WO2016087387A1 - Vacuum insulating panel - Google Patents

Vacuum insulating panel Download PDF

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Publication number
WO2016087387A1
WO2016087387A1 PCT/EP2015/078095 EP2015078095W WO2016087387A1 WO 2016087387 A1 WO2016087387 A1 WO 2016087387A1 EP 2015078095 W EP2015078095 W EP 2015078095W WO 2016087387 A1 WO2016087387 A1 WO 2016087387A1
Authority
WO
WIPO (PCT)
Prior art keywords
insulating panel
vacuum insulating
core
film
vacuum
Prior art date
Application number
PCT/EP2015/078095
Other languages
French (fr)
Inventor
Marko MEGLIC
Uros COTELJ
Original Assignee
Knauf Insulation Sprl
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Knauf Insulation Sprl filed Critical Knauf Insulation Sprl
Priority to LU93161A priority Critical patent/LU93161B1/en
Priority to EP15804724.1A priority patent/EP3227503A1/en
Publication of WO2016087387A1 publication Critical patent/WO2016087387A1/en

Links

Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25D—REFRIGERATORS; COLD ROOMS; ICE-BOXES; COOLING OR FREEZING APPARATUS NOT OTHERWISE PROVIDED FOR
    • F25D23/00—General constructional features
    • F25D23/06—Walls
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
    • B29C63/02—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material
    • B29C63/04—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material by folding, winding, bending or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/046—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/065—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/04—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by at least one layer folded at the edge, e.g. over another layer ; characterised by at least one layer enveloping or enclosing a material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/08—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B32B5/20—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material foamed in situ
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
    • B29C63/02—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material
    • B29C2063/021—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material characterized by the junction of material sections
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0012—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular thermal properties
    • B29K2995/0015—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/03—3 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/108—Rockwool fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/14—Mixture of at least two fibres made of different materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0278—Polyurethane
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/31—Heat sealable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2311/00—Metals, their alloys or their compounds
    • B32B2311/24—Aluminium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00—Buildings or parts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2509/00—Household appliances
    • B32B2509/10—Refrigerators or refrigerating equipment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25D—REFRIGERATORS; COLD ROOMS; ICE-BOXES; COOLING OR FREEZING APPARATUS NOT OTHERWISE PROVIDED FOR
    • F25D2201/00—Insulation
    • F25D2201/10—Insulation with respect to heat
    • F25D2201/12—Insulation with respect to heat using an insulating packing material
    • F25D2201/124—Insulation with respect to heat using an insulating packing material of fibrous type
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25D—REFRIGERATORS; COLD ROOMS; ICE-BOXES; COOLING OR FREEZING APPARATUS NOT OTHERWISE PROVIDED FOR
    • F25D2201/00—Insulation
    • F25D2201/10—Insulation with respect to heat
    • F25D2201/14—Insulation with respect to heat using subatmospheric pressure

Definitions

  • the present invention relates to a vacuum insulating panel (VIP) and a method for manufacturing vacuum insulating panels.
  • Vacuum insulating panels are commonly used for thermal insulation, notably for refrigeration systems such as refrigerators or refrigerated transport containers. They may also be used for building insulation, especially when low thermal conductivity in combination with small thickness is desired.
  • Vacuum insulating panels usually consist of a core material retained within a sealed envelope. Conventionally, the panel cores are inserted into prefabricated bags and subsequently evacuated and sealed along the open side. One or more sealing flaps of the finished panel project from end and/or side faces; these sealing flaps are folded against the panel and fixed with adhesive tape. The sealing flaps at end and/or side faces of the vacuum insulation panels the flaps may interfere with sealing of the panel into an opening and/or contribute to undesired thermal conduction at the panel edges.
  • US 201 1/0129637 discloses a method for manufacturing vacuum insulating panels in which sealing flaps are folded towards each other at a major surface of the panel.
  • One aim of the present invention is to provide a construction of vacuum insulating panel which is simple and inexpensive to manufacture whilst providing low thermal conductivity.
  • the present invention provides a vacuum insulating panel as defined in claim 1. Additional aspects are defined in other independent claims. The dependent claims define preferred and/or alternative embodiments.
  • Folding of the sealing flaps in the same direction facilitates manufacture of the panel, notably high speed manufacture; for example by allowing, in some configurations, a single roller moving in a single direction or moving in a continuous path to sequentially fold each of the sealing flaps.
  • Folding of the sealing flaps in the same direction also facilitates installation of the vacuum insulating panels in a frame or support, notably when installation comprises sliding the vacuum insulating panel into a support; in this case, the vacuum insulating panel is preferably slid into its support from a leading edge of the vacuum insulating panel which is substantially parallel to the length of the sealing flaps to a trailing edge of the vacuum insulating panel with the sealing flaps configured such that they are folded in a direction from the leading edge towards the trailing edge of the of the vacuum insulating panel. In this way, the vacuum insulating panel may be slid in to position with minimal risk of snagging of the sealing flaps thus increasing assembly efficiency and productivity.
  • the vacuum insulating panel may be secured in a frame or support, for example a wall of a refrigerator, using a foam or adhesive, for example a polyurethane foam, which is injected on the assembly line.
  • a foam or adhesive for example a polyurethane foam
  • the core of the vacuum insulating panel may comprise a mineral fibre insulating material for example comprising mineral wool, glass wool, rock wool or combinations thereof.
  • the fibre insulating material comprises glass fibres.
  • the fibres of the core may be bound together, notably at intersections between fibres, for example by means of a binder, preferably an inorganic binder and/or by treatment with an acid, notably a dilute acid, for example sulphuric acid or nitric acid. Such acid treatment may create fusion points between individual fibres.
  • the vacuum insulating panel may have a density which is ⁇ 250 kg/m 3 , preferably ⁇ 200 kg/m 3 , more preferably ⁇ 180 kg/m 3 and/or which is ⁇ 50 kg/m 3 , preferably ⁇ 100 kg/m 3 , more preferably ⁇ 120 kg/m 3 .
  • the vacuum insulating panel may have a substantially parallelepiped shape. It may have:
  • the vacuum insulating panel may have a thermal conductivity of ⁇ 10 mW/m-K, preferably less ⁇ 8 mW/m-K, more preferably ⁇ 6 mW/m-K.
  • the level of vacuum in the vacuum insulating panel may be ⁇ 3 mbar, ⁇ 2 mbar, ⁇ 1 .5 mbar, ⁇ 1 mbar, ⁇ 0.5 mbar or ⁇ 0.1 mbar.
  • the first and/or second film sections may have a thickness >100pm, preferably ⁇ 50 ⁇ , more preferably >20pm.
  • the first and/or second film section may comprise a plurality of stacked layers, for example comprising an adhesive layer, a barrier layer notably a metal barrier layer, and/or a surface protection layer, notably in this sequence.
  • the adhesive layer may provide a layer facing the core of the panel; the surface protection layer may provide an exposed layer at the external side of the panel.
  • the adhesive layer on one film may provide a layer adapted to be thermally welded to the other film, for example by heat sealing, notably to provide a seal and maintain a vacuum.
  • the surface layer may comprise a structure in which a polyethylene terephthalate (PET) film and a nylon film are stacked.
  • PET film may have a thickness between 5 and 20 ⁇ , preferably from 10 to 15pm; the surface layer may have a thickness of between 15 m to 50pm, preferably from 20 to 30 ⁇ .
  • the surface layer may comprise a strengthening vinyl resin which may be applied to an upper side of a PET film, and the vinyl resin may include polyvinyl chloride (PVC), polyvinyl acetate (PVA), polyvinyl alcohol (PVAL), polyvinyl butyric (or PVB), polyvinylidene chloride (PVDC) or combinations thereof.
  • a metal barrier layer of the film section may comprise aluminium (Al) foil.
  • the metal barrier layer may have a thickness of between 5 and 10pm, preferably from 6 to 7pm; it may serve to block gas permeation through the film and/or protect the core material.
  • An adhesive layer of the film section may comprise at least one plastic film selected from polyethylene (PE), high-density polyethylene (HOPE), low-density polyethylene (LDPE). linear low-density polyethylene (LLDPE), polypropylene (PP), cast polypropylene (CPP), oriented polypropylene (OPP), polyvinylidene chloride (PVDC), polyvinyl chloride (PVC), ethylene vinyl acetate (EVA) copolymer, and ethylene vinyl alcohol (EVOH) copolymer films.
  • the adhesive layer may have a thickness of at least 1 m, at least 20pm, at least 50pm; at least 75 ⁇ or at least 95pm.
  • the surface protection layer, the metal barrier layer, and the adhesive layer of the cover material may be bonded to each other, notably by a polyurethane resin.
  • the vacuum insulating panel may comprise a getter, notably enclosed inside the vacuum insulating panel, comprising one or more materials capable of absorbing moisture and/or absorbing one or more gasses.
  • the getter serves to help maintain the degree of vacuum in the vacuum insulation panel.
  • the getter may comprise calcium oxide, preferably calcium oxide powder notably having a purity of at least 90 % packed in a pouch; the pouch may be formed of nonwoven fabric which may be impregnated with crepe paper and polypropylene (PP). A quantity of ⁇ 10g and/or ⁇ 50 g of calcium oxide is generally appropriate.
  • the getter may have a moisture absorptivity of at least 20%, preferably at least 25%.
  • the first film portion of the envelope is wrapped around the core leaving an uncovered portion at one major surface, notable at a central portion of one major surface.
  • the second film portion suitably dimensioned, may be arranged at this previously uncovered portion and the adjacent peripheries of the first and second film portions assembled together to form flaps projecting away from the core which are subsequently sealed.
  • the second film portion may be arranged at the panel core and the first film portion subsequently wrapped around the core.
  • the same dimension of the first film portion may be used for different dimensions of vacuum insulating panels with different dimensions for the second film portion.
  • a tautly fitting envelope may be achieved by pulling adjacent peripheries of the first and second films towards each other prior to sealing the flaps.
  • the second film portion may be stretched over a forming chute for connection with the first film portion.
  • Fig 1 is a schematic end view of a vacuum insulation panel before sealing in which the flaps are folded in the same direction.
  • Fig. 1 shows an embodiment of a vacuum insulation panel 10 comprising a core 1 1 enclosed by an envelope which consists of a first 21 and second 41 film section. In practice the envelope lies tightly against the surface of the core 1 1 but is illustrated in an exploded view for clarity.
  • the core 1 1 of the vacuum insulating panel is produced by:
  • the envelope around the core 1 1 is produced by:
  • the first and second film sections 21 , 41 are a laminate comprising a top layer of a 12 pm polyvinylidene chloride (PVDC)/polyethylene terephthalate (PET) film, a 25 pm nylon film, a 6 pm aluminium foil, and, as a lower layer facing the core material a 50 pm low- density polyethylene (LDPE) film.
  • PVDC polyvinylidene chloride
  • PET polyethylene terephthalate
  • LDPE low- density polyethylene
  • Fig 1 illustrates the flaps 51 , 52 being folded in the same direction so that they lie flat against the major surface 36. Once folded against the major surface, the flaps 51 , 52 are held in place by welding, adhesive or adhesive tape.
  • a first end (not shown) of the envelope is sealed, air is evacuated from the core and the second end 62 is sealed to provide the vacuum insulating panel. Folding of the flaps 51 , 52 against the major surface 36 may be carried out prior to or subsequent to evacuation of the panel.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Thermal Sciences (AREA)
  • General Engineering & Computer Science (AREA)
  • Refrigerator Housings (AREA)
  • Thermal Insulation (AREA)

Abstract

A vacuum insulating panel (10) comprises a core (11) in an envelope. The envelope comprises two film sections (21, 41) which are connected by spaced-apart sealing flaps (51, 52), the sealing flaps (51, 52) being especially arranged at a major surface (36) of the vacuum insulation panel (10) and folded against the major surface (36) in the same direction.

Description

Vacuum insulating panel
[0001 ] The present invention relates to a vacuum insulating panel (VIP) and a method for manufacturing vacuum insulating panels.
[0002] Vacuum insulating panels are commonly used for thermal insulation, notably for refrigeration systems such as refrigerators or refrigerated transport containers. They may also be used for building insulation, especially when low thermal conductivity in combination with small thickness is desired.
[0003] Vacuum insulating panels usually consist of a core material retained within a sealed envelope. Conventionally, the panel cores are inserted into prefabricated bags and subsequently evacuated and sealed along the open side. One or more sealing flaps of the finished panel project from end and/or side faces; these sealing flaps are folded against the panel and fixed with adhesive tape. The sealing flaps at end and/or side faces of the vacuum insulation panels the flaps may interfere with sealing of the panel into an opening and/or contribute to undesired thermal conduction at the panel edges. US 201 1/0129637 discloses a method for manufacturing vacuum insulating panels in which sealing flaps are folded towards each other at a major surface of the panel.
[0004] One aim of the present invention is to provide a construction of vacuum insulating panel which is simple and inexpensive to manufacture whilst providing low thermal conductivity. [0005] According to one of its aspects, the present invention provides a vacuum insulating panel as defined in claim 1. Additional aspects are defined in other independent claims. The dependent claims define preferred and/or alternative embodiments.
[0006] Folding of the sealing flaps in the same direction facilitates manufacture of the panel, notably high speed manufacture; for example by allowing, in some configurations, a single roller moving in a single direction or moving in a continuous path to sequentially fold each of the sealing flaps. Folding of the sealing flaps in the same direction also facilitates installation of the vacuum insulating panels in a frame or support, notably when installation comprises sliding the vacuum insulating panel into a support; in this case, the vacuum insulating panel is preferably slid into its support from a leading edge of the vacuum insulating panel which is substantially parallel to the length of the sealing flaps to a trailing edge of the vacuum insulating panel with the sealing flaps configured such that they are folded in a direction from the leading edge towards the trailing edge of the of the vacuum insulating panel. In this way, the vacuum insulating panel may be slid in to position with minimal risk of snagging of the sealing flaps thus increasing assembly efficiency and productivity. The vacuum insulating panel may be secured in a frame or support, for example a wall of a refrigerator, using a foam or adhesive, for example a polyurethane foam, which is injected on the assembly line. A further advantage of folding the sealing flaps in the same direction, notably folding the sealing flaps in a direction from a leading edge towards a trailing edge of the vacuum insulating panel, is to facilitate flow of foam or adhesive injected in a direction from the leading edge towards the trailing edge in a way that minimises obstruction to flow caused by the sealing flaps. This is particularly useful to facilitate the flow of a mixture of for example isocynate and polyol to encapsulate the vacuum insulation panel completely before polymerization to polyurethane (PU) takes place with the vacuum insulation panel being positioned in such way that the flow of the reacting mixture is not obstructed by the sealing flaps [0007] The core of the vacuum insulating panel may comprise a mineral fibre insulating material for example comprising mineral wool, glass wool, rock wool or combinations thereof. Preferably, the fibre insulating material comprises glass fibres.
[0008] The fibres of the core may be bound together, notably at intersections between fibres, for example by means of a binder, preferably an inorganic binder and/or by treatment with an acid, notably a dilute acid, for example sulphuric acid or nitric acid. Such acid treatment may create fusion points between individual fibres. The vacuum insulating panel may have a density which is < 250 kg/m3 , preferably < 200 kg/m3, more preferably < 180 kg/m3 and/or which is≥ 50 kg/m3, preferably≥ 100 kg/m3, more preferably≥ 120 kg/m3.
[0009] The vacuum insulating panel may have a substantially parallelepiped shape. It may have:
- a length which is≥ 10 cm,≥ 20 cm or≥ 30 cm and/or which is < 120 cm, < 100cm or < 80 cm; and/or
- a width which is≥ 10 cm,≥ 20 cm or≥ 30 and/or which is < 100 cm, < 80 cm or < 60 cm; and/or
- a thickness which is≥ 0.5 cm,≥ 1 or≥ 1.5 and/or which is < 5 cm, < 4 cm or < 3 cm.
[0010] The vacuum insulating panel may have a thermal conductivity of < 10 mW/m-K, preferably less < 8 mW/m-K, more preferably < 6 mW/m-K. The level of vacuum in the vacuum insulating panel may be < 3 mbar, < 2 mbar, < 1 .5 mbar, < 1 mbar, < 0.5 mbar or < 0.1 mbar. [001 1 ] The first and/or second film sections may have a thickness >100pm, preferably ≥50μπΊ, more preferably >20pm.
[0012] The first and/or second film section may comprise a plurality of stacked layers, for example comprising an adhesive layer, a barrier layer notably a metal barrier layer, and/or a surface protection layer, notably in this sequence. The adhesive layer may provide a layer facing the core of the panel; the surface protection layer may provide an exposed layer at the external side of the panel. The adhesive layer on one film may provide a layer adapted to be thermally welded to the other film, for example by heat sealing, notably to provide a seal and maintain a vacuum.
[0013] The surface layer may comprise a structure in which a polyethylene terephthalate (PET) film and a nylon film are stacked. The PET film may have a thickness between 5 and 20μηΊ, preferably from 10 to 15pm; the surface layer may have a thickness of between 15 m to 50pm, preferably from 20 to 30μιτι. The surface layer may comprise a strengthening vinyl resin which may be applied to an upper side of a PET film, and the vinyl resin may include polyvinyl chloride (PVC), polyvinyl acetate (PVA), polyvinyl alcohol (PVAL), polyvinyl butyric (or PVB), polyvinylidene chloride (PVDC) or combinations thereof. [0014] A metal barrier layer of the film section may comprise aluminium (Al) foil. The metal barrier layer may have a thickness of between 5 and 10pm, preferably from 6 to 7pm; it may serve to block gas permeation through the film and/or protect the core material.
[0015] An adhesive layer of the film section may comprise at least one plastic film selected from polyethylene (PE), high-density polyethylene (HOPE), low-density polyethylene (LDPE). linear low-density polyethylene (LLDPE), polypropylene (PP), cast polypropylene (CPP), oriented polypropylene (OPP), polyvinylidene chloride (PVDC), polyvinyl chloride (PVC), ethylene vinyl acetate (EVA) copolymer, and ethylene vinyl alcohol (EVOH) copolymer films. The adhesive layer may have a thickness of at least 1 m, at least 20pm, at least 50pm; at least 75μιη or at least 95pm.
[0016] The surface protection layer, the metal barrier layer, and the adhesive layer of the cover material may be bonded to each other, notably by a polyurethane resin.
[0017] The vacuum insulating panel may comprise a getter, notably enclosed inside the vacuum insulating panel, comprising one or more materials capable of absorbing moisture and/or absorbing one or more gasses. The getter serves to help maintain the degree of vacuum in the vacuum insulation panel. The getter may comprise calcium oxide, preferably calcium oxide powder notably having a purity of at least 90 % packed in a pouch; the pouch may be formed of nonwoven fabric which may be impregnated with crepe paper and polypropylene (PP). A quantity of ≥ 10g and/or < 50 g of calcium oxide is generally appropriate. The getter may have a moisture absorptivity of at least 20%, preferably at least 25%.
[0018] In one embodiment, the first film portion of the envelope is wrapped around the core leaving an uncovered portion at one major surface, notable at a central portion of one major surface. The second film portion, suitably dimensioned, may be arranged at this previously uncovered portion and the adjacent peripheries of the first and second film portions assembled together to form flaps projecting away from the core which are subsequently sealed. Alternatively, the second film portion may be arranged at the panel core and the first film portion subsequently wrapped around the core. The same dimension of the first film portion may be used for different dimensions of vacuum insulating panels with different dimensions for the second film portion. A tautly fitting envelope may be achieved by pulling adjacent peripheries of the first and second films towards each other prior to sealing the flaps. The second film portion may be stretched over a forming chute for connection with the first film portion.
[0019] An embodiment of the invention will now be described, by way of example only, with reference to the accompanying drawing of which:
Fig 1 is a schematic end view of a vacuum insulation panel before sealing in which the flaps are folded in the same direction.
[0020] Fig. 1 shows an embodiment of a vacuum insulation panel 10 comprising a core 1 1 enclosed by an envelope which consists of a first 21 and second 41 film section. In practice the envelope lies tightly against the surface of the core 1 1 but is illustrated in an exploded view for clarity. [0021 ] The core 1 1 of the vacuum insulating panel is produced by:
- mixing loose glass wool fibres in a dilute sulphuric acid solution to produce a slurry;
- transferring the slurry on to a perforated conveyor belt;
- removing moisture from the slurry through the conveyor belt, notably via gravity and applied suction, and further drying the fibres remaining from the slurry, notably by passage through a drying oven;
- cutting to desired length and width dimensions. [0022] The envelope around the core 1 1 is produced by:
- arranging a first film section 21 around the core so that it entirely covers one major surface 31 of the core, covers the two side faces 32, 33 of the core and covers peripheral sections
34, 35 of the other major surface 36 of the core;
- arranging a second film section 41 at the central portion of the other major surface 36 of the core which is not covered by the first film section 21 such that, at each of the two portions at the other major surface 36 where the first 21 and second 41 film sections meet, a flap 51 , 52 is formed from contact between the undersides of peripheral portions of the first and second film sections;
- sealing the first and second film sections together along each of the flaps.
[0023] The first and second film sections 21 , 41 are a laminate comprising a top layer of a 12 pm polyvinylidene chloride (PVDC)/polyethylene terephthalate (PET) film, a 25 pm nylon film, a 6 pm aluminium foil, and, as a lower layer facing the core material a 50 pm low- density polyethylene (LDPE) film.
[0024] Base sections of the first 21 and second 41 films which form the flaps are pulled together under tension prior to heat sealing of the flaps to facilitate tight fitting of the envelope against the surface of the core. Fig 1 illustrates the flaps 51 , 52 being folded in the same direction so that they lie flat against the major surface 36. Once folded against the major surface, the flaps 51 , 52 are held in place by welding, adhesive or adhesive tape.
[0025] Subsequently, a first end (not shown) of the envelope is sealed, air is evacuated from the core and the second end 62 is sealed to provide the vacuum insulating panel. Folding of the flaps 51 , 52 against the major surface 36 may be carried out prior to or subsequent to evacuation of the panel.
[0026] The absence of flaps at the side faces 32, 33 facilities close abutment of adjacent panels and/or cooperation of the side faces 32, 33 with a housing.

Claims

1 . A vacuum insulating panel comprising a core sealed in an envelope, characterised in that the envelope comprises first and second film sections which are connected by spaced-apart sealing flaps, the sealing flaps being arranged at a main surface of the vacuum insulation panel and wherein the sealing flaps are folded in the same direction and lie substantially flat against a main surface of the insulating panel.
2. A vacuum insulating panel according to claim 1 , wherein the core comprises mineral fibres.
3. A vacuum insulating panel according to claim 2, wherein the mineral fibres comprises glass wool, rock wool or combination thereof.
4. A vacuum insulating panel according to any preceding claim, wherein the vacuum insulating panel comprises a getter, preferably a getter comprising calcium oxide.
5. A vacuum insulating panel according to any preceding claim, wherein at least one of the film sections comprises a film of aluminium.
6. A cooling device, notably a cooling device selected from a refrigerator, a freezer, a chiller cabinet and a cool box, incorporating a vacuum insulating panel according to any preceding claim, notably incorporating a vacuum insulating panel according to any preceding claim in one of its walls, particularly in a wall of a door.
7. A cooling device in accordance with claim 6, wherein the vacuum insulating panel is retained in the wall of the cooling device by a thermally insulating foam material, notably by a polyurethane foam.
8. A method of manufacturing a vacuum insulating panel comprising:
- mixing mineral fibres in an acid solution;
- forming a core of mineral fibres by separating the mineral fibres from the acid solution;
- arranging a first film section around the core so that it entirely covers one major surface of the core, covers two side or end faces of the core and covers peripheral sections of the other major surface of the core, arranging a second film section at the portion of the other major surface of the core which is not covered by the first film section such that, at each of the two portions at the other major surface where the first and second film sections meet, a flap is formed from contact between the undersides of peripheral portions of the first and second film sections;
- sealing the first and second film sections together along each of the flaps; and
- folding each of the flaps against the major surface of the panel in the same direction.
9. A method of installing a vacuum insulating panel according to any of claims 1 to 6 in a cooling device, notably in a wall of a cooling device selected from a refrigerator, a freezer, a chiller cabinet and a cool box, comprising arranging the sealing flaps of the vacuum insulating panel such that they are folded in a direction from a leading edge towards a trailing edge of the vacuum insulating panel, injecting a foam forming fluid over the vacuum insulating panel in a direction from the leading edge towards the trailing edge and subsequently allowing solidification of the foam forming fluid to form a solid thermally insulating foam, notably a polyurethane foam, which secures the vacuum insulating panel in the cooling device.
10. A method in accordance with claim 9, in which the solid thermally insulating foam encapsulates the vacuum insulating panel.
PCT/EP2015/078095 2014-12-01 2015-11-30 Vacuum insulating panel WO2016087387A1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
LU93161A LU93161B1 (en) 2014-12-01 2015-11-30 VACUUM INSULATION PANEL
EP15804724.1A EP3227503A1 (en) 2014-12-01 2015-11-30 Vacuum insulating panel

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GBGB1421307.8A GB201421307D0 (en) 2014-12-01 2014-12-01 Vacuum insulating panel
GB1421307.8 2014-12-01

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Cited By (2)

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Publication number Priority date Publication date Assignee Title
WO2018069116A1 (en) * 2016-10-13 2018-04-19 Kingspan Holdings (Irl) Limited Vacuum insulation panel
GB2607097A (en) * 2021-05-28 2022-11-30 Knauf Insulation Mineral wool insulation

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2264261A (en) * 1992-02-20 1993-08-25 Schuller Int Inc Producing encapsulated fibrous insulation blanket
DE10015876A1 (en) * 2000-03-30 2001-10-11 Jobst H Kerspe Vacuum insulation panel for lining refrigerating units, cold storage rooms and similar items comprises cover foils which are welded to one another so that the panel contact edges are at least largely free from protrusions
US20070027281A1 (en) * 2003-09-15 2007-02-01 Basf Aktiengesellschaft Use of an aqueous binding agent devoid of formaldehyde for substrates
WO2007061196A2 (en) * 2005-11-22 2007-05-31 Lg Electronics Inc. Vacuum insulation panel and insulation structure of refrigerator using the same
JP2008121757A (en) * 2006-11-10 2008-05-29 Sharp Corp Vacuum insulation material and refrigerator

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2264261A (en) * 1992-02-20 1993-08-25 Schuller Int Inc Producing encapsulated fibrous insulation blanket
DE10015876A1 (en) * 2000-03-30 2001-10-11 Jobst H Kerspe Vacuum insulation panel for lining refrigerating units, cold storage rooms and similar items comprises cover foils which are welded to one another so that the panel contact edges are at least largely free from protrusions
US20070027281A1 (en) * 2003-09-15 2007-02-01 Basf Aktiengesellschaft Use of an aqueous binding agent devoid of formaldehyde for substrates
WO2007061196A2 (en) * 2005-11-22 2007-05-31 Lg Electronics Inc. Vacuum insulation panel and insulation structure of refrigerator using the same
JP2008121757A (en) * 2006-11-10 2008-05-29 Sharp Corp Vacuum insulation material and refrigerator

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2018069116A1 (en) * 2016-10-13 2018-04-19 Kingspan Holdings (Irl) Limited Vacuum insulation panel
CN110099789A (en) * 2016-10-13 2019-08-06 金斯潘控股有限公司 Vacuum heat-insulating plate
US10968625B2 (en) 2016-10-13 2021-04-06 Kingspan Insulation Limited Vacuum insulation panel
AU2017341275B2 (en) * 2016-10-13 2021-09-23 Kingspan Holdings (Irl) Limited Vacuum insulation panel
GB2607097A (en) * 2021-05-28 2022-11-30 Knauf Insulation Mineral wool insulation

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GB201421307D0 (en) 2015-01-14
EP3227503A1 (en) 2017-10-11

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