Wall Insulation Panel

Abstract

A wall insulation panel for use on a wall comprises at least the successive layers of: a first protective panel having a wall-meeting surface and a vacuum insulating panel (VIP) facing surface, an intermediate VIP panel; and a second protective panel having a VIP facing surface and an outward facing surface. There is an expansion region between at least one of the first and second protective panels and the VIP panel to allow for expansion of the VIP panel without deformation of the outward facing surface of the second protective panel. In this way, the expansion region allows for expansion of the VIP panel without deformation of the VIP facing surface of the second panel, and thus without deformation of the outward facing surface. This maintains the integrity and aesthetic appearance of the outward facing surface, and any further surface or layer thereon, such as a rendered layer.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and all the advantages of U.S. Provisional Patent Application No. 61/566,747, filed on Dec. 5, 2011, the content of which is incorporated herein by reference.

TECHNICAL FIELD

The present invention relates to a wall insulation panel for use on a wall and including a vacuum insulating panel (VIP), as well as wall insulation cladding comprising a series of said wall insulation panels, in particular to provide a continuous VIP plane.

BACKGROUND

Vacuum insulating panels (VIPs), often also termed ‘VIP panels’, are a highly efficient advanced thermal insulation technology, having at least 3-7 times more effective insulation ability than conventional plastic foams or fibrous insulation. VIP panels are increasingly used to enhance the performance of static goods such as refrigerators, and in refrigerated vehicles.

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

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

After adding the insulation panels during wall construction, a final layer, generally a ‘rendered’ layer, is usually added to provide a smooth and uniform finish to the outside of the building, both for weather shielding, and as the final outwardly facing layer that defines the ‘view’ of the building.

VIP panels, by involving a vacuum, are generally less robust, and require at least some protection during installation and fixing to withstand the handling involved. Thus, conventionally, VIP panels for building purposes are completely enveloped on all sides in one or more foam protective layers to form an insulation panel.

However, such fully protected and enveloped VIP panels have two problems. Firstly, whilst vacuum technology is improving, the existence of the vacuum in the VIP panels still makes possible the transfer of gasses from the atmosphere to the interior of the panel through the panel membrane, i.e. ‘leaking’ of the vacuum. But any leakage will affect the overall size of enveloped VIP panels, expanding the whole insulation panel, and therefore deforming any weather shielding or rendered finish thereon. The render will crack and allow moisture ingress, affecting the integrity of the panel, as well as being aesthetically unsightly.

Secondly, the overall effectiveness of the vacuum insulation is reduced when a number of such panels are brought together to form an overall surface or cladding. This is because the foam protection surrounds the VIP panels on all sides, isolating the VIP panels, so that providing a number of such panels together does not create any continuation of the ‘vacuum insulation’ properties of the separate VIP panels. Thus, ‘heat highways’, i.e. easier pathways for heat to travel, are created for the passage of heat from one side the such insulation panels to the other side, generally from the outside to the inside. The heat highways are formed between the VIP panels where the foam protection breaks the meeting of the actual vacuum insulation part of each panel, despite the insulation panels meeting.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide an improved wall insulation panel having a VIP panel for use in wall insulation and being able to accommodate VIP leakage, and/or reduce the number of heat highways across a series of such panels.

According to one aspect of the present invention, there is provided a wall insulation panel for use on a wall comprising at least the successive layers of: a first protective panel having a wall-meeting surface and a vacuum insulating panel (VIP) facing surface, an intermediate VIP panel; and

a second protective panel having a VIP facing surface and an outward facing surface; characterised in that there is an expansion region between at least one of the first and second protective panels and the VIP panel to allow for expansion of the VIP panel without deformation of the outward facing surface of the second protective panel.

In this way, the expansion region allows for expansion of the VIP panel without deformation of the VIP facing surface of the second panel, and thus without deformation of the outward facing surface. This maintains the integrity and aesthetic appearance of the outward facing surface, and any further surface or layer thereon, such as a rendered layer.

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

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

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

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

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

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

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

The wall insulation panel may comprise one or more intermediate VIP panels, being the same or different; optionally having the same or similar dimensions and other parameters, and references herein to the term “the intermediate VIP panel” include a single intermediate VIP panel or multiple intermediate VIP panels, layered between the first and second protective panels.

As discussed above, the membrane or covering material of the VIP panel is intended to resist to the transfer of gasses from the atmosphere to the interior of the panel, which obviously reduces the vacuum-insulating performance of the panel, and also expands the size of the panel. A membrane material such as aluminium foil has good vacuum-resisting properties, as well as being easily ‘sealable’ during the method of manufacturing the VIP panels. One or more further layers or coverings may be inside or outside the membrane material. However, it is not possible to produce a perfect vacuum layer, especially at the vacuum pressures used to form VIP panels, and which will be subject to the ‘conditions’ of building walls, such as temperature variations, long term exposure, any impacts, etc., as well as achieving the long product lifetime and effectiveness generally desired by building manufacturers.

The VIP panel may include one or more internal media. Internal media include materials such as aerogel, silica, especially fumed silica, fibreglass and microfibreglass.

According to one embodiment of the present invention, the VIP panel used in the present invention is a fumed silica VIP panel, available from Dow Corning Corporation of Midland, Mich., USA.

The expansion region between at least one of the first and second protective panels and the VIP panel of the present invention allows for expansion of the VIP panel without deformation of the outward facing surface of the second panel. Thus, the integrity of the outward facing surface can be maintained. This integrity includes but is not limited to, being a barrier against the environment, in particular the weather, as well as the aesthetic appearance of the outward facing surface, or any further layer or surface or material added on to the outward facing surface. For example, any deformation in the outward facing surface would crack a rendered layer added thereon, allowing moisture ingress with its known associated problems, as well as looking permanently unsightly.

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

The expansion region may extend partly, substantially or wholly across one or more surfaces of the VIP panel. In particular, it may be partly, substantially or wholly of the same dimensions as at least one of the VIP facing surfaces of the first and second protective panels.

According to one embodiment of the present invention, the length and width of the expansion region wholly or substantially matches the length and width of the VIP panel.

According to another embodiment of the present invention, the expansion region has a wholly or substantially constant depth, ‘depth’ being that dimension extending transverse from one side of the VIP panel.

According to another embodiment of the present invention, the expansion region includes a compensation layer. The compensation layer optionally comprises one or more layers and/or materials, and is able to compensate for any expansion in the size of the VIP panel.

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

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

Optionally, the expansion region is formed of one or more deformable materials as defined above and one or more gaseous areas or spaces, such as one or more air spaces or pockets.

The deformable materials may extend regularly or irregularly across the expansion region, and may extend partly, substantially or fully across the expansion region.

According to another embodiment of the present invention, the expansion region or compensation layer includes one or more of the group comprising: ribs, tubes, springs and a soft and/or compressible foam, for example a very soft foam.

Optionally, the expansion region comprises a series of ribs or tubes extending between a VIP facing surface and the VIP panel, at least a portion of which ribs or tubes are deformable. Such ribs or tubes could be formed from a low density PU soft foam, or another low density soft foam, or a flexible foam, or flexible tubes, extruded or moulded foams, or even a silicone foam or acrylic materials. Optionally, the ribs or tubes provide a corrugated surface between the VIP facing surface and the VIP panel. Also optionally, the ribs or tubes extend from the VIP facing surface to meet the VIP panel.

In another embodiment of the present invention, the compensation layer is a sheeted material shaped to directly fit into the expansion layer. The sheeted material may comprise a first surface having a deformable material such as a number of ribs or corrugations extending transversely from the first sheet. Optionally, the sheet has a second opposing surface, forming a ‘sandwich’ effect between the deformable material. Such a sheeted material can be formed as an extruded material, and cut into the desired shape for easy insertion into the expansion region during manufacture of the wall insulation panels. Alternatively, compensation layer can be moulded.

Preferably, the expansion region is between the VIP facing surface of the second panel and the VIP panel. Optionally, the expansion region is located between the VIP panel and the VIP facing surface of the first protective panel to provide the same allowance for expansion of the VIP panel without deformation of the outward facing surface of the second protective panel. Alternatively, an expansion region could be located on each side of the VIP panel, able to accommodate the expansion of the VIP panel from one or both sides of the VIP panel.

As mentioned above, VIP panels have generally only been used when completely surrounded by one or more protective layers in conventional insulation panels, in order to protect the integrity of the more fragile VIP panel during use in the construction industry, etc. However, because the protection surrounds the VIP panels on all sides, providing a number of such panels together to cover a wall does not allow continuation of the ‘vacuum insulation’ properties of the isolated and thus separate VIP panels within each of the insulation panels. That is, heat highways are formed between the VIP panels, despite the insulation panels meeting.

Thus, in another embodiment of the present invention, the wall insulation panel of the present invention comprises a VIP panel extending to two opposing sides of the wall insulation panel. In this way, such sides of the VIP panel can directly meet the VIP sides of other such panels placed thereagainst, so as to provide a continuation of the vacuum insulation effect across two or more adjacent, abutting, conjoining or otherwise adjoining wall insulation panels of the present invention. Thus, there is no heat highway possible thereinbetween, and reduction of the number of ‘heat highways’ in an insulated wall cladding increases the effectiveness of the overall insulation effect across a number of panels.

The term ‘directly meet’ as used herein relates to the meeting or abutment of the VIP panels in such a way as to provide a continuance of the vacuum insulation effect. That is, where any intermediate layer between the two VIP panels exists, it has a de minimus effect on the vacuum insulation property. Preferably, the two VIP panels of this embodiment of the present invention abut without any intermediate layer.

According to another embodiment of present invention, the outward facing surface of the outer panel has a rendered finish thereon.

Optionally, the outer panel includes a transverse warning line parallel to the outward facing surface, to indicate a cutting zone. Indicated cutting zones on building panels are known in the art, and generally comprise one or more lines formed by visual or shaped, two dimensional or three dimensional additions or alterations in the outer facing surface, to indicate to a user what area of the wall insulation panel can be cut away in order to form the final necessary or desired shape of the wall insulation panel, generally to match a corresponding space on the wall, without affecting the VIP panel, and more particularly without cutting through the VIP panel and therefore negating the vacuum insulating effect. Such warning lines include continuous or non-continuous red lines or indented lines.

According to another aspect of the present invention, there is provided a wall insulation cladding comprising a series of abutting wall panels as defined herein. The wall insulation cladding may extend to in two or three dimensions, generally but not limited thereto, being a flat outer wall of a building, such as a commercial building or premises.

Preferably, the wall insulation cladding of the present invention provides a continuous VIP plane in at least in one dimension, based on the use of abutting two or more wall insulation panels of the present invention, each comprising a VIP panel extending to two opposing sides of the wall-insulation panel, to increase the overall vacuum insulation effect of the wall insulation cladding.

BRIEF DESCRIPTION OF THE DRAWINGS

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

FIGS. 1a and 1b are side and perspective views respectively of a wall insulation panel according to one embodiment of the present invention in an expanded format;

FIGS. 2a and 2b are side and perspective views respectively of the wall insulation panel of FIGS. 1a and 1b in a formed format;

FIG. 3 is a side of the wall insulation panel of FIG. 2a after expansion of the VIP panel;

FIG. 4 is a schematic front view of two abutting wall insulation panels of FIGS. 1 and 2; and

FIG. 5 is a schematic perspective view of a number of abutting wall insulation panels of FIGS. 1 and 2 to form a wall insulation cladding according to another embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring to the drawings, FIGS. 1a, 1b, 2a and 2b show a wall insulation panel 2 according to one embodiment of the present invention, comprising a first protective panel 4 having a wall meeting surface 6 and a vacuum insulating panel (VIP) facing surface 8, an intermediate VIP panel 10, and a second protective panel 12 having a VIP facing surface 14 and an outward facing surface 16.

FIGS. 1a and 1b show the wall insulation panel 2 in an expanded form, prior to bringing together the panels in a manufacturing method to provide the formed or completed wall insulation panel 2 shown in FIGS. 2a and 2b.

Each of the first and second protective panels 4, 12 are made of expanded polystyrene (EPS). EPS can be easily extruded into the relevant shapes, or indeed other similar shapes able to achieve the protective effect, to surround the VIP panel 10 in a protective or clam-shell manner.

Whilst the present invention is not limited thereto, FIGS. 1 and 2 show the first protective panel 4 forming a ‘base channel’, having a back wall portion 18 and two outstanding shoulder portions 19, having the inner dimensions of three sides of the VIP panel 10 so as to accommodate and protect the VIP panel 10 on three sides. The shoulder portions 19 of the first protective panel 4 are also shaped to accommodate corresponding outstanding top and bottom walls 20 of the second protective panel 12, which overlap when formed together as shown in FIGS. 2a and 2b.

The VIP panel 10 is formed from an aluminum membrane and an internal fumed silica media, available from Dow Corning Corporation of Midland, Mich., USA.

Whilst not being limited thereto, the dimensions of the wall insulation panel 2 could be in the range 1.5 m×1.5 m×0.5 m.

The second protective panel 12 includes an expansion region 22 which, once the wall insulation panel 2 is formed as shown in FIGS. 2a and 2b, extends between the VIP facing surface 14 of the second protective panel 12 and the opposing surface of the VIP panel 10.

The expansion region 22 includes a compensation layer formed by a series of regular parallel ribs 24 extending from the VIP facing surface 14 of the second protective panel 12, so as to provide a corrugated pattern or surface between the VIP facing surface 14 and the VIP panel 10. The ribs 24 are formed from a suitable material such as low density PU soft foam, that will deform/compress when a VIP panel is compromised as shown in FIG. 3 and as discussed hereinafter.

As shown in FIGS. 1 and 2, the ribs 24 extend wholly from the VIP facing surface 14 of the second protective panel 12 to meet the VIP panel 10, and the ribs 24 extend across the whole of this VIP facing surface 14.

The wall insulation panel 2 includes a transverse warning line 26 parallel to the outward facing surface 16 to indicate a cutting zone. The warning line 26 is in the form of a groove or channel along the top of the second protective panel 12, and it can be differently coloured, such as red, compared with the colour of the second protective panel 12. The warning line 26 gives an indication to the installer of how far the second protective panel 12 can be cut or otherwise shaped without cutting back into to the VIP panel 10, and thereby destroying its integrity.

FIGS. 1 and 2 also show two vertical sides 28 of the VIP panel 10 extending to two opposing sides of the wall insulation panel 2. Such sides are not being limited to being “vertical” as such, depending upon the use and installation of the wall insulation panel 2. The vertical sides 28 extend to the vertical side edges of the wall insulation panel 2, i.e. they have the same ‘length’ as the first and second protective panels 4, 12.

FIG. 3 shows the formed wall insulation panel 2 of FIG. 2a following leakage of the vacuum in the VIP panel 10, which expands the size of the VIP panel 10, in particular a frontwall 30 of the VIP panel 10. The expansion of this frontwall 30 is shown in exaggerated form for best illustration of the benefit of the present invention.

As the VIP panel frontwall 30 deforms outwardly, generally in a convex manner, its additional space can be accommodated by deformation, i.e. crushing, of the opposing ribs 24, making the expansion region 22a smaller. The extent of the deformation of the frontwall 30, and its nearness to the VIP facing surface 14 of the second protective panel 12, is shown in exaggerated form for FIG. 3, and the expected deformation over the product lifetime of the wall insulation panel 2 can be pre-calculated, to leave an extensive margin of error within the expansion region to avoid any complete crushing of the ribs 24 over the product life time.

FIG. 3 shows the accommodation of the expansion of the VIP panel 10 by the crushing of the opposing ribs 24, but without the expanded frontwall 30 reaching the VIP facing surface 14 of the second protective panel 12. Thus, there is no deformation of the outward facing surface 16 of the second panel 12.

It can be seen that the expansion region 22 could be similarly located between the VIP panel 10 and the first protective panel 4 to provide the same allowance for expansion of the opposite wall of the VIP panel 10, still without deformation of the outward facing surface 16 of the second protective panel 12. Alternatively, an expansion region could be located on each side of the VIP panel 10, able to accommodate the expansion of one or both VIP panel sidewalls.

FIG. 4 is a front view of the outward facing surfaces 16 of two wall insulation panels 2 of the present invention abutting along one vertical side 32. In this way, the vertical sides 28 of the VIP panels 10 within each wall insulation panel 2 can directly abut, so as to form a continuous VIP plane 34 across the extent of the two wall insulation panels 2, and so provide a continuation of the vacuum insulation effect of the two VIP panels 10 across the abutment 32. The location of other wall insulation panels alongside the two wall insulation panels 2 shown in FIG. 4 would extend the continuation of the vacuum insulation effect in the same direction across the whole extent of the covering of the wall insulation panels 2.

FIG. 5 shows a ‘3×3’ series, by way of example only, of wall insulation panels 2 located on a building wall 40 to form a wall insulation cladding 42 according to another embodiment of the present invention. The wall insulation panels 2 abut along their vertical edges in a manner shown in FIG. 4, so as to provide a continuation of the vacuum insulation effect 34 as described hereinabove.

Following the application of the wall insulation cladding 42, one or more layers of render can then be added across the outward facing surfaces 16 of the wall insulation panels 2, to provide a final rendered surface 44. The addition of one or more rendered layers provides shielding against the environment, especially the weather, as well as providing a more aesthetically pleasing final finish to the outside of the building.

It is well known that render is susceptible to cracking should there be any disturbance, particularly deformation, of the surface upon which it is laid. Thus, the ability of the present invention to maintain over the product life time the outward facing surfaces 16 of the wall insulation panels 2 without deformation, allows the wall insulation panels 2 to maintain the integrity and aesthetic appearance of the outward facing surfaces 16, and/any further surface or layer thereon, such as the rendered surface 44. Maintenance of the integrity of the rendered surface 44 is not only aesthetically pleasing, but also avoids or minimizes the possibility of the ingress of moisture through the rendered surface 44.

Thus, the present invention can allow for the expansion of a VIP panel within a wall insulation panel should it occur, without deformation of the outward facing surface of the second protective panel. In this way, the present invention maintains the integrity and aesthetic appearance of the outward facing surface, or any further surface or layer thereon. The present invention can also provide a continuation of the vacuum insulation effect across two or more adjacent or abutting wall insulation panels.

Claims

1. A wall insulation panel for use on a wall comprising at least the successive layers of:

a first protective panel having a wall-meeting surface and a vacuum insulating panel (VIP) facing surface,

an intermediate VIP panel; and

a second protective panel having a VIP facing surface and an outward facing surface;

wherein there is an expansion region between at least one of the first and second protective panels and the VIP panel to allow for expansion of the VIP panel without deformation of the outward facing surface of the second protective panel.

2. The wall insulation panel as claimed in claim 1, wherein the expansion region includes a compensation layer.

3. The wall insulation panel as claimed in claim 2, wherein the compensation layer includes one or more solid or semi-solid materials, at least a portion of which is deformable to accommodate expansion of the VIP panel.

4. The wall insulation panel as claimed in claim 3, wherein the expansion region includes one or more of the group comprising: ribs, tubes, springs, low density soft foam, adhered ribs or tubes, extruded ribs or tubes, silicone foams.

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

6. The wall insulation panel as claimed in claim 5, wherein the ribs or tubes provide a corrugated surface between the VIP facing surface and the VIP panel.

7. The wall insulation panel as claimed in claim 5, wherein the ribs or tubes extend wholly or substantially from the VIP facing surface to meet the VIP panel.

8. The wall insulation panel as claimed in claim 1, wherein the expansion region is between the VIP facing surface of the second panel and the VIP panel.

9. The wall insulation panel as claimed in claim 1, wherein the VIP panel extends to two opposing sides of the wall insulation panel.

10. The wall insulation panel as claimed in claim 1, wherein the outward facing surface of the second protective panel has a rendered finish thereon.

11. The wall insulation panel as claimed in claim 1, wherein the VIP panel is a fumed silica VIP panel.

12. The wall insulation panel as claimed in claim 1, wherein the second panel includes a transverse warning line parallel to the outward facing surface to indicate a cutting zone.

13. A wall insulation cladding comprising a series of abutting wall insulation panels as defined in claim 1.

14. The wall insulation cladding as claimed in claim 13, wherein the abutting wall insulation panels each comprise a VIP panel extending to two opposing sides of the wall insulation panel, for the wall insulation cladding to provide a continuous VIP plane.

15. The wall insulation panel as claimed in claim 6, wherein the ribs or tubes extend wholly or substantially from the VIP facing surface to meet the VIP panel.

16. The wall insulation panel as claimed in claim 3, wherein the expansion region includes ribs or tubes, and the ribs or tubes provide a corrugated surface between the VIP facing surface and the VIP panel.

17. The wall insulation panel as claimed in claim 16, wherein the ribs or tubes extend wholly or substantially from the VIP facing surface to meet the VIP panel.