Method for manufacturing vacuum insulation panels

Patent metadata

Field	Value
Publication number	US-9644781-B2
Application number	US-201414889287-A
Country	US
Kind code	B2
Filing date	May 7, 2014
Priority date	May 7, 2013
Publication date	May 9, 2017
Grant date	May 9, 2017

Abstract

The invention relates to a method for manufacturing vacuum insulation panels with a fiber core, comprising the steps of: providing a core blank of fibers, compressing the core blank to a predetermined final thickness for forming the core, evacuating a foil sleeve enclosing the core up to a pressure of ≦1 mbar, and sealing the foil sleeve. The method according to the invention is characterized by the fact that, in the compression step, the core blank is arranged between two cover elements and is mechanically compressed therebetween, that the core is kept under compression pressure until the foil sleeve is sealed, and that the compression step is performed at the place of manufacture at room temperature without thermal impact. Thus, a method for manufacturing vacuum insulation panels with a fiber core can be improved such that it can be performed with reduced energy requirement and yet the insulating effect of the vacuum insulation panels does not suffer therefrom.

First claim

The invention claimed is:

1. A method for manufacturing vacuum insulation panels ( 1 ; 1 ′) with a core ( 3 ) of fibers, comprising the steps of:
providing a core blank of fibers,
arranging a foil sleeve ( 2 ; 2 ′) over the core blank of fibers, and having foil sections ( 2 a , 2 b ) thereof arranged at the upper and lower sides of the core blank of fibers,
subsequent to arranging the foil sleeve ( 2 ; 2 ′) over the core blank of fibers, compressing the core blank to a predetermined thickness for forming the core ( 3 ),
wherein in the compression step the core blank is arranged between two cover elements and is mechanically compressed therebetween, and
wherein the compression step is performed at the place of manufacture at room temperature without thermal impact,

welding the foil sleeve ( 2 ; 2 ′) on three sides while maintaining the compression;
evacuating the foil sleeve ( 2 ; 2 ′) enclosing the core ( 3 ) up to a pressure of ≦1 mbar, and
sealing the foil sleeve ( 2 ; 2 ′) wherein the mechanical compression of the core ( 3 ) is maintained until the foil sleeve ( 2 ; 2 ′) is sealed, and while maintaining the core ( 3 ) in the evacuated state.

2. The method according to claim 1 , characterized in that the foil sleeve ( 2 ) is formed of a metal foil, and that the core blank is enclosed with the foil sleeve ( 2 ) prior to the compression step, wherein foil sections ( 2 a , 2 b ) thereof serve as the two cover elements.

3. The method according to claim 1 , characterized in that the foil sleeve ( 2 ′) is formed of a composite plastic foil, wherein, prior to the compression step, two support plates ( 4 ) serving as cover elements are additionally arranged at large faces of the core blank, and wherein the support plates ( 4 ) are formed of a pressure-resistant metal or plastic material not degassing under vacuum.

4. The method according to claim 1 , characterized in that the fibers do not comprise any organic binder disintegrating in vacuum.

5. The method according to claim 1 , characterized in that the fibers are organic fibers of a thermoplastic material selected from the group consisting of polyethylene, polyamide, or polypropylene.

6. The method according to claim 1 , characterized in that the fibers are inorganic fibers, selected from the group consisting of mineral wool, glass wool, rock wool, and textile glass fibers.

7. The method according to claim 6 , characterized in that the providing of the core blank comprises drying of the inorganic fibers of the core blank up to a residual moisture of <0.1%.

8. The method according to claim 7 , characterized in that the step of drying is performed at a temperature ranging at least 200 K below the softening temperature of the fibers.

9. The method according to claim 1 , characterized in that the providing of the core blank comprises providing at least one felt web section of fibers, and cutting of the felt web to a predetermined finished size, and in the case of providing a plurality of felt webs, stacking the plurality of cut felt web sections.

10. The method according to claim 1 , characterized in that the step of the evacuating of the core ( 3 ) enclosed with a foil sleeve ( 2 ; 2 ′) is performed up to a pressure of ≦0.05 mbar.

11. The method according to claim 1 , characterized in that in the step of compression the core ( 3 ) is compressed to a density of approximately 250 kg/m 3 .

12. The method according to claim 1 , comprising using, as the fibers, mineral wool, wherein the mineral wool comprises fibers with a fiber yarn count corresponding to a micronaire of less than or equal to 20 l/min.

13. The method according to claim 9 , characterized in that the felt web comprises a weight per unit area of between 800 g/m 2 and 2500 g/m 2 prior to drying.

14. The method according to claim 1 , characterized in that the foil sleeve ( 2 ) is formed of a stainless steel foil, and that the core blank is enclosed with the foil sleeve ( 2 ) prior to the compression step, wherein foil sections ( 2 a , 2 b ) thereof serve as the two cover elements.

15. The method according to claim 1 , characterized in that the foil sleeve ( 2 ′) is formed of a composite plastic foil, wherein, prior to the compression step, two support plates ( 4 ) serving as cover elements are additionally arranged at large faces of the core blank, and wherein the support plates ( 4 ) are formed of a pressure-resistant HDPE, polyamide, PVC, or polypropylene plastic material not degassing under vacuum.

16. The method according to claim 1 , characterized in that the fibers comprise organic fibers of a thermoplastic material.

17. The method according to claim 1 , characterized in that the step of the evacuating of the core ( 3 ) enclosed with a foil sleeve ( 2 ; 2 ′) is performed up to a pressure of ≦0.01 mbar.

18. The method according to claim 1 , characterized in that in the step of compression the core ( 3 ) is compressed to a density of between 150 kg/m 3 and 350 kg/m 3 .

19. The method according to claim 1 , comprising using, as the fibers, mineral wool, wherein the mineral wool comprises fibers with a fiber yarn count corresponding to a micronaire of less than or equal to 15 l/min.

Assignees

• Saint Gobain Isover

Inventors

• Thiery Julien
• Passon Ulrich
• Gerhards Wolf

Classifications

• B32B37/18

  involving the assembly of discrete sheets or panels only · CPC title

• B32B2307/31

  Heat sealable · CPC title

• B32B3/04

  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} · CPC title

• B32B27/34

  comprising polyamides · CPC title

• B32B2307/304

  Insulating · CPC title