ROCHEFORT, Malcolm (The Old Rectory, Leinthall StarkesLudlow, SY8 2HP, GB)
PARGETER, Adrian (25 Borrowdale Close, Brierly HillWest Midlands, DY5 3RW, GB)
ROCHEFORT, Malcolm (The Old Rectory, Leinthall StarkesLudlow, SY8 2HP, GB)
| Claims 1. A prefabricated composite insulation board comprising a facer, a plurality of separate vacuum insulated panels adhesively bonded to the facer, at least some of the vacuum insulated panels being spaced-apart on the facer to define gaps therebetween, and a of insulating foam material overlying the vacuum insulating panels and extending into the gaps between the vacuum insulation panels. 2. An insulation board as claimed in claim I wherein the facer has a pre-applied adhesive thereon. 3. An insulation board as claimed in claim 2 wherein the adhesive is activated by one or more of heat. I'V. chemical reaction or IR. 4. An insulation board as claimed in claim 3 wherein the adhesive is heat activated. 5. An insulation board as claimed in any one of claims 2 to 4 wherein the adhesive comprises a plastic material. 6. An insulation board as claimed in claim 5 wherein the adhesive comprises a lenc material. 7. An insulation board as claimed in any one of claims 1 to 6 wherein the adhesive comprises a film material. S. An insulation board as claimed in any one of claims I to 7 w herein the facer comprises a laminate and the adhesive comprises a layer of the facer to w hich the vacuum insulation panels are attached. 9. An insulation board as claimed in claim 2 wherein the adhesive is covered by a removable protector. 10. An insulation board as claimed in any one of claims 1 to 9 w herein the gaps are at least partially defined by shaping the vacuum insulating panels. 11. Λη insulation board as claimed in claim 10 wherein the vacuum insulating panels comprise rounded or angled corners. 12. An insulation board as claimed in any one of claims 1 to I 1 wherein the facer has indicia thereon to indicate the location of the gaps. 13. An insulation board as claimed in any one of claims 1 to 12 comprising a second facer overlying the vacuum insulating panels and the facer to which the vacuum insulating panels are bonded. 14. An insulation board as claimed in claim I 1 w herein the first and second facers are of the same material. 15. An insulation board as claimed in an} of claims 1 to 12 w hen the facer(s) is of a flexible sheet material. An insulation board as claimed in any of claims I to I 5 w herein the facer(s) comprises a metal or metallised material. 17. An insulation board as claimed in claim 16 wherein the facer(s) comprises an aluminium foil. 18. An insulation board as claimed in claim 16 wherein the facer(s) comprises a stainless steel foil. 19. An insulation board as claimed in claim 16 wherein the facer(s) comprises a metallised polymeric film. 20. An insulation board as claimed in any one of claims 1 to I 0 wherein the facer comprises paper. 21. An insulation board as claimed in any one of claims 1 to 20 w herein the facer comprises a 22. Λη insulation board as claimed in any one of the claims I to 21 wherein the facer comprises a composite of two or more selected from metal foil, polymer film, paper and glass fibre tissue or scrim 23. An insulation board substantially as hereinbefore described. 24. A method lor manufacturing an insulating panel comprising the steps of :- providing a first facer: adhesively bonding a plurality of vacuum insulation panels to the facer, at least some of the vacuum insulation panels being spaccd-apart on the facer to define gaps therebetween: leading the facer with the vacuum insulation panels bonded thereto to a lay-dow n station: laying down liquid foam reactants over the vacuum insulation panels: and allowing the foam to expand to form an insulating body. 25. A method as claimed in claim 24 comprising the step of activating the adhesive prior to attachment of the vacuum insulation panel. 26. A method as claimed in claim 25 wherein the adhesive is activated by heating the facer. 27. A method as claimed in claim 26 comprising the step of leading the facer over a heated surface. 28. A method as claimed in claim 27 comprising leading the facer across a heated bed. 29. A method as claimed in claim 27 or 2X comprising leading the facer over a heated roller. 30. Λ method as claimed in any one of claims 24 to 29 comprising the step of controlling the temperature during and or after application of a vacuum insulation panel. 31. A method as claimed in claim 30 comprising heating and/ or cooling at least one bed. 32. A method as claimed in any one of claims 24 to 31 comprising the steps of :- picking up a vacuum insulating panel: and placing the vacuum insulating panel on the facer. 33. A method as claimed in any of claims 24 to 32 comprising applying a second facer over the liquid foam reactants 34. A method for manufacturing an insulating panel substantially as hereinbefore described with reference to the accompam ing drawings. 35. An insulating panel when manufactured by a method as claimed in any one of claims 24 to 34 |
Introduction
This invention relates to vaeuum insulation panels (VIP).
Current VIP technology generall) comprises a single panel of insulation material formed typically of fumed silica, mineral fibre or other microporous material core, which may or ma\ not contain infra red opaciflers. 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 typiealh of the order of 0.005 W/ ' niK. If the vacuum is lost the panel loses a large proportion of its cftcctix eness as a thermal insulator, with the thermal conductivity reverting to that of the core material, which is tvpicallv above 0.020 \V 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 the floor, wall or roof of buildings 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 drilling of holes for w iring, shelf fixing and the like. ft has been suggested to provide VIPs with compartments and sealed regions around the compartments. However, such scaled 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 prefabricated composite insulation board comprising a facer, a plurality of separate vacuum insulated panels adhesively bonded to the facer, at least some of the v acuum insulated panels being spaced-apart on the facer to define gaps therebetween, and a bod) of insulating foam material overlying the vacuum insulating panels and extending into the gaps between the vacuum insulation panels.
In one embodiment the facer has a pre-applied adhesive thereon. I lie adhesive may be activated by one or more of heat. U V. chemical reaction or IR.
In one ease the adhesive is heat actuated. The adhesive may comprise a plastic material such as a polyethylene material. The polyethylene (or more general!} the plastic) ma} be a homopohmer or a copohmer with other suitable material(s).
In one case the adhesive comprises a film material.
In one embodiment the facer comprises a laminate and the adhesive comprises a laver of the facer to w hich the vacuum insulation panels are attached. This las er ma} be of a plastic material such as polyethy lene. In another embodiment the adhesive is covered by a remov able protector.
In one aspect of the invention the gaps are at least partially defined by shaping the vacuum insulating panels. For example, the vacuum insulating panels may comprise rounded or angled corners.
In one embodiment the facer has indicia thereon to indicate the location of the gaps.
In one aspect of the invention the insulation board comprises a second facer overlying the vacuum insulating panels and the facer to which the vacuum insulating panels are bonded.
The first and second facers may be of the same material. The facer(s) may be of a flexible sheet material.
In one case the facer(s) comprises a metal or metallised material such as an aluminium foil, a stainless steel foil, or a metallised polymeric film.
The facer ma} 1 comprise a paper, polymer film and/or a glass tissue composite. In one embodiment the facer comprises a composite of two or more selected from metal foil, polymer film. paper and glass fibre tissue or scrim
The invention also provides a method for manufacturing an insulating panel comprising the steps of:- providing a first facer: adhesively bonding a plurality of vacuum insulation panels to the facer, at least some of the vacuum insulation panels being spaced-apart on the facer to define gaps
therebetween: leading the facer with the vacuum insulation panels bonded thereto to a lay-down station: laying down liquid foam reactants over the vacuum insulation panels; and allowing the foam to expand to form an insulating body. In one embodiment the method comprises the step of activating the adhesive prior to attachment of the vacuum insulation panel. The adhesive may be activated heating the facer.
In one embodiment the method comprises the step of leading the facer over a heated surface such as across a heated bed and/or over a heated roller.
In one case the method comprises the step of controlling the temperature during and or after application of a vacuum insulation panel. This may involve heating and or cooling at least one bed. There ma\ be several such beds which can be independently controlled. In one aspect of the invention the method comprises the steps of:- picking up a vacuum insulating panel: and placing the vacuum insulating panel on the facer In one embodiment the method comprises applying a second facer over the liquid foam reaclants The invention also provides an insulating panel when manufactured by a method of the invention.
The invention provides an insulating panel comprising a carrier and a vacuum insulating panel attached thereto.
The vacuum insulated panel may be adhesive!} bonded to the carrier.
The carrier may comprise a panel lacing. The facing may have a pre-applied adhesive thereon.
In one embodiment the insulating panel comprises a body of insulating material overlying the vacuum insulated panel.
In one case there are a plurality of separate vacuum insulated panels attached to the carrier. Spaces may be delined between at least some of the vacuum insulated panels. At least some of the spaces may be filled with an insulating material. In one embodiment the spaces arc at least partially defined by shaping the vacuum insulating panels. The vacuum insulating panels may comprise rounded or angled corners. In one case the facing has indicia thereon that indicate the location of the spacing.
In one embodiment the insulating panel comprises a second facing overlying the vacuum insulating panels and the carrier facing.
The carrier may comprise a flexible sheet material.
The first facing and 'or the second facing may be of a flexible sheet material.
The first facing and or the second facing max be of a metal or metallised material.
The first and Or second facings be of aluminium foil. The first and/or second facings may be of stainless steel foil. In one case the first and/or second facings are of metallised polymeric film. In one case the first and or second facings are of the same material.
In one embodiment the insulating material is an insulating foam material.
The invention also provides a method for manufacturing an insulating panel comprising the steps of:- leading a carrier to a \acuum insulation panel placing station: and
attaching a vacuum insulation panel to the carrier.
In one embodiment the method comprises adhesively bonding the vacuum insulation panel to the carrier.
The method may comprise the step of providing a carrier having an adhesive pre-applied thereto. The adhesive may be activated by heat, for example by leading the carrier across a heated bed or heated roller.
In one ease the method comprises the steps of :- picking up a vacuum insulating panel: and placing the vacuum insulating panel on the carrier. The method may comprise the steps of :- laying liquid foam reaetants onto the vacuum insulating panel and carrier: and allowing the foam to expand to form an insulating body. In one embodiment the method comprises applying a second facing over the liquid loam reactants.
The vacuum insulated panel ma} be inserted after application of a first laxdown. The first lav down may comprise a bonding material which is compatible with the liquid foam reactants. The first !aydown max comprise liquid foam reactants.
In one case a plurality of x acuum insulating panels are inserted. In one embodiment the xacuum insulating panel contains an insulating medium which is self supporting.
The insulating medium max 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 max be of insulating foam material, fumed silica or aerogel.
Brief Description of the Drawindgs
The invention xxill be more elearlx understood from the follow ing description of an embodiment thereof, given by way of example only, with reference to the accompanying drawings, in which:
Fig. 1 is a longitudinal cross sectional view of a composite insulation board according to the invention: Fig.2 is a perspective viexv illustrating steps in the manufacture of the board oT Fig. I on a continuous manufacturing line:
Fig.3 is a plan view of a vacuum panel insertion station used in manufacturing the board; Fig.4 is a side view illustrating further steps in the method of the invention:
Figs. 5 to 7 are top plan views of various composite insulation boards according to the invention:
Fig. 8 is a plan view of a composite insulation board according to another embodiment of the invention:
Fig. 9 is a cross sectional view illustrating the fixing of the board of Fig. 8 to a building substrate:
Figs. 10 and 11 are perspective views of alternative steps in the manufacture of the composite insulation board of Fig. I: Fig. 12 is a side v iew illustrating steps in the manufacture of a board according to the invention: and
Fig. 13 is a side view illustrating steps in an alternative method for manufacturing a board according to the invention.
Detailed Description
Referring to the drawings and initially to Figs. I to thereof there is illustrated a prefabricated composite insulation board 1 according to the invention. The board 1 comprises a carrier facer 2 of a flexible sheet material and a plurality of vacuum insulation panels 3 attached thereto. Λ body of insulating loam 4 overlies the vacuum insulating panels 3 and the carrier facer 2.
The vacuum insulation panels 3 may be arranged in any desired configuration on the carrier facer 2. Some alternative set-ups are illustrated in Figs. 2. 3 and 5 to 7. In some instances there are gaps 5 between adjacent individual vacuum insulation panels 3 and these gaps arc filled w ith the foam 4. Alternatively, groups of YlP " s 3 m ay be positioned close to one another and gaps 6 left at defined locations. These gaps 6 may be used to provide regions at which the panel may be cut to a desired length without cutting through any VIP's 3. Fxternal markings such as cut-lines 7 may be provided to indicate the location of these gaps 6. To manufacture a prefabricated composite insulation board I of the invention on a continuous manufacturing line a carrier facer sheet 2 with a pre-applied adhesive 6 is provided on a supply reel 10 as illustrated in Fig. 2. The adhesive 6 be a low tack adhesive which facilitates impeding but retains VIP ' s 3 in place, in use. Alternatively, an adhesiv e lav or ~! of a higher tack on the facer 2 may be cov ered by a remov able film protector 8 (Fig. 10).
In one case (Fig. 11) a carrier facer sheet 2 is led continuous!} from a supply reel 10 to an applicator station 11 at which a layer of adhesive 12 be applied to the uppermost face of the carrier 2. for example, using an applicator head.
The VIP ' s 3 may be applied over the adhesive bonding lay er on the carrier facer 2 in any suitable manner. For example, as illustrated in F ig.3 the VIP ' s may be prov ided in a supply cartridge or stack 15 and individual VIP ' s 3 or groups of VIP ' s 3 may be picked up and placed onto the adhesive on the carrier facer 2. using for example robots 16.
Referring particularly to fig.4. after application of the VIP ' s 3 liquid loam reactants are applied over the VIP ' s 3 and the carrier facer 2 using an applicator 18 at a foam lav -dow n station 19. An upper substrate or facer sheet 20 may be applied over the foam reactants and VIP ' s 3. The sandwich thus formed is then led through a laniinator oven 21 in which the loam expands and a continuous length of rigid polymeric insulating foam board is formed. The board 15 may be led through an insulating tunnel and then cut to a desired length.
The facer sheets 2.20 may be of the same or different materials. The facer sheets 2. 20 mav for example comprise a foil or film material such as a metal or metalised material. One example of such material is an aluminium foil. Alternatively or additionally one or both of the facer sheets 2. 20 may comprise Kraft paper and or a glass tissue material.
The use of adhesive enables accurate, stable positioning of VIP ' s during the manufacturing process. Accurate positioning will allow minimal gaps between VIP ' s reducing edge losses and allowing better tolerance for cutting final panel si/es. The loam covering over the VIP's provides protection for the VIP ' s against damage due lo handling, installation and in use. The foam covering may also improve the life span of the VIP ' s by reducing moisture \apour and o.\\ gen transfer.
Alternatively or additional!} the adhesive max be activated by application of heat. I 'V. IR. or the like. One such system is illustrated in Fig. 12. In this case a carrier sheet 2 is provided w ith a pre- applied adhesixe which is actixated by heat supplied by a bed 70. I he bed 70 max be in independently controlled sections 71. 72. 73. 74. 75 to vary the amount of heat applied and thereby closely control the activation of the adhesixe prior to application of the vacuum insulation panels 3. After application of the vacuum insulation panels 3 liquid foam reactants are laid down from a lay-down head 18 and an upper substrate or lacing sheet 20 is applied as described above. After initial heating and application of the vacuum insulation panels the beds 72. 73. 74 max be used to heal and or cool to optimise the integration of the panels with the foam. The adhesive may be provided by a film or layer of a suitable plastic material such as polyethylene which is heated to render it tacky prior to application of the xacuum insulation panels. To cause the plastic to become tacky quickly (possibly in a few seconds), as max be required in a continuous process, a high temperature such as 50 to 100 degrees centigrade above the melting point of the plastic max be applied via the heated bed or other application device. such as roller. In some cases the temperature max be increased gradually as the plastic passes over a heated bed. Alternatively or additionally as illustrated in f ig. 13. the plastic max be heated by passing it over a heated roller SO. This has the advantage of retaining the material taut so thai heat can be applied efficiently ox er the w idth of the film/ layer. The heated roller 80 max in some cases be used in conjunction w ith beds 71. 72. 73. 74. The first bed 71 max be heated and the other beds 72. 73. 74 max be heated or cooled to optimise the integration of the vacuum insulation panels 3 with the foam.
A laminated facer 2 with an inner plastic layer max be used to provide for the adhesion of the vacuum insulated panels as described above. This provides significant advantages as it max be readily integrated into a continuous foam board factory scale production line.
The invention provides a process for manufacturing an insulation foam board in a continuous manner on a factory scale. Referring to Fig.8 there is illustrated another prefabricated composite insulation hoard according to the invention which is similar to the panels of Figs. 1 and 5 to 7 and like parts are assigned the same reference numerals. In this case, the vacuum insulation panels 3 are shaped to define gaps for receiving fixings 50 such as of the type illustrated in Fig. 9 having a fixing shaft 51 (w hich may be threaded) and a head 52. For example, the vacuum insulated panels 3 may have rounded or angled corners to create sufficient space to receive a fixing between adjacent vacuum insulating panels 3. In Fig. 860 indicates an edge fixing region and 61 indicates a centre fixing region. Such regions may be identified on the facing(s) using suitable indicia, for example. Fig. 9 illustrates the fixing of the panel to an underlying substrate 55.
The prefabricated composite insulation boards of the invention may be used to form an insulating layer along walls, floors or roofs. They may be used during construction or in retrofitting to improve the insulation performance. Modification 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.