ground cold through)

High-rise rooms, skyscraper containers, high-rise building elements, etc. Vehicle insulation up to the e.g. Battery insulation, etc. Solar collector plates that produce distilled water for hot water storage etc.

Ceiling and wall insulation with the corresponding optics both indoors and outdoors frost-resistant road surface (under the tar cover, no more slipperiness)

Radiation protection (for example in house construction before radio beams) in any areas where space savings or stability is required

Further applications or uses of inventive vacuum insulation panels are in the field of sound insulation and sound insulation.

Furthermore, the invention provides a manufacturing method for such vacuum insulation panels. This method according to the invention for producing a vacuum insulation panel comprises the following steps: a) plates are produced which in cross section have the shape and arrangement of adjacent walls of the half chambers but are substantially longer than the height of the walls of the chambers; then a composite is made by another such plate is placed on a first such plate so that the whole chambers are formed, c) then the plates are connected to each other at their contact points permanently and gas-tight, d) then successively on the top Plate of the composite further plates according to step b) placed and connected to the top plate of the composite according to step c) permanently and gas-tight, e) then the composite is cut transversely to the plates into chamber discs of desired thickness according to the intended chamber height, and f) finally the chamber discs on the open sides of the chambers are permanently and gas-tightly connected to the cover layers.

Preferably, the method further provides that the cover layers are successively connected to the respective honeycomb disc, and that the joining of the second cover layer with the assembly of the chamber disc and the first cover layer under a vacuum, in a vacuum or in a gas atmosphere with a gas takes place, which is intended as a filling for the chambers. Alternatively, it can also be provided that the cover layers are connected simultaneously to the respective honeycomb disk, and that the bonding of the cover layers to the chamber disk takes place under reduced pressure, in a vacuum or in a gas atmosphere with a gas which is provided as a filling for the chambers ,

Particularly the preparation of the honeycomb, or more precisely their walls coated with melamine resin paper under pressure (30 bar) and heat (185 ⁰ C) is advantageous and preferred. This type of honeycomb production has many advantages: it produces thin, about 0.5 mm honeycomb walls, which are highly resilient high thermal load capacity low weight inexpensive production ultra-fast networking (for example, in 6 s) easy production cheap tool prices and much more.

Furthermore, the process of honeycomb evacuation according to the invention is very advantageous. Hereinafter, a method section in a specific preferred embodiment is shown:

1. Preimpregnated paper is produced

2. in a heating station, the paper is preheated to soften and deform

3. in a preform, a stamp brings the paper into shape so that in a side press 30 honeycombs or other desired or suitable number can be pressed at once; Preferably, punches drive one after the other into the paper so that it can follow from one side

4. In the side press with 30 honeycomb or another desired or suitable number, the bevels are pressed simultaneously, the soil remains uncrosslinked

5. Welding of the honeycombs is carried out by placing honeycombs with their still uncrosslinked bottoms together and pressing them together with a press so that the honeycomb bottoms merge to form a complete honeycomb; This can be done in a so-called honeycomb welding device in which thus the honeycomb bottoms are welded together.

The honeycomb block is created on one side by welding a half honeycomb to the previous one. This is done by dipping an anvil into the last honeycomb and pressing a welding stamp from one side against the anvil. The two not yet networked honeycomb bottoms are fused together. If the anvil consists of a rather filigree stamp, it moves down into a stabilization plate, so that the anvil is held on two sides, in this way e.g. 30 honeycomb floors simultaneously welded together.

From all of the available documents, further preferred and advantageous embodiments of the manufacturing method according to the invention of vacuum insulation panels emerge. This results in particular more protectable embodiments of this method. Further preferred and / or advantageous embodiments of the invention and its individual aspects emerge from the claims and their combinations as well as the entire present application documents.

The invention will now be described by way of example with reference to exemplary embodiments with reference to the drawing, in which

Fig. 1 in a schematic perspective view a

Embodiment of a manufacturing precursor of a vacuum insulation panel shows

2 shows a schematic side or longitudinal sectional view of a detail of a vacuum insulation panel according to the embodiment of the manufacturing precursor in FIG. 1, FIG.

3 shows a schematic view of a part of the manufacturing process of the vacuum insulation panel from FIG. 2,

Fig. 4 in a schematic view one opposite the

3 shows a larger part of the manufacturing process of the vacuum insulation panel from FIG. 2,

5 shows in a schematic plan view a part of a vacuum insulation panel from FIG. 2 in a production preliminary stage,

Fig. 6 in a schematic perspective view a

Embodiment of another manufacturing precursor of a vacuum insulation panel shows 7 shows in a schematic view the penultimate process of the manufacturing process of the vacuum insulation panel from FIG. 2,

8 shows in a schematic view the last process of the manufacturing process of the vacuum insulation panel from FIG. 2,

Fig. 9 is a schematic sectional view of an alternative embodiment of the structure of the core, and

10 is a schematic perspective view of the alternative embodiment of the construction of the core according to FIG. 9.

With reference to the embodiments and application examples described below and illustrated in the drawings, the invention will be explained only by way of example, i. it is not limited to these embodiments and examples of application or to the combinations of features within these embodiments and applications. Process and device features result analogously also from device or process descriptions.

Individual features that are indicated and / or illustrated in connection with a specific embodiment, are not limited to this embodiment or the combination with the other features of this embodiment, but may in the context of the technically possible, with any other variants, even if they are in are not treated separately.

The same reference numerals in the individual figures and illustrations of the drawing designate the same or similar or the same or similar components. On the basis of the illustrations in the drawing, those features are also clear that are not provided with reference numerals, regardless of whether such Features are described below or not. On the other hand, features that are included in the present description but are not visible or illustrated in the drawing will be readily understood by those skilled in the art.

FIG. 1 schematically shows, from an exemplary embodiment of a vacuum insulation panel 1, a production precursor 2 in a perspective view to clarify the shape and arrangement of chambers 3 and their walls 4 or partitions. 2 shows in a side view or a longitudinal section schematically the structure of the vacuum insulation panel 1. The vacuum insulation panel 1 will be described later in connection with FIGS. 3 to 8 in the course of an embodiment of a manufacturing process for it together with the respective manufacturing steps explained.

The vacuum insulation panels 1 consist of a chamber core 5, which was modeled in the present embodiment honeycombs and therefore may also be referred to as honeycomb core. It is a hexagonal shape is used, which also octagonal and other shapes, including irregular shapes are possible. The chamber core 5 is formed by the walls 4 and thus contains the chambers 3. Such designs and structures are very stable, require little material and are also very light.

To form the chambers 3 in the form of half chambers 6 corresponding plates 7 are pressed and then glued together to form the entire chambers 3, as the representations in Figs. 3 to 6 illustrate, or alternatively welded. This creates closed individual systems. The plates produced can also be referred to as half-chamber plates 7 and are placed one on the other in the arrangement shown in FIG. 1 and glued to the fixed and gas-tight connection at their contact points 8, for example, preferably always placed on an existing composite 9, a new plate 7 and then it is glued before the Such a block or composite 9 is cut transversely to the chamber or honeycomb openings 10 so that the height of the chambers 3 and their walls 4 gives the height of the chamber or honeycomb core 5, such as is illustrated by the illustration of FIG. 6. In Fig. 6 are also given by way of example only to be understood dimensions.

The chamber openings 10 are closed on both sides, each with a cover layer 11 by the cover layers 11 are tightly and firmly mounted on the respective sides of the chamber core 5. This results in many small closed cells or chambers 3, and the height of the chambers 3 together with the thickness of the cover layers 11 gives the thickness of the vacuum insulation panel 1. Preferably, the two cover layers 11 are successively glued in separate operations with the chamber core 5 and is the glued second cover layer 11 in a particular approximately 98% vacuum. Instead of gluing other types of attachment, such as welding or direct bonding with each other via not or only partially cured materials of the chamber core 5 and / or the cover layers 11 are possible. Preferably, the material of the cover layers 11 contains a not yet cured resin, so that the curing of the resin happens at any rate during application and bonding of the second cover layer 11 under a vacuum, so that this vacuum is automatically maintained in the individual chambers or honeycomb cells 4 and maintained ,

Preferably, the cover layers 11 are made of a reinforced epoxy resin. Each cover layer 11 is, as the flow chart-like representations of FIGS. 7 and 8 illustrate, introduced in a single production step wet in a mold and cured under vacuum. The walls 4 of the chambers 3 are pressed into the not yet cross-linked cover layers 11, so that when curing the resin of the respective cover layer 11, the walls 4 of the chambers 3 with airtight connect this cover layer 11. By this procedure, the advantage is achieved that in the quasi-combined production and attachment of the cover layers 11 to the core 5, the cover layers 11 are firmly and non-detachably and gas-tightly connected to the wall material of the core 5.

The result is a sandwich material with high rigidity, low weight and very low framework. The core 5 with the walls 4 of the chambers 3, ie without cover layers 11, has in special embodiments a density of about 60 kg / m ³ and a scaffold ratio to the cubic meter of 1:17. However, this ratio can also be in the range of 1:33, for example. Such a low framework / space ratio benefits the insulation performance.

For the cover layers 11, other materials can be used, such as a derivative of melamine and phenolic resin, which is a very inexpensive solution. Under certain circumstances, such cover layers 11 separately to connect to the core 5 of the vacuum insulation panel 1, for example by gluing. Also other plastics can be used. In particular, the cover layers 11 can also contain reinforcements 12 made of glass mats, kraft paper or sisal or similar materials. A particularly preferred layer thickness of the cover layers 11 is approximately 1 mm.

In a further embodiment, the cover layers 11 are provided on their outer sides, ie the sides, which are remote from the core 5, with a protective film 13, such as in particular an aluminum foil 14. Such a protective film 13 and in particular an aluminum foil 14 has the advantage that in the production and connection of a cover layer 11 with the chamber walls 4, the corresponding shape, in which ultimately the bonding step takes place, is protected, in particular resin material, contained in the cover layers 11 so that no undesirable adhesions of such resin material can take place in the mold. Furthermore, such Protective films or layers 13 form an effective diffusion barrier against the ingress of air into the vacuum chambers 3. Especially when using an aluminum foil 14 or the like, the further advantage is achieved that it serves with its shiny surface as a reflection barrier for IR radiation, whereby the insulating performance of the vacuum insulation panel 1 is additionally increased.

The heat transfer occurs in conventional insulation materials known from practice via the so-called scaffold line, the gas line and the radiation line. The largest portion of the gas line with about 2/3 of the total heat conduction. In order to eliminate this proportion, modern thermal insulation materials are evacuated, whereby the gas line is at least largely eliminated. The radiation line is suppressed via reflective surfaces that reflect IR radiation back.

Also in the vacuum insulation panels according to the invention, the air is evacuated, whereby the gas line is eliminated. In the corresponding embodiment with the aluminum foil 14 as a protective film 13, IR radiation is prevented via the high-gloss surface. What remains is the scaffold line, which is calculated from the thermal conductivity of the base material and its mass.

In the presently discussed embodiment, the core 5 of the vacuum insulation panel 1 of so-called hard paper. Depending on the reinforcing material used, hard paper has a value of 0.1 - 0.2 W / mK in relation to one cubic meter. The core with the chambers 2 weighs 30 - 60 kg / m ³ , depending on the size of the chambers. This results in the framework proportions based on the cubic meter, as previously mentioned with a ratio of, for example, about 1:17 to about 1:33, which are preferably values. The thermal conductivity of a paper, for example, used with the already specified values of 0.1 - 0.2 W / mK causes the values of the Scaffolding line of the vacuum insulation panels 1 of, for example, 0.0058 - 0.0117 W / mK to z. B. 0.0029 - 0.0058 W / mK lie.

An essential aspect of vacuum insulation panels 1 is the diffusion of air into evacuated cavities. The vacuum insulation panels 1 are subject to a constant gas pressure, which tries to create a pressure equalization between the atmosphere and the prevailing in the chambers 3 of the vacuum insulation panel 1 vacuum.

Vacuum insulation panels known from practice consist of a foam core, a protective fleece and a plastic barrier film, which is usually vapor-deposited with aluminum. Due to its low layer thickness, this barrier film provides only little protection against diffusion. In the case of vacuum insulation panels known from practice, an attempt is made to compensate for this deficiency by means of special barrier films. Another disadvantage of the known vacuum insulation panels is that they consist of only one vacuum chamber, since the foam core is made of an open-cell foam, and thus a pressure equalization on the entire system acts simultaneously.

The particular construction of the vacuum insulation panels 1 according to the present invention has very significant advantages here, since the pressure generally only on the outer lying on the edge 15 between the outer layers 11 chambers 3 or honeycomb loads. Since the individual chambers 3 are sealed against each other, a pressure equalization would first have to take place in these outer chambers 3 and then spread successively inwards. This advantage is achieved just by the fact that the core 5 of the vacuum insulation panels 1 according to the invention consists of many individual chambers 4, in which only successively from the edge 15 between the cover layers 11 air can penetrate. In order to further prevent this effect, it is provided according to preferred embodiments that the core 5 is provided at its free edges 15 between the cover layers 11 with synthetic resin, such as resin putty, or the like is sealed diffusion-tight.

The air pressure also acts on all chambers 4 at the same time via the cover layers 11. Here, the vacuum insulation panels 1 according to the invention are particularly protected according to corresponding special embodiments, the cover layers 11 not, as usual, consists of a thin sensitive Kunststofffo- lie, but from a particular about 1 mm thick reinforced epoxy resin 12, which additionally with a Aluminum foil 14 may be provided as a protective layer 13, as Fig. 2 illustrates. As an alternative to the aluminum foil 14, a high-barrier foil can also be part of the protective layer 13 or form it. Instead of the design as a film, the protective layer 13 can also be realized as a coating.

Below will be discussed in more detail on some production processes or steps, in the scope of other device features of the vacuum insulation panel 1 are given or clarified.

In a chamber pressing station K (see Fig. 4), the plates 7 are pressed, which form half-chambers 6 in cross section and from which the core 5 is glued together later. The material of the walls 4 or partitions of the chambers 3, or in other words the core 5, consists in the embodiment shown of kraft paper, which is coated with a melamine-phenolic resin derivative. The resin cures under a pressure of 30 bar and a temperature of 185 ⁰ C in about 6 s. The advantage of the resin is that the crosslinking takes place only as long as energy is supplied. So the resin can be dried without curing completely. The wall material is delivered ready for further processing and, in contrast to other resin systems, is dry and only reacts under pressure and heat to cure. The cross-linking process is complete within approx. 6 s. A subsequent outgassing no longer takes place. Another advantage of this Materials is that it is inexpensive and can be stored as a raw material without problems over a long period of time.

The walls 4 of the chambers 3 are about 0.5 mm thick, and have dimensions of 10 mm, resulting in a material length of 49.6 mm per chamber 3 for the walls 4 results. These values are to be understood as examples and may vary depending on the design and requirements.

In order not to let the required pressure be too high in a press P used, for example, five half-chambers 6 are pressed simultaneously in a plate 7. In order not to stretch the wall material, the material is preferably preformed. For example, the material at 60 ⁰ C is flexible and can be deformed with little pressure, so at the beginning of the chamber pressing station K, a heat radiator W is used. As an alternative to the heat radiator W, the pressing tool can also be heated. Further, since the pre-deformation can be very fast and requires little pressure, a simple prepress VP with a pneumatic cylinder PZ can be used and driven. From the prepress VP a pre-plate T is obtained, which is completed in the subsequent pressing step to the plate 7. An example of this process section is illustrated schematically in FIGS. 3 and 4. Accordingly, the entire pressing process from the heating of the paper, the preforming and the actual pressing together.

The thus produced plates 7 having in cross-section the shape of half chambers 3 are fed to a core or block glueing machine (not shown) in which these plates 7 are glued to a block 16, which may also be referred to as a honeycomb block or chamber block , In the figure 5 is shown schematically how two such plates 7, which are shown only in part, are placed on each other to be solid and gas-tight connected to form the chambers 3 at their contact points 8, which by gluing or welding or other appropriate type can be done. For example, the points or contact points 8 of two plates 7 arranged on one another are provided with a fast-curing adhesive, which is applied, for example, by a machine. In practice, the adhesive is applied to the individual plates 7 before they are brought into contact with each other and then glued quickly and well. These steps are repeated until a sufficient number of plates 7 fixedly connected to one another forms a block 16.

Instead of gluing plates 7 to a block 16, the latter can also be produced in the same way by welding, for example, in a press (not shown) of plates 7.

Such a block 16, which can be seen, for example, with exemplary dimensions in FIG. 6, is then transported to a saw (not shown). From the block 16 are then transverse to the plates 7 chamber discs 17 according to the later desired panel thickness, d. H. taking into account the thickness of the still to be applied cover layers 11, cut. The chamber disks 17 correspond directly to the cores 5 of the vacuum insulation panels 1 produced therewith.

In the next manufacturing process section, the chamber disks 17 are provided with the cover layers 11 and, for example, a vacuum is generated in the chambers 3. As already stated above, it is also possible to fill the chambers 3 with selected gas material. The process of applying the first cover layer 11 and also the second cover layer is shown schematically in FIGS. 7 and 8 and reference is made to these illustrated sequences with regard to the details.

In a form F, in accordance with FIG. 7, the protective film 13, such as the aluminum foil 14, is laid in step S1. in the Step S2 is placed on the protective film 13, the armored resin layer 12. In turn, a chamber disk 17 or the core 5 is placed in step S3, whereupon the mold F is closed with a lid D and the air is sucked out of the interior of the mold F closed with the lid D (step S4). The lid D is loosely covered with a blanket G toward the interior of the mold F, so that the evacuation of the interior of the mold F and an inflow of air between the lid D and the blanket G the latter against the free side of the core 5 and this so that it presses on the armored resin layer 12, which is also pressed onto the protective layer 13 at the same time, as shown in step S5. In this case, the core 5 is pressed firmly into the wet resin of the cover layer 11. This state is maintained until the resin of the cover layer 11 has cured. In step S6, after this hardening, air is again allowed to flow into the interior of the mold F and, after opening the lid D, it is possible to remove the composite from the core 5 with the first cover layer 11.

Then, as illustrated in FIG. 8, the protective sheet 13 such as the aluminum foil 14 is laid in a mold F 'in the step S11. In step S12, the armored resin layer 12 is placed on the protective sheet 13. In turn, in step S13, the composite of the core 5 with the first cover layer 11 is laid, whereupon the mold F ^{1 is closed} with a lid D ¹ and the air is sucked out of the interior of the mold F 'closed with the lid D' becomes (step S14). The lid D ¹ is to the interior of the mold F ¹ out with a blanket G 'loosely coated, so that the evacuation of the interior of the mold F' and an influx of air between the lid D ¹ and the blanket G ^1, the latter against the free Side of the composite of the core 5 with the first cover layer 11 and this compound presses thereon on the armored resin layer 12, which is also pressed simultaneously on the protective layer 13, as shown in step S15. In this case, the composite of the core 5 with the first cover layer 11 is pressed firmly into the wet resin of the second cover layer 11. This stand is maintained until the resin of the second cover layer 11 is cured. In step S16, after this hardening, air is again allowed to flow into the interior of the mold F ¹ and, after the lid D ^{1 has been opened,} the finished vacuum insulation panel 1 can be removed from the mold F ¹ . Thereafter, the vacuum insulation panel 1 can still be cut into any shape.

In FIGS. 9 and 10, an alternative embodiment for the design of the chamber core 5 with a design in a sectional view and a perspective view, respectively, is shown schematically in each case. In this design, semicircular chambers 3 ¹ and cruciform chambers 3 "are obtained, thus achieving a favorable contouring for a low heat conduction over the walls 4 between the cover layers 11. With respect to the illustration in FIGS. 9 and 10, the chamber core 5 is produced for a vacuum insulation panel 1 as in the previously described embodiments of the manufacturing process slices (in the illustration of FIG. 10 just parallel to the surface of the drawing sheet) geschitten from a blok- kartige production precursor.

With regard to the design of the design of the chambers, other variants are possible. Thus, mutually equal hemispheres (not shown) on the one hand in a plane in the same orientation can be arranged. A second layer in turn with each other and to the hemispheres of the first layer equal hemispheres can then be arranged so that each touch a hemisphere of the first layer and a hemisphere of the second layer at exactly one point. On the open sides of the hemispheres, the cover layers are applied. Eien heat conduction must and can be done only over the points of contact of the hemispheres, which means very little material. This version is not limited to hemispheres, but works with any dome-like shape, which can also be correspondingly flat according to the small thickness of the vacuum insulation panel 1, such as spherical segments or segments of spherical bodies or other dome-like formations. Such designs can be made, for example, by injection molding, thermoforming, and other known techniques, both in precursors such as individual first and second layers, or as a finished core in a single process.

With regard to the material pairing in the material of the core 5, all combinations are advantageous which have the result of optimizing the lowest possible heat conduction. These are not only the already mentioned material combination consisting of paper and a melamine / phenolic resin derivative. Replacing the organic material paper or wood with an inorganic material such as fiberglass mat material will reduce heat conduction. It is also conceivable for the material of the core 5, a pure ceramic base material, so not necessarily a combination of several materials.

The invention is illustrated by way of example only and not by way of example in the description and the drawing, but includes all variations, modifications, substitutions and combinations that the skilled person the present documents, in particular in the context of the claim and the general representations in the introduction This description and the description of the embodiments can be found and combined with his expert knowledge and the prior art. In particular, all individual features and design options of the invention and its embodiments can be combined.

Claims

claims

1. Vacuum insulation panel (1) having a core (5) with insulating cavities and the core (5) to the environment towards tightly sealed cover layers (11), characterized in that the cavities of the core (5) by gas-tight closed chambers ( 3) are formed, which together with their walls (4) or partitions from one cover layer (11) to the other cover layer (11) and from the walls (4) or partitions and the cover layers (11) are formed.

2. Vacuum insulation panel according to claim 1, characterized in that the walls (4) or intermediate walls of the chambers (3) form a honeycomb structure.

3. Vacuum insulation panel according to claim 2, characterized in that the honeycomb structure is quadrangular, hexagonal or octagonal, contains circular shapes or is regular or irregular.

4. Vacuum insulation panel according to one of the preceding claims, characterized in that each cover layer (11) consists of a gas-tight material or is coated with a gas-tight material.

5. Vacuum insulation panel according to one of the preceding claims, characterized in that each cover layer (11) a layer or plate (12) made of in particular reinforced epoxy, melamine or phenolic resin or the like in direct contact with the walls (4) or partitions contains the chambers (3).

6. Vacuum insulation panel according to claim 5, characterized in that the reinforcement of the cover layer (11) contains glass fiber material, kraft paper or sisal or the like.

7. Vacuum insulation panel according to one of the preceding claims, characterized in that each cover layer (11) on its side facing away from the walls (4) or intermediate walls of the chambers (3) has a protective layer (13).

8. Vacuum insulation panel according to claim 7, characterized in that the protective layer (13) contains a mirrored high barrier or aluminum foil (14) or a high barrier or aluminum coating or the like.

9. Vacuum insulation panel according to one of the preceding claims, characterized in that each cover layer (11) has a thickness of greater than about 0.5 mm, preferably greater than about 1 mm and more preferably about 1 mm.

10. Vacuum insulation panel according to one of the preceding claims, characterized in that the walls (4) or intermediate walls of the chambers (3) consist of a gas-tight material or are coated with a gas-tight material.

11. Vacuum insulation panel according to one of the preceding claims, characterized in that the walls (4) or intermediate walls of the chambers (3) contain paper or pulp, and / or that the walls (4) or partitions of the chambers (3) has a coating with melamine resin, phenolic resin or a melamine-phenolic resin derivative, and / or that the walls (4) or intermediate walls of the chambers (3) contain kraft or hard paper, in particular with a reinforcement.

12. Vacuum insulation panel according to one of the preceding claims, characterized in that the walls (4) or intermediate walls of the chambers (3) contain a metallic foil or are vapor-deposited with a metallic layer.

13. Vacuum insulation panel according to one of the preceding claims, characterized in that the walls (4) or intermediate walls of the chambers (3) based on a cubic meter, a thermal conductivity of less than about 0.3 W / mK, preferably less than about 0.2 W / mK, and more preferably less than about 0.1 W / mK.

14. Vacuum insulation panel according to one of the preceding claims, characterized in that the walls (4) or intermediate walls of the chambers (3) a

Thickness of about 0.5 mm.

15. Vacuum insulation panel according to one of the preceding claims, characterized in that in the chambers (3) there is a vacuum of about 98%.

16. Vacuum insulation panel according to one of claims 1 to 14, characterized in that in the chambers (3) a heat-insulating gas, such as argon or another noble gas or a corresponding gas mixture, is included.

17. Vacuum insulation panel according to one of the preceding claims, characterized in that the core (5) is sealed at its free edges (15) between the cover layers (11) with synthetic resin or the like.

18. A method for producing a vacuum insulation panel according to one of the preceding claims, characterized in a) that first plates (7) are produced, which have the shape and arrangement of adjoining walls (4) of the half chambers (3) in cross section, but much longer than the height of the walls (4) of the chambers (3), b) that then a composite (9) n is prepared by a further such a plate (7) is placed on a first such plate (7) in that the whole chambers (3) are formed, c) that then the plates (7) at their contact points (8) are connected to each other permanently and gas-tight, d) that then placed on the top plate (7) of the composite (9) further plates (7) according to step b) and with the top plate (7) of the composite (9) according to step c) are permanently and gas-tightly connected, e) that thereupon the composite (9) transversely to the plates (7) in chamber discs (17) of desired thickness corresponding to f) Finally, the chamber discs (17) on the open sides of the chambers (3) are permanently and gas-tightly connected to the cover layers (11).

19. The method according to claim 18, characterized in that the cover layers (11) are successively connected to the respective chamber disc (17), and that the joining of the second cover layer (11) with the assembly of the chamber disc (17) and the first Cover layer (11) takes place under reduced pressure, in a vacuum or in a gas atmosphere with a gas which is provided as a filling for the chambers (3).

20. The method according to claim 18, characterized in that the cover layers (11) are connected simultaneously with the respective chamber disc (17), and that the joining of the cover layers (11) with the chamber disc (17) under reduced pressure, in a vacuum or takes place in a gas atmosphere with a gas which is provided as a filling for the chambers (3).