WO2013086005A1

WO2013086005A1 - Wall insulation panel series

Info

Publication number: WO2013086005A1
Application number: PCT/US2012/067962
Authority: WO
Inventors: Robert H. Bruno; Lawrence Carbary; Peter Everett; Matthew L. Phillips
Original assignee: Dow Corning Corporation
Priority date: 2011-12-05
Filing date: 2012-12-05
Publication date: 2013-06-13
Also published as: KR20140109910A; BR112014013532A8; CA2857726A1; MX2014006569A; EP2788556A1; US20140331586A1; JP2015505922A; CN103975113A; BR112014013532A2

Abstract

A series of wall insulating panels for a modular wall insulating system, each wall insulating panel comprising at least the successive layers of: a first protective shell, one or more intermediate VIP panels; and a second protective shell; characterised in that the wall insulating panels of the series comprise two or more sets, each set comprising first and second protective shells having wholly or substantially the same outer dimensions, and at least first and second sets comprising either: (i) a different number of the same VIP panels; or (ii) differently shaped VIP panels; or both (i) and (ii). In this way, there can be provided to the architect, designer and/or installer of the wall insulation panels, different sets of VIP wall insulation panels having a single 'shape' or 'outer shape'. The designer, etc. can then more easily work out, plan or otherwise predict how many and which wall insulation panels are required and where, both overall, and for each wall section, position or location, etc.

Description

WALL INSULATION PANEL SERIES

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and all the advantages of U.S. Provisional Patent Application No. 61/566,748, filed on December 5, 2011, the content of which is incorporated herein by reference.

TECHNICAL FIELD

[0002] The present invention relates to a series of sets of wall insulation panels for a modular wall insulating system, each panel including a one or more vacuum insulating panels, as well as wall insulation cladding comprising said wall insulation panels.

BACKGROUND

[0003] Vacuum insulation panels (VIPs), often also termed 'VIP panels', are a highly efficient advanced thermal insulation technology, having at least 3-7 times more effective insulation ability than conventional plastic foams or fibrous insulation.

VIP panels are used to enhance the performance of static goods such as refrigerators, and in refrigerated vehicles.

[0004] VIP panels are increasingly being used or proposed to be used in the insulation of buildings, especially with the aim of making buildings more thermally efficient. VIP panels are generally more compact (by being thinner) than existing insulation panels, ensuring savings in both space and energy. Insulation within 'cavity' walls is well known, but increasingly it is desired to improve the insulation on the outside walls of buildings.

[0005] Conventionally, outer wall insulation for buildings is provided by solid panels formed with traditional foam or fibrous insulation. Such panels provide a robust product able to withstand handling during the construction and insulating processes, as well as being able to be cut and shaped into any size, and be secured to the wall by easy fixing methods including nails and other fixing brackets, which can deliberately or accidently go through such panels without affecting it properties.

[0006] VIP panels, by involving a vacuum, are generally less robust, and require at least some protection during installation and fixing to withstand the handling involved. Thus, conventionally, VIP panels for building purposes are completely enveloped in foam protective layers in the form of a 'sandwich', being only of one-size or shape which does not allow for any significant re-sizing. Such conventional panels cannot be cut or significantly trimmed into any shape, as that would cut through the VIP panel itself, negating the vacuum insulation effect. They can also not be secured to a wall except by their edges, to again avoid cutting the VIP panel inside.

[0007] Thus, when covering a wall that is not exactly shaped to accommodate an exact and full number of such insulating panels, there must be the use of other types of non-VIP 'filler' panels. This is especially where there are a number of windows in the wall, such that there can be a number of significant areas where the one-sized conventional insulating panels cannot be used, losing some of the overall effectiveness of the use of vacuum insulation.

SUMMARY OF THE INVENTION

[0008] It is an object of the present invention to provide a series of improved wall insulation panels providing sets of panels having a variable number or shape of VIP panels.

[0009] According to one aspect of the present invention, there is provided a series of wall insulating panels for a modular wall insulating system, each wall insulating panel comprising at least the successive layers of: a first protective shell, one or more intermediate VIP panels; and a second protective shell; characterised in that the wall insulating panels of the series comprise two or more sets, each set comprising first and second protective shells having wholly or substantially the same outer dimensions, and at least first and second sets comprising either:

(i) a different number of the same VIP panels; or

(ii) differently shaped VIP panels; or

(iii) both (i) and (ii).

[0010] In this way, there can be provided to the architect, designer and/or installer of the wall insulation panels, different sets of VIP wall insulation panels having a single 'shape' or 'outer shape'. The designer, etc. can then more easily work out, plan or otherwise predict how many and which wall insulation panels are required and where, both overall, and for each wall section, position or location, etc. This can be based on knowing the make-up of the wall insulation panels having different number and/or shape of VIP panels therein. In particular, different wall insulating panels from the same series of VIP-based panels of the present invention can be used to suit areas of the wall to be insulated which are not regular, or which require distinct gaps such as windows, doors or other portals, as well as to suit edges of the wall that may not exactly match the complete dimensions of VIP wall insulating panels.

[0011] The wall insulating panels of the present invention include one or more panels having at least 20% or 25% or 35% or 40% or 45% or 50% or 55% or 60% or 65% or 70% or 75% of its external or internal length or space without one or more intermediate VIP panels: which areas of the wall insulation panels having such non- VIP inclusion can be cut to provide a necessary or desired final wall insulation panel shape required for specified wall positions.

[0012] According to one embodiment of the present invention, the first and second protective shells of all the sets of wall insulating panels of the present invention have the same outer dimensions, in particular length, height and depth.

[0013] Preferably, the wall insulating panels of the present invention are regularly shaped, including but not limited to being square, rectangular or polygonal: more preferably being of a shape able to tessellate.

[0014] For example, the wall insulation panels may be rectangular at approximately 2 to 1 side ratio.

[0015] The wall insulation panels of the present invention are usable on any type, form and extent of wall, being for example an inner wall, outer wall, ceiling, roof, floor, door or any other surface intended to provide a similar structure, and not limited thereto. The nature, extent, design and shape of the wall are not limiting factors to the present invention.

[0016] Preferably, the wall insulation panel is usable on the outer wall of a building.

[0017] The nature, size, shape and design of each first protective shell is not limiting to the present invention. It can be formed of any suitable material, preferably a durable plastic foam, and more preferably selected from the group consisting of expanded polystyrene (EPS), extruded polystyrene (XPS), polyurethane (PU), PIR (Polyisocyanurate foam), aluminium or any rigid plastic.

[0018] Similarly, the nature, size, shape and design of each second protective shell is not limiting to the same invention, and can be the same or different to that of the first protective shell. Preferably, the second protective shell can also be formed of any suitable material, more preferably a durable plastic foam, and even more preferably selected from the group consisting of expanded polystyrene (EPS), extruded polystyrene (XPS), polyurethane (PU), polyurethane (PU), PIR (Polyisocyanurate foam), aluminium or any rigid plastic.

[0019] Each second protective shell has an outward facing surface. The term "outward" is used herein to mean the opposite to the wall-meeting surface, in the same way that most building walls have an inner facing surface and an outer or outward facing surface. Generally the "outward" facing surface of a panel is that surface of the panel which is still visible following the application of the panel to a wall.

[0020] Optionally, the first and second protective shells have the same or similar nature, size, shape and design to simplify the manufacturing process. Preferably, each set comprises the same first and second protective shells, optionally formed of the same material.

[0021] Typical but not limiting dimensions of the wall insulation panels could be in the range 0.3m to 2.5m 'wide', 0.3m to 4m 'tall' , and 50mm to 500m 'thick'.

[0022] A clear benefit of the present invention is the provision of any number, range or combination of differently shaped or smaller/larger wall insulation panels, based on the easy manufacture of differently shaped, etc. first and second protective shells, whilst still using (a different number of and/or a different arrangement of) existing- shaped VIP panels.

[0023] Also preferably, the first and second protective shells are moulded, or otherwise formed by a moulding process, including but not limited to blow moulding and injection moulding.

[0024] The first and second protective shells may be pre-manufactured and then sandwiched to the VIP panel(s) (for example using adhesives), or the whole insulating panel may be produced by curing foam around one or more VIP panels.

[0025] Alternatively, a not yet reacted liquid foam, (possibly having the consistency of shaving cream), is poured onto one side of the VIP panel(s), and the combination put through a press, such as a "mangle", and then the same process is carried out on the other face of the VIP panel(s).

[0026] Preferably, the first and second protective shells of the present invention form a multiple cavity thereinbetween for the accommodation of a variable number of

VIP panels, variable shaped VIP panels, or both.

[0027] Thus, according to another aspect of the present invention, there is provided wall insulating panel including one or more VIP panels, and comprising first and second moulded protective shells having wholly or substantially the same outer dimensions and forming a multiple cavity thereinbetween, said shells able to accommodate either:

(i) a different number of the same VIP panels; or

(ii) differently shaped VIP panels; or

(iii) both (i) and (ii).

[0028] The intermediate VIP panels of the present invention may have any suitable nature, size, shape and design accommodatable between the first and second protective shells. The VIP panels may be formed of any suitable outer film, membrane, wall, covering, etc., generally termed the 'membrane material', within which there is a vacuum. The vacuum may be of any suitable pressure, generally being lower than 'ambient' or 'atmospheric' pressure, such as less than 5 mbar for fumed silica filled VIP, and less than 1 mbar for mineral wool filled VIP. The vacuum pressure may be related to the size and other construction parameters of the VIP panel.

[0029] The VIP panels may include one or more internal media. Internal media include materials such as aerogel, silica, especially fumed silica, fibreglass and micro fibreglass.

[0030] According to one embodiment of the present invention, the VIP panels used in the present invention are fumed silica VIP panels, available from Dow Corning Corporation of Midland, MI, USA.

[0031] A membrane material such as aluminium foil has good vacuum-resisting properties, as well as being easily 'sealable' during the method of manufacturing the VIP panels. One or more further layers or coverings may be within or without the membrane material. However, it is not possible to produce a perfect vacuum layer, especially at the vacuum pressures used to form VIP panels, and which will be subject to the 'conditions' of building walls, such as temperature variations, long term exposure, any impacts, etc., as well as achieving the long product lifetime and effectiveness generally desired by building manufacturers.

[0032] Thus, the wall insulation panels of the present invention may further comprise one or more expansion regions between at least one of the first and second protective shells and the or each intermediate VIP panel to allow for expansion of the or each VIP panel without deformation of the outward facing surface of the second panel. [0033] In this way, the integrity of the outward facing surface can be maintained. This includes but is not limited to, being a barrier against the environment, in particular the weather, as well as the aesthetic appearance of the outward facing surface, or any further layer or surface or material added on to the outward facing surface whose integrity would be affected by the integrity of the outward facing surface. For example, any deformation in the outward facing surface would crack a rendered layer added thereon, allowing moisture ingress (and associated problems), as well as looking unsightly.

[0034] The expansion region may comprise any area or space able to accommodate expansion of the vacuum insulation panel within the dimensions of the wall insulation panel, without affecting the shape or plane of the outward facing surface of the second protective shell.

[0035] According to another embodiment of the present invention, the expansion region includes a compensation layer. The compensation layer optionally comprises one or more layers and/or materials, and is able to compensate, in two or three dimensions, any expansion in the size of the VIP panel, without deforming the outward facing surface of the second protective shell.

[0036] Preferably, the compensation layer comprises one or more solid or semisolid materials, at least a portion of which is deformable to accommodate expansion of the VIP panel. Optionally, the compensation layer may be formed from one or more materials, being the same or different, wherein at least one of said materials is deformable and at least one of said materials is non-deformable by deformation or expansion of the VIP panel.

[0037] The 'different' materials of the compensation layer may include a material having the same chemical or material composition, such as one or more plastics, but having different properties, such as different density, molecular weight, etc. Plastics such as EPS are available at different densities, molecular weights, etc., to provide the same type of plastic, but with different properties, especially different mechanical properties such as strength.

[0038] Optionally, the expansion region is formed of one or more deformable materials as defined above and one or more gaseous areas or spaces, such as one or more air spaces or pockets. [0039] According to another embodiment of the present invention, the expansion region or compensation layer includes one or more of the group comprising: ribs, tubes, springs and a soft and/or compressible material, for instance, a very soft foam.

[0040] Optionally, the expansion region comprises one or more of the group comprising: ribs, tubes, springs, low density soft foam, adhered ribs or tubes, extended ribs or tubes, silicone foams. Any such series of ribs or tubes, etc. could extend between a VIP facing surface and the VIP panel, and at least a portion of such ribs or tubes, etc. are deformable, for example by being made from a PU low density soft foam. Optionally, the ribs or tubes provide a corrugated surface between the VIP facing surface and the VIP panel. Also optionally, the ribs or tubes extend from the

VIP facing surface to meet the VIP panel.

[0041] The present invention provides a set of similarly shaped, preferably regularly shaped, wall insulation panels comprising either a different number, different shapes, or both, of VIP panels therein. For example, there could be provided a first set of the wall insulation panels acting as a template of 'full' or complete' panels, which could include 2, 3, 4, 5, 6, etc. same-shaped or similarly-shaped VIP panels, able to completely fill the space or cavities intermediate the first and second protective shells, usually in a geometric pattern or shape. There could then be provided a second set of wall insulation panels, being knowledgeably without at least one or more of said VIP panels in a particular location or locations within the wall insulation panel. For example, a 'complete' first set of wall insulation panels may be able to accommodate two or four intermediate VIP panels in particular locations, and a second set of panels could be based on the same template, but wherein at least one VIP panel is not located in the same regular position as the 'complete' wall insulation panel.

[0042] Similarly, there can be provided a first set of wall insulation panels having one shape of VIP panel, such as square or rectangular therein, wholly or substantially able to completely fill the space intermediate the first and second protective shells and a second set of wall insulation panels can be provided having different shapes of one or more intermediate VIP panels.

[0043] Thus, according to another embodiment of the present invention, the series of wall insulating panels of the present invention could comprise at least:

(a) a first set of wall insulating panels comprising two same-shaped VIP panels;

(b) a second set of wall insulating panels comprising one VIP panel; and (c) a third set of wall insulating panels comprising two differently shaped VIP panels.

[0044] Optionally, the wall insulating panels of the second set are based on the wall insulation panels of the first set, having only one of the VIP panels included, (or having one of the two VIP panels not included); and the third set of wall insulating panels comprises two differently shaped VIP panels being intermediate between those of the first set and second set. For example, the third set could comprise wall insulating panels comprising one VIP panel similar to that of the first and second sets, with an additional VIP panel being of a smaller size than the original VIP panel.

[0045] Thus, according to another embodiment of the present invention, the VIP panels of the first set, the second set, and optionally one of the third set, have the same

VIP panel shape. Optionally, the VIP panels of the third set comprise a first VIP panel having a first shape, and a second VIP panel being half the width and/or height of the shape of the first VIP panel.

[0046] In this way, the present invention can provide a series of wall insulating panels having a first set of panels with two VIP panels therein, for example in the form of a 'full VIP domino', a second set of wall insulating panels being 'half VIP dominos' , and a third set of wall insulation panels being intermediate the first and second sets, by having one and a half VIP 'domino' panels.

[0047] The series of the present invention may include additional sets of wall insulation panels having a different number and/or differently shaped VIP panels.

[0048] The series of the present invention may also include markings or indicia on an outer surface, generally the outer surface of the first or second protective shells, or both, indicating either the position of the or each intermediate VIP panel, or the portion(s) of the wall insulating panel able to cut without cutting the or each intermediate VIP panel, or both. Such markings or indicia include coloured lines, indentations etc., and ensure cutting of the wall insulating panels during installation without cutting of the intermediate VIP panels.

[0049] According to another embodiment of the present invention, one or both of the first and second protective shells further comprise longitudinal spline recesses, and the series includes a plurality of splines to fit intermediate abutting wall insulating panels.

[0050] The splines may be formed of the same or different material to that of the first and second protective shells, and provide direct and easy alignment of two abutting wall insulation panels. Where all the wall insulation panels of the series are the same shape or outer shape, most especially having the same outer dimensions, these spline recesses can be most easily located in corresponding positions around each of the wall insulation panels, for matching with spline recesses in other wall insulating panels.

[0051] According to another embodiment of the present invention, each wall insulating panel includes a number of wall fixing apertures, preferably one at each panel corner, and one wall fixing aperture through a centrepoint offset from a VIP panel, each aperture extending transversely to the successive panel layers.

[0052] The wall fixing apertures at each panel corner may not be fully complete, i.e may only be cut away portions of the corners of the panels, which, when matched against a number of similar abutting wall insulation panels, create a final complete aperture. The apertures can accommodate any suitable wall fixing device, such as pins, optionally having a flanged head against which the wall insulation panel is secured in use.

BRIEF DESCRIPTION OF THE DRAWINGS

[0053] Embodiments of the present invention will now be described by way of example only, and with reference to the accompanying drawings in which:

[0054] Figures la and lb are expanded and closed perspective views respectively of a wall insulation panel of one set of a series according to one embodiment of the present invention;

[0055] Figure 2 is a perspective view of a number of the wall insulation panels shown in Figures la and lb;

[0056] Figure 3 is a cross sectional side view along the line AA of Figure 2;

[0057] Figure 4 is a plan view of three wall insulation panels representing first, second and third sets of a series of wall insulation panels according to another embodiment of the present invention; and

[0058] Figure 5 is a front view of a wall covered by the series of the wall insulation panels of Figure 4 to form a wall insulation cladding according to another embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0059] Referring to the drawings, Figure la and lb show a wall insulation panel 2 as a representative of wall insulation panels able to provide a series of wall insulation panels for a modular wall insulating system according to embodiments of the present invention.

[0060] Figures la and lb show the wall insulating panel 2 having a first protective shell 4, an intermediate VIP panel 6, and a second protective shell 8.

[0061] The first and second protective shells 4, 8 are formed from EPS as moulded products, having the same or substantially the same dimensions, in particular the same length, height and depth. Optionally, there may be some variation between opposing shoulders of the first and second protective shells 4, 8 to provide an overlap of the shoulders when the first and second shells 4, 8 are closed as shown in Figure lb. Also optionally, one or both of the first and second protective shells 4, 8 may include a number of spline recesses 10 discussed in more detail hereinafter.

[0062] The first and second protective shells 4, 8 form a multiple cavity thereinbetween, represented in Figure la by the two depressed tray sections 12 shown in the first protective shell 4, and similar and opposing depressed trays in the second protective shell 8 (not shown).

[0063] Between the first and second protective shells 4, 8, there is located an intermediate VIP panel 6, shaped and dimensioned to fit within one of the cavities created by the tray depressions 12 in the first and second protective shells 4, 8.

[0064] The VIP panel 6 could be formed from an aluminium membrane and an internal fumed silica media, available from Dow Corning Corporation of Midland, MI,

USA.

[0065] An expansion region is also provided or formed between the VIP panel 6 and the opposing inside surface of the second protective shell 8, to allow for expansion of the VIP panel 6 without deformation of the outward facing surface 8a of the second protective shell 8. The expansion region includes a compensation layer, formed of a surface sheet having a number of extruded ribs regularly extending thereacross, in order to form a sheeted material 14 having corrugated like structure, such corrugations running transverse to the surface of the VIP panel 6 upon which it neighbours.

[0066] The ribs are deformable, such that any leakage of the VIP panel 6 increasing the size of the VIP panel 6 can be accommodated by crushing of the ribs within the area of the expansion region, thereby avoiding any impact of the expanded VIP panel 6 upon the opposing inner surface of the second protective shell 8. [0067] As a consequence, deformation of the outward facing surface of the second protective shell 8 is also avoided. Thus, the integrity of the outward facing surface can be maintained. This integrity includes but is not limited to, being a barrier against the environment, in particular the weather, as well as the aesthetic appearance of the outward facing surface, or any further layer or surface or material added on to the outward facing surface. For example, any deformation in the outward facing surface would crack a rendered layer added thereon, allowing moisture ingress with its known associated problems, as well as looking permanently unsightly.

[0068] Figure 1 a shows the first and second protective shells 4, 8 forming a second cavity as a second depressed tray 12, of the same size and dimensions as the first cavity, but excluding any VIP panel therein. The empty cavity could be foam filled with the same material as the first and second protective shells.

[0069] Figure lb shows the wall insulation panel in a closed form, and the addition of splines 16 within each of the spline recesses 10. The closed form of the wall insulation panel 2 is rectangular at an approximately 2 to 1 side ratio.

[0070] Figures la and lb also show the wall insulation panel 2 having partial cutaway wall fixing apertures 18 at each corner, and one complete wall fixing aperture 20 through a centrepoint offset from the VIP panel 6, each aperture extending traversely to the successive panel layers. The fixing apertures 18, 20 may vary in diameter, in particular to match the shape of a suitable fixing pin 22. The fixing pin 22 has an enlarged or flanged head, such that fixing apertures 18, 20 include a countersunk portion, in which the flanged heads of the fixing pins 22 can be accommodated within the overall plane of the outward facing surfaces 8a of the wall insulation panels 2 once together.

[0071] Figure 2 shows three wall insulation panels 22 being similar to those of the wall insulation panel 2 of Figures la and lb, having spline recesses 24 along their sides, and a number of splines 26 adapted to be accommodated within opposing spline recesses 24 of two neighbouring wall insulation panels 22, thereby to assist their positioning and overall combination once abutted together.

[0072] Figure 3 shows a cross sectional view along line AA of Figure 2, showing the inter-positional fit of the spline 26 between two wall insulating panels 22. Figure 3 also shows the first and second protective shells 28, 30, the VIP panel 32, and the expansion region 34 of the wall insulating panels 22. [0073] Figure 4 shows three representative wall insulation panels forming a series of wall insulation panels according to an embodiment of the present invention, the series comprising:

(a) a first set 40 of wall insulating panels comprising two same-shaped VIP panels 46; (b) a second set 42 of wall insulating panels comprising one VIP panel 46; and

(c) a third set 44 of wall insulating panels comprising two differently shaped VIP panels.

[0074] The first set 40 of wall insulating panels may be defined as having a 'complete' or 'complete template' of VIP panels 46 therein, which substantially cover the plane of the first set 40 of wall insulating panels.

[0075] The second set 42 of wall insulating panels comprise only one VIP panel 46, on one side, being the same as the VIP panels 46 in the first set 40 of wall insulating panels. Thus, the second set 42 of wall insulation panels can be seen to have less than 50% of the plane of the wall insulation panel covered by the VIP panel 46. The remaining portion 43 of the second set 42 of wall insulation panels is effectively 'blank', and able to be shaped, in particular cut, as necessary or desired by an installer, without affecting the VIP panel 46.

[0076] The third set 44 of wall insulation panels has one VIP panel 46 having the same shape as the VIP panels 46 in the first and second sets of wall insulating panels 40, 42. The third set 44 of wall insulating panels also includes a second VIP panel 48, having half the width and/or height of the shape of the first VIP panel 46. The remaining 'blank' portion 49 of the third set 44 of wall insulating panels can be cut or otherwise shaped as discussed above, without affecting the VIP panels 46, 48.

[0077] In particular, it can bee seen from Figure 4 that the provision of first and second protective shells having the same dimensions allows them to be formed from the same moulding process and from the same material. In this way, a feature of the present invention is to be able to provide a number of different sets of wall insulating panels, whilst each set comprises the same first and second protective shells. This reduces the number of different components required to form the series of wall insulating panels, thereby reducing manufacturing costs, as well as simplifying transportation costs. More importantly, it provides a regular shape of wall insulation panel to the architect, designer and/or installer, simplifying the processes of locating, designing and/or installing the wall insulation panels to adapt the particulars of the wall, most especially any windows, doors, or other portals, and the edges of the wall, or the edges of the insulated part of the wall.

[0078] Moreover, by using the same shaped VIP panel 46 in all three sets 40, 42, 44 shown in Figure 4, there are minimal manufacturing changes required to effect the provision the of first and second sets 40, 42, and only one additional VIP shape 48 required to form the third set 44. The simplicity of manufacture of the three sets 40, 42, 44 of wall insulation panel shown in Figure 4, their ease of transportation, and their simplicity to a designer, installer, etc. can be contrasted with conventional wall insulation panel systems using VIP panels of only one size across their complete extent. Not only can such conventional wall insulation panels not be cut beyond any de minimus trimming around their edges, but filler pieces are required in order to complete the extent of insulation required across a wall, in particular to fit complete panelling around windows, doors and edges etc.

[0079] Figure 5 shows the use of the first, second and third sets of wall insulation panels 40, 42 and 44 shown in Figure 4, across the full extent of a wall (not visible in

Figure 5) having a window 52 and a side edge 54. In particular, Figure 5 shows the application of a number of the first set 40 of wall insulation panels where no cutting of such wall insulation panels is required to match the window 52 or edge 54. Figure 5 also shows the application of a number of the second set 42 of wall insulation panels, wherein the blank portions 43 can be cut away to match the shape of the window 52, in the knowledge that such cutting will not cut through the VIP panels 46. Figure 5 also shows the application of a number of the third set 44 of wall insulation panels, formed particularly to use the second VIP panel shape 48 along the edge 54 of the wall.

[0080] Figure 5 shows how a series of the wall insulating panels of the present invention are able to provide a modular wall insulation system, based on a single outer shape of the wall insulation panels, and a variation in the number and/or shape of VIP panels therein, so as to best suit the shape and exclusion areas of the wall to be insulated. Once all the wall insulation panels have been brought together, Figure 5 shows a complete wall insulation cladding 56 comprising the abutting series of two or more wall insulation panels as described, as well as the modular wall insulation system using said two or more different wall insulation panels.

Claims

1. A series of wall insulating panels for a modular wall insulating system, each wall insulating panel comprising at least the successive layers of: a first protective shell,

one or more intermediate VIP panels; and

a second protective shell;

characterised in that the wall insulating panels of the series comprise two or more sets, each set comprising first and second protective shells having wholly or substantially the same outer dimensions, and at least first and second sets comprising either:

(i) a different number of the same VIP panels; or

(ii) differently shaped VIP panels; or

(iii) both (i) and (ii).

2. The series as claimed in claim 1 wherein one or more of the wall insulating panels further include one or more expansion regions between at least one of the first and second protective shells and a VIP panel to allow for expansion of the or each VIP panel without deformation of an outward facing surface of the second protective shell.

3. A series as claimed in claim 2 wherein the expansion region includes a compensation layer.

4. A series as claimed in claim 2 or claim 3 wherein the expansion region comprises a series of ribs or tubes extending between a VIP facing surface and a VIP panel, at least a portion of which ribs or tubes are deformable.

5. The series as claimed in any one of the preceding claims wherein each VIP panel is a fumed silica VIP panel.

6. The series as claimed in any one of the preceding claims wherein the wall insulating panels are rectangular at an approximately 2 tol side ratio.

7. The series as claimed in any one of the preceding claims wherein the first and second protective shells form a multiple cavity thereinbetween for the accommodation of a variable number of VIP panels, variable shaped VIP panels, or both.

8. The series as claimed in any one of the preceding claims comprising at least:

(b) a second set of wall insulating panels comprising one VIP panel; and

(c) a third set of wall insulating panels comprising two differently shaped VIP panels.

9. The series as claimed in claim 8 wherein the VIP panels of the first set, the second set, and optionally of one of the third set, have the same VIP panel shape.

10. A series as claimed in claim 8 or claim 9 wherein the VIP panels of the third set comprise a first VIP panel having a first shape, and a second VIP panel being half the width and/or height of the shape of the first VIP panel.

11. A series as claimed in any one of the preceding claims wherein each set comprises the same first and second protective shells, optionally formed of the same material.

12. A series as claimed in any one of the preceding claims wherein the first and second protective shells are moulded.

13. A series as claimed in any one of the preceding claims wherein one or both of the first and second protective shells further comprise longitudinal spline recesses, and wherein the series includes a plurality of splines to fit intermediate abutting wall insulating panels.

14. A series as claimed in any one of the preceding claims, wherein each wall insulating panel includes wall fixing apertures at each panel corner, and one wall fixing aperture through a centrepoint offset from a VIP panel, each aperture extending transversely to the successive panel layers.

15. A wall insulating panel including one or more VIP panels, and comprising first and second moulded protective shells having wholly or substantially the same outer dimensions and forming a multiple cavity thereinbetween, said shells able to accommodate either: (iv) a different number of the same VIP panels; or

(v) differently shaped VIP panels; or

(vi) both (i) and (ii).

16. A wall insulating panel as claimed in claim 15 wherein the first and second protective shells are able to accommodate one or more VIP panels having a first shape, and one or more VIP panels being half the width and/or height of the shape of the first VIP panel.

17. A wall insulation cladding comprising an abutting series of two or more wall insulation panels as defined in any one of claims 1 to 14.

18. A modular wall insulation system comprising two or more different wall insulating panels as defined in claim 15 or claim 16.