GB2477401A

GB2477401A - Vacuum insulating panel with insulation filled compartments

Info

Publication number: GB2477401A
Application number: GB1101235A
Authority: GB
Inventors: Adrian Pargeter; Malcolm Rochefort
Original assignee: Kingspan Holdings IRL Ltd
Current assignee: Kingspan Holdings IRL Ltd
Priority date: 2010-01-26
Filing date: 2011-01-25
Publication date: 2011-08-03
Anticipated expiration: 2031-01-25
Also published as: WO2011092679A3; GB2477401B; GB201101235D0; IE20110032A1; WO2011092679A2; IE86810B1

Abstract

A vacuum insulating panel comprises a first or outer sheet 3, a second or inner sheet 4 and a bridging element 1 extending between the sheets 3, 4. In cross section the bridging element 1 has a wave form. The wave form may be a trapezoidal form. The bridging element 1 has attachment flattened regions 2 which are used to bond, for example by adhesive bonding, the bridging element 1 to the upper and lower sheets 3, 4. The sheets 3, 4 and the bridging element are all of flexible sheet materials and compartments 5 defined by the sheets 1, 3, 4 are filled with a suitable insulation material. The compartments 5 are then evacuated. The insulation-filled evacuated compartments are isolated from one another so that if one compartment is punctured there is no adverse impact on the other compartments. Fastening region without a compartment or filler may be provided.

Description

"AN INSULATION PANEL"

Introduction

This invention relates to vacuum insulation panels (VIP).

Current VIP technology used in refrigeration units and the like generally comprises a single panel of insulation material formed typically of fumed silica, mineral fibre or other microporous material core, which may or may not contain infra red opacifiers, the core wrapped in a flexible, gas-tight envelope and a vacuum applied before sealing. The vacuum is essential to the panel's thermal insulating performance. Thermal conductivity properties of VIPs are typically of the order of 0.005 W/mK. If the vacuum is lost the panel loses a large proportion of its effectiveness as a thermal insulator, with the thermal conductivity reverting to that of the core material, which is typically above 0.020 W/m.K The use of VIP technology in construction is not widespread but could enable improved insulation properties and allow a significant reduction in thickness of insulation materials required to meet ever increasing requirements for thermal efficiency of buildings. However, in considering the use of VIP for insulation in building's floor, wall or roof there is a need to create robustness against various threats to piercing due to one or more of handing damage; cutting to size on site; fixing of panels to building substrate; and damage caused by drilling of holes for wiring, shelf fixing and the like.

It has been suggested to provide VIPs with compartments and sealed regions around the compartments. However, such sealed regions between compartments have poor thermal insulation properties and lead to a reduction in the overall thermal performance of the panel.

Statements of Invention

According to the invention there is provided a vacuum insulating panel comprising a first sheet of a flexible material, a second sheet of a flexible material, and a bridging element of a flexible material extending between the first and the second sheets, the bridging element comprising regions for attaching the bridging element to the sheets, the bridging element and the sheets defining therebetween a plurality of separate evacuated compartments containing a self-supporting insulating medium.

In one embodiment the attachment regions are substantially flat. The attachment regions may be bonded to the sheets. The attachment regions may be adhesively bonded to the sheets.

In one embodiment the bridging element is of wave form extending between the first sheet and the second sheet. The wave crests and/or wave valleys may have flattened regions for attachment to the first sheet and the second sheet.

In one case the bridging element is of a generally trapezoidal wave form.

In one embodiment the compartments defined by the bridging element and the sheets are of generally triangular or trapezoidal shape.

The panel may comprise at least two panel parts which are separated by a fixing gap. The gap may extend longitudinally along the length of the panel. The panel may include a filler for filling the gap. There may be at least two spaced -apart fixing gaps.

The bridging element may substantially reduce heat conduction across the panel.

In one embodiment the bridging element is pre-formed to a shape. The bridging element may be of a polyethylene film.

In one case the bridging element comprises a single layer.

In another case the bridging element comprises a plurality of layers. The bridging element may comprise a barrier layer, a first bonding layer on one face of the barrier layer for bonding to the first sheet, and a second bonding layer on an opposite face of the barrier layer for bonding to the second sheet. The barrier layer of the bridging element may comprise a metal or metallised material. The first sheet may comprise an outer barrier layer and an inner bonding layer for bonding to the first bonding layer of the bridging element. The second sheet may comprise an outer barrier layer and an inner bonding layer for bonding to the second bonding layer of the bridging element. In one case the barrier layer of the first and/or second sheet is of a metal or metallised material. The or each barrier layer may be of aluminium foil or of stainless steel foil.

The or each barrier layer may be of metallised polymeric film.

In one embodiment the first and second sheets are of the same material. In some cases the bridging element is of the same material as the first and/or second sheet.

In one embodiment the insulating medium comprises a plurality of insulation pieces and a binder. The insulating medium may comprise an insulating foam material.

The invention provides an insulating panel with compartmentalisation in which a single inner bridging element may be sealed with controlled spacings to upper and lower sheets. The resulting compartments are filled with insulation material and a vacuum is applied. This provides a rigid panel with a ftilly sealed circumference.

According to the invention there is provided a vacuum insulating panel comprising a first sheet a second sheet, and a bridging element extending between the first and the second sheets; the bridging element and the sheets defining therebetween a plurality of separate evacuated compartments containing an insulating medium.

In one embodiment the bridging element comprises regions for attaching the bridging element to the sheets. The attachment regions may be substantially flat. The attachment regions may be bonded, for example adhesively bonded to the sheets.

In one case the compartments defined by the bridging element and the sheets are of generally triangular shape.

In one embodiment the panel comprises at least two panel parts which are separated by a fixing gap.

The gap may extend longitudinally along the length of the panel. There may be a filler for filling the gap.

In one case the panel has at least two spaced -apart fixing gaps.

In one embodiment the first facing and the second facing are of a flexible sheet material. The bridging element may also be of a flexible sheet material.

The first sheet and/or the second sheet may be of a metal or metallised material such as aluminium foil, stainless steel foil or metallised polymeric film.

In one embodiment the first and/or second sheets are of the same material. The bridging element may be of the same material as the first and/or second sheet.

In one embodiment all 3 laminate layers are of metallised polymeric film.

In one embodiment all 3 laminate layers are of aluminium foil or stainless steel.

In one embodiment the upper and lower laminate layers are of aluminium foil or stainless steel film and the inner 1 laminate layers is of metallised polymeric film.

In one embodiment the upper and lower laminate layers are of aluminium foil or stainless steel film and the inner 1 laminate layers is of a thicker preformed metallised polymeric film.

In one embodiment the insulating medium is self supporting.

The insulating medium may comprise a plurality of insulation pieces and a binder.

The insulating medium may be of an insulating foam material.

In one embodiment the insulating bodies are in powder form.

In one embodiment the insulating bodies are in solid form and may be of insulating foam material, fumed silica or aerogel.

Brief Description of the Drawings

The invention will be more clearly understood from the following description of an embodiment thereof, given by way of example only, with reference to the accompanying drawings, in which: Fig. 1 is an isometric view of a vacuum insulating panel according to the invention; Fig. 2 is a cross sectional view of the panel of Fig. 1; Fig. 3 is a cross sectional view of a bridging element of the panel of Figs. 1 and 2; Fig. 4 is an isometric view of the element of Fig. 3; Fig. 5 is an isometric view of two like panels; Fig. 6 is an enlarged view of a joint detail between the panels of Fig. 5; Fig. 7 is a cross sectional view of another vacuum insulating panel according to the invention; Fig. 8 is a cross sectional view of a bridging element of the panel of Fig. 7; Fig. 9 is a cross sectional view illustrating the mounting of a vacuum insulating panel to a building substrate; Fig. 10 is an enlarged view of ajoint detail between adjacent panels of the invention; Fig. 11 is an enlarged view of another joint detail between adjacent panels of the invention; Fig. 12 is a perspective view of a panel according to the invention having one separation gap along its length; Fig. 13 is a top view of the panel of Fig. 12; Fig. 14 is a cross sectional view of portion of the panel of Figs. 12 and 13; Fig. 15 is a perspective view of another panel according to the invention having two separation gaps along its length; Fig. 16 is atop view of the panel of Fig. 15; Fig. 17 is an isometric view of another panel according to the invention; Fig. 18 is a view of the panel of Fig. 17 with one facing peeled back; Fig. 19 is a perspective view of a panel with one separation gap along its length with an infill piece; Fig. 20 is a perspective view of the panel of Fig. 19 with the infill piece in place; Fig. 21 is a cross section of the panel with the infill piece in place; Fig. 22 is a cross sectional view of a panel with a single fixing area; and Fig. 23 is a cross sectional view of a panel with two fixing areas.

Detailed Description

The invention provides a compartmentalised vacuum insulation panel which combines one panel part to provide a greater area of vacuumed insulation per square metre, avoiding the poor thermal insulation performance between compartments. The compartmentalisation is segmented with horizontal separation The insulation material in both panel parts is covered top and bottom in a foiL/film. This foil/film seals around the compartments and holds the vacuum applied to the insulation materials. The foil/film construction can be made of several layers designed to resist water vapour, oxygen and/or nitrogen transmission, all of which threaten the integrity of the vacuum over time.

The following features of the panels of the invention have the following advantages: * Compartmentalisation provides panel protection from puncture * Single inner layer provides for more cost effective panel production * Preformed single inner layer provides for more cost effective panel construction.

* Final product is a solid panel similar to existing products * Using Aluminium laminate foil in upper and lower facings allows for long life time (better Moisture vapour transfer rate, Oxygen transfer rate, Nitrogen transfer rate, barrier properties) * Using Pet met laminate as the inner reduces the edge effects of Aluminium foil Referring to the drawings and initially to Figs. 1 to 6 thereof there is illustrated a vacuum insulating panel according to the invention which comprises a first or outer sheet 3, a second or inner sheet 4 and a bridging element 1 extending between the sheets 3, 4. In cross section the bridging element 1 has the appearance of a wave form and extends from one sheet 2 to the outer sheet 3. The bridging element defines a single divider which provides a compartmentalised panel that can be produced efficiently. The bridging element has attachment regions which in this case are in the form of flattened regions 2 which are used to bond (for example by adhesive bonding) the bridging element 1 to the upper and lower sheets 3, 4.

The bridging element 1 is of wave form extending between the first sheet 3 and the second sheet 4. The wave crests and wave valleys have flattened regions 2 for attachment to the first sheet 3 and the second sheet 4. In this case the bridging element 1 is of a generally trapezoidal wave form.

One advantage of a bridging element of wave form is that the bridging element can be created without a requirement to pre-form. Such bridging elements can be readily bonded to the outer facings at regular alternate intervals. A straight line wave form provides a straight line connection between each seal between the bridging element and facings.

The sheets 3, 4 and the bridging element are all of flexible sheet materials and the compartments defined by the sheets 1, 3, 4 are filled with a suitable self supporting insulation material. The term self supporting means that the insulation is capable of resisting forces applied under vacuum without collapsing. The compartments 5 are then evacuated. The insulation-filled evacuated compartments are isolated from one another so that if one compartment is punctured there is no adverse impact on the other compartments.

The sheets 1, 3, 4 may be of suitable materials such as metallised polymeric films or foil. The insulation may comprise fumed silica, aerogel, and/or a suitable foam material such as a phenolic or polyisocyanurate foam.

Referring to Figs. 5 and 6 a joint between two adjacent like panels is illustrated. The joint is a chamfered butt joint in which two panels 6, 7 are engaged on the angle defined by respective bridging elements 11, 13. The right hand panel 6 has inner and outer facings 10, 8 with insulation 9. The left hand panel 7 has inner and outer facings 15, 12 with insulation 14. The overlapping of the facings ensures sealing integrity at the joint.

The bridging element 1 substantially reduces heat conduction (thermal bridging) across the panel.

The bridging element 1 may be pre-formed to a desired shape. For example, the bridging element may be of a single layer such as a polymeric material such as a polyethylene film material. Such a film would typically have a thickness of about 0.2mm.

Referring to Figs. 7 and 8 there is illustrated another vacuum insulating panel according to the invention. In this case a bridging element 50 comprises a plurality of layers. There is a barrier layer 51 which is typically of a metal or metallised material. There is a first bonding layer 52 on one face of the barrier layer 5 and a second bonding layer 53 on an opposite face of the barrier layer 51.

The first sheet in this case comprises an outer barrier layer 55 and an inner bonding layer 56 for bonding to the first bonding layer 52 of the bridging element 50. Similarly, the second sheet in this case comprises an outer barrier layer 58 and an inner bonding layer 59 for bonding to the second bonding layer 53 of the bridging element 50.

One advantage of this embodiment is that the vacuum insulation chambers have added protection on either side of a puncture to prevent loss of vacuum over time. The barrier layer 51 of the bridging element is typically of a metallised polymer material such as metallised polyester. The bonding layers 52, 53 may be of a polyethylene such as low density polyethylene film. The bonding layers 52, 53 of the bridging element 50 are compatible with the bonding layers 56, 59 of the associated first and second sheets of the vacuum insulating panel. The bonding may be achieved using an adhesive and/or by heat sealing.

Using a metallised polymeric material as the barrier layer of the bridging element greatly reduces thermal bridging across the panel. In the case of a single layer bridging element use of a polymeric film such as low density polyethylene also greatly reduces thermal bridging.

Referring to Fig. 9 the fixing of a vacuum insulated panel 60 according to the invention to an underlying building substrate 61 is illustrated. In this case the fixing is achieved using a bonding layer 62 between the outer face of the inner sheet of the panel and the building substrate 61. One advantage of such a fixing method is that puncturing of a vacuum insulating compartment of the panel is avoided.

Referring to Fig. 10 there is illustrated a joint between two adjacent panels of the invention. The arrangement is similar to that of Fig. 6 and like parts are assigned the same numerals. In this case there is an additional bonding layer 65 at the joint to substantially prevent air flow at a joint between panels. The bridging layer 11 may be coated on both sides with adhesive whilst the layers 8, 10 only require an inner adhesive layer. Alternatively or additionally a jointing tape may be applied over the inner and/or outer sheets at the joint.

Referring to Fig. 11, in the case of a bridging element which is not metallised, the outer foils are extended to form extensions 40, 41 to cover the butting ends of adjacent panels to enhance barrier properties at the joint. Such non-metallised bridging elements 1 may be pre-formed to a desired shape.

Referring to Figs. 12 and 13 there is illustrated a panel 16 according to the invention which has a single gap 17 extending longitudinally along the length of the panel. This gap facilitates fixing of the panels, in use, for example to an underlying support structure. The separate compartments containing insulation material are indicated by interrupted lines 19. The bridging elements 1 defining the separate compartments are illustrated in Fig. 14.

There may be any desired number and/or arrangement of such fixing gaps. For example Figs. 15 and 16 illustrate a panel 18 with two such gaps 17. The compartments are again indicated by interrupted lines 19.

In another arrangement illustrated in Fig. 17 a panel 20 does not have any separation gaps (i.e. a monoblock) and the foil facings 21 are wrapped around the panel edges to seal the panel.

Referring to Fig. 18 another monoblock panel 22 is illustrated. In this case the facings have overlapping or flange portions 23 which are used to complete the finished panels.

Referring to Figs. 19 to 21 there is illustrated a panel 16 with a separation gap 17 along its length with an infill piece 24 which is fitted in the direction of the arrows. The infill 24 can be a vacuum insulated panel or other insulation material and is designed to complete the panel once fixed into position. The infill can be glued in place Fig. 21 illustrates the infill piece 24 in place. The infill piece is in this case a vacuum insulating panel having a top facing 25, bottom facing 27 and insulation material core 26. The infill piece 24 fits inside the main panel 28. The main VIP section shows the top laminate facing 29, bottom laminate facing 31 and insulation material core 30 of a main panel 28. The panel 28 is fixed to the building substrate 32 by a fixing 33. The fixing 33 is then covered by the infill piece 24.

Fig. 22 illustrates a wide single area of seal between dotted lines 34 which can be pierced for fixing to a building substrate. Fig. 23 shows a double seal where each seal width is shown by dotted lines 35 and is thinner than the arrangement of Fig. 22 but further apart giving a wider area for a fixing to go through.

Modifications and additions can be made to the embodiments of the invention described herein without departing from the scope of the invention. For example, while the embodiments described herein refer to particular features, the invention includes embodiments having different combinations of features. The invention also includes embodiments that do not include all of the specific features described.

The invention is not limited to the embodiments hereinbefore described, with reference to the accompanying drawings, which may be varied in construction and detail.

Claims

Claims 1. A vacuum insulating panel comprising a first sheet of a flexible material, a second sheet of a flexible material, and a bridging element of a flexible material extending between the first and the second sheets, the bridging element comprising regions for attaching the bridging element to the sheets, the bridging element and the sheets defining therebetween a plurality of separate evacuated compartments containing a self-supporting insulating medium.
2. A vacuum insulating panel as claimed in claim 1 wherein the attachment regions are substantially flat.
3. A vacuum insulating panel as claimed in claim 1 or 2 wherein the attachment regions are bonded to the sheets.
4. A vacuum insulating panel as claimed in claim 3 wherein the attachment regions are adhesively bonded to the sheets.
5. A vacuum insulating panel as claimed in any of claims 1 to 4 wherein the bridging element is of wave form extending between the first sheet and the second sheet.
6. A vacuum insulating panel as claimed in claim 5 wherein the wave crests and wave valleys have flattened regions for attachment to the first sheet and the second sheet.
7. A vacuum insulating panel as claimed in any of claims 1 to 6 wherein the bridging element is of a generally trapezoidal wave form.
8. A vacuum insulating panel as claimed in any of claims 1 to 7 wherein the compartments defined by the bridging element and the sheets are of generally triangular or trapezoidal shape.
9. A vacuum insulating panel as claimed in any of claims 1 to 8 wherein the panel comprises at least two panel parts which are separated by a fixing gap.
10. A vacuum insulating panel as claimed in claim 9 wherein the gap extends longitudinally along the length of the panel.
11. A vacuum insulating panel as claimed in claim 9 or 10 comprising a filler for filling the gap.
12. A vacuum insulating panel as claimed in any of claims 9 to 11 comprising at least two spaced -apart fixing gaps.
13. A vacuum insulating panel as claimed in any of claims 1 to 12 wherein the bridging element substantially reduces heat conduction across the panel.
14. A vacuum insulating panel as claimed in any of claims 1 to 13 wherein the bridging element is pre-formed to a shape.
15. A vacuum insulating panel as claimed in claim 14 wherein the bridging element is of a polyethylene film.
16. A vacuum insulating panel as claimed in any of claims 1 to 15 wherein the bridging element comprises a single layer.
17. A vacuum insulating panel as claimed in any of claims 1 to 15 wherein the bridging element comprises a plurality of layers.
18. A vacuum insulating panel as claimed in claim 17 wherein the bridging element comprises a barrier layer, a first bonding layer on one face of the barrier layer for bonding to the first sheet, and a second bonding layer on an opposite face of the barrier layer for bonding to the second sheet.
19. A vacuum insulating panel as claimed in claim 18 wherein the barrier layer of the bridging element comprises a metal or metallised material.
20. A vacuum insulating panel as claimed in claim 18 or 19 wherein the first sheet comprises an outer barrier layer and an inner bonding layer for bonding to the first bonding layer of the bridging element.
21. A vacuum insulating panel as claimed in any of claims 18 to 20 wherein the second sheet comprises an outer barrier layer and an inner bonding layer for bonding to the second bonding layer of the bridging element.
22. A vacuum insulating panel as claimed in claim 20 or 21 wherein the barrier layer of the first and/or second sheet is of a metal or metallised material.
23. A vacuum insulating panel as claimed in any of claims 18 to 22 wherein the or each barrier layer is of aluminium foil.
24. A vacuum insulating panel as claimed in any of claims 18 to 22 wherein the or each barrier layer is of stainless steel foil
25. A vacuum insulating panel as claimed in any of claims 18 to 22 wherein the or each barrier layer is of metallised polymeric film.
26. A vacuum insulating panel as claimed in any of claims 1 to 25 wherein the first and second sheets are of the same material.
27. A vacuum insulating panel as claimed in any of claims 1 to 26 wherein the bridging element is of the same material as the first and/or second sheet.
28. A vacuum insulating panel as claimed in any of claims 1 to 27 wherein the insulating medium comprises a plurality of insulation pieces and a binder.
29. A vacuum insulating panel as claimed in any of claims 1 to 28 wherein the insulating medium comprises an insulating foam material.
30. A vacuum insulating panel substantially as hereinbefore described.