Body module for refrigerated vehicles including a vacuum insulation panel, and associated manufacturing process

Abstract

The body module for a refrigerated vehicle, particularly for a road freight vehicle, comprises: - at least one vacuum insulation element 32, - a base 34 defining at least one housing 42 within which said vacuum insulation element 32 is disposed, - at least one closing cover 36 fixed to the base 34 and mounted against said vacuum insulation element 32, said vacuum insulation element 32 being entirely housed between the base and said closing cover, and - at least one sealing means 38 which is interposed between the base 34 and said closing cover 36 and which is peripheral to said vacuum insulation element 32. Figure for the abbreviation: Fig 4

Description

Title of the invention: Body module for refrigerated vehicle comprising a vacuum insulation panel, and associated manufacturing method

[0001] The present invention relates to the field of refrigerated vehicles, and in particular to refrigerated vehicles used for the transport of goods.

[0002] More particularly, the present invention relates to a body module used for the manufacture of a refrigerated body intended to be mounted for example on the chassis of a road transport vehicle such as a truck, a semi-trailer, a trailer or a carrier.

[0003] A refrigerated body allows for the transport of goods or perishable foodstuffs that need to be kept at a constant temperature, generally lower than the outside temperature. For this purpose, the body includes a refrigeration unit or machine to supply temperature-controlled air into its cargo space.

[0004] Conventionally, the walls of a refrigerated body are formed from multilayer composite panels.

[0005] To improve the thermal insulation properties without increasing the thickness of the walls of the refrigerated body, it is known to use vacuum insulation panels comprising a porous insulating material forming a core which is encapsulated inside an oxygen and water-tight membrane.

[0006] French patent application FR-A1-2 963 291 (CHEREAU) describes, for example, a body module comprising a vacuum insulation panel and a protective casing overmolded around the panel so as to completely encapsulate it. The protective casing is made of expanded polyurethane.

[0007] According to another design, the body module may comprise a support plate to which the vacuum insulation panel is fixed, and a protective casing overmolded onto both the panel and the support plate. For further details, reference may be made to patent application FR-A1-2 991 250 (CHEREAU).

[0008] However, such solutions involving overmolding a protective casing can be relatively difficult for a refrigerated vehicle body manufacturer to implement industrially. Indeed, the use of this process makes it challenging to control parameters such as the homogeneity and density of the overmolded polyurethane of the protective casing, which influence the thermal insulation properties of the material.

[0009] Furthermore, the overmolding process can also lead to macro defects scopic factors, such as pores on the surface of the protective casing or air bubbles within its thickness, also hinder the achievement of improved thermal insulation properties.

[0010] Furthermore, to allow for proper expansion of the polyurethane during overmolding, it is necessary to provide peripheral material strips with a sufficiently large width. This implies machining the body module in width and length to optimize the ratio between the surface area of ​​the vacuum insulation panel and the surface area of ​​the expanded polyurethane.

[0011] The present invention aims to remedy these drawbacks.

[0012] More particularly, the present invention aims to provide a body module for a refrigerated vehicle, in particular for a road vehicle for the transport of goods, having good thermal insulation properties and easy to manufacture.

[0013] The invention relates to a body module for a refrigerated vehicle, particularly for a road freight vehicle, comprising at least one vacuum insulation element, a base defining at least one compartment within which said vacuum insulation element is disposed, and at least one closing cover fixed to the base and mounted against said vacuum insulation element. Said vacuum insulation element is entirely housed between the base and said closing cover.

[0014] According to a general characteristic, the module further comprises at least one sealing means which is interposed between the base and said closing cover and which is peripheral to said vacuum insulation element.

[0015] With such a body module, it is possible to use for the base and the cover blocks which have been manufactured beforehand, for example blocks of rigid polyurethane already expanded and whose quality can be checked before the incorporation of the vacuum insulation element(s).

[0016] In addition, the size of the recess(es) in the base can be optimized without risk of degrading the quality of the material at its edges, unlike solutions with overmolding.

[0017] Furthermore, before incorporating the vacuum insulation element(s), it is possible to carry out machining on the base for the integration of tie-down bars or rails, metal insert rebates etc., which eliminates the risk of damage to the vacuum insulation elements during these operations.

[0018] Regarding the means of sealing the module, this prevents migration of catalyzed resin between the base and the cover towards the vacuum insulation element during the manufacture of the body panel integrating the module.

[0019] This prevents potential deterioration of the vacuum insulation element by the catalyzed resin. The sealing means also provides a bridge-breaking function. thermal insulation inside the module, preventing catalyzed resin from passing through the thickness of the module.

[0020] In one embodiment, the sealing means covers at least in part the abutment surface which is provided on the base and against which said closing cover is mounted in support.

[0021] Thus, the sealing means is compressed during the assembly of the cover and the base, which further increases its effectiveness.

[0022] The base may include at least one shoulder offset laterally outwards relative to said housing and offset towards said closing cover relative to the bottom of said housing, the peripheral sealing means extending at least along said shoulder.

[0023] In a particular embodiment, the vacuum insulation element can be centered on the longitudinal median plane of the module. This limits the bending stresses on the vacuum insulation element, particularly during the manufacture of the body panel incorporating the module, thereby limiting potential damage.

[0024] In a particular embodiment, said closing cover has a different color than the base. Alternatively or in combination, said closing cover may have a different texture than the base. Advantageously, the surface area of ​​the closing cover is larger than that of the vacuum insulation element, such that the cover extends beyond the vacuum insulation element over its entire periphery.

[0025] Thus, during the manufacture of the module, it is possible to visually locate the position of the vacuum insulation element(s). Furthermore, once the body panel incorporating the module has been manufactured, and in the event of an urgent repair requiring drilling, it is possible to perforate the opaque composite skins of the panel covering the module to a depth of a few millimeters, down to the surface of the module, and visually determine whether or not it is possible to continue drilling.

[0026] Advantageously, the base and the closing cover are preferably each made of a thermally insulating material. As mentioned above, the base can be made of expanded polyurethane. The closing cover can also be made of expanded polyurethane. Alternatively, the base and / or the cover can be made of other materials, for example, polystyrene, PET foam, or more generally any expanded polymer.

[0027] In a particular embodiment, the base delimits a plurality of housings within each of which is disposed a vacuum insulation element, the module comprising a plurality of closing covers each associated with a vacuum insulation element.

[0028] In one embodiment, the vacuum insulation element is provided with a core and an encapsulating membrane for said core. The vacuum insulation element may be in the form of a panel. The core of the vacuum insulation element may be in the form of a plate made of a thermally insulating material, which may, for example, be open-pore. Advantageously, the encapsulating membrane is impermeable to gases, in particular oxygen, and to water.

[0029] The sealing means may, for example, be in the form of a cord.

[0030] The sealing means may, for example, be glue. Alternatively, the means The sealing agent can, for example, be an adhesive. In these cases, the sealing agent also contributes to bonding the cover to the base. Alternatively, the sealing agent may not participate in securing the cover and only perform its sealing function. In this case, the sealing agent can be a rubber, an elastomer, etc.

[0031] The invention also relates to a body panel for a refrigerated vehicle, in particular for a road goods transport vehicle, comprising a plurality of body modules as defined above and aligned longitudinally relative to each other.

[0032] The invention further relates to a refrigerated vehicle body, in particular for a road goods transport vehicle, comprising an interior loading space delimited by walls forming vertical sides, a floor and a ceiling, in which at least one of said walls comprises a body panel as defined above.

[0033] The invention also relates to a method for manufacturing a body module as defined above, comprising:

[0034] - a step of mounting said vacuum insulation element inside said base housing,

[0035] - a step of depositing the sealing means onto a surface of the base which is pe peripheral housing of the base, and

[0036] - a step of pressing the lid against said vacuum insulation element and against said sealing means deposited on the surface of the peripheral base of said housing.

[0037] In an advantageous embodiment, the lid pressing step is carried out under vacuum.

[0038] In a particular embodiment, the method further comprises a step of applying an adhesive to the base and / or to a first principal face of said vacuum insulation element, and to said closing cover and / or to a second opposite principal face of said vacuum insulation element. The sealing means is separate from the adhesive means.

[0039] The present invention will be better understood upon reading the detailed description of embodiments taken by way of non-limiting examples and illustrated by the accompanying drawings, in which:

[0040] [fig.l] is a side view of a refrigerated body according to an embodiment of the invention,

[0041] [fig.2] is a cross-sectional view along axis II-II of figure 1,

[0042] [fig.3] is a longitudinal cross-sectional view of a module of the refrigerated body Figures 1 and 2, according to a first example of an embodiment of the invention,

[0043] [fig.4] is an exploded perspective view of the module in figure 3,

[0044] [fig.5] is a longitudinal cross-sectional view of a body module according to a second example of an implementation of the invention,

[0045] [fig.6] and

[0046] [fig.7] are exploded perspective views of body modules according to third and fourth examples of the realization of the invention.

[0047] Figure 1 shows a refrigerated body, referenced 10 in its entirety, mounted on a chassis 12 carrying a road transport vehicle extending longitudinally and equipped with wheels 14.

[0048] The body 10 comprises two opposing vertical sides 16 extending longitudinally (only one being visible in the figure), a floor 18, a ceiling 20, a front face 22 and a rear door 24 assembled together to delimit an interior loading space 26 which is partially visible in figure 2.

[0049] As illustrated in Figure 2, the side 16 comprises a plurality of identical body modules 30, aligned longitudinally and assembled relative to one another as will be described in more detail later. The body modules 30 are in the form of panels with a generally parallelepiped shape and a rectangular cross-section.

[0050] As illustrated in figures 3 and 4, each body module 30 comprises a vacuum insulation panel 32, a base 34 for mounting this panel, and a closing cover 36.

[0051] As will be described in more detail later, each body module 30 also includes a sealing means 38 for protecting the vacuum insulation panel 32. The sealing means 38 is separate from the base 34 and the cover 36.

[0052] The vacuum insulation panel 32 is entirely disposed between the base 34 and the cover 36. In other words, the vacuum insulation panel 32 is inaccessible from outside the module 30.

[0053] The base 34, the vacuum insulation panel 32 and the cover 36 are stacked in a vertical direction illustrated by the axis X-X'.

[0054] The vacuum insulation panel 32 comprises a core 39 and an encapsulation membrane 40 surrounding the core and impermeable to gases, particularly oxygen and water. In the illustrated embodiment, the vacuum insulation panel 32 is in the form of a flexible parallelepiped plate with a rectangular cross-section. The vacuum insulation panel 32 comprises two opposing principal faces 32a, 32b defining its thickness.

[0055] The core 39 is made of a thermally insulating material and advantageously comprises an open-pore structure. The core 39 may, for example, be made of polystyrene foam, polyurethane, aerogel, silica, etc. The core 39 is encapsulated in the membrane 40 at zero or low pressure.

[0056] The encapsulating membrane 40 covering the core 39 can, for example, be made of polyester, polyethylene, aluminum, or any other suitable material that forms a gas-tight barrier. The insulation panel 32 is evacuated by removing the air trapped in the core 39 in order to reduce the thermal conductivity of the panel. For further details on the materials that can be used and on the manufacturing processes for vacuum insulation panels, reference may be made, for example, to US patents B2-6,863,949 and EP-B1-1,265,746.

[0057] To increase the performance and longevity of the vacuum insulation panel 32, a desiccant (not shown) can be added inside the core 39 to absorb water vapor and residual atmospheric gases and / or those infiltrating inside the membrane 40.

[0058] The base 34 here has a general parallelepiped shape with a rectangular cross-section. The base 34 is advantageously made of expanded polyurethane. The base 34 can be obtained by machining or by molding.

[0059] The base 34 includes internally a recess 42 for mounting the vacuum insulation panel 32. The recess 42 is open on the side of the cover 36. The recess 42 is form-fitting with the vacuum insulation panel 32. In the illustrated embodiment, the recess 42 is centered on the base 34.

[0060] The main face 32b of the vacuum insulation panel rests against the bottom of the housing 42 of the base. The vacuum insulation panel is fixed inside the housing 42. The vacuum insulation panel 32 is, for example, fixed by gluing to the bottom of the housing 42. The vacuum insulation panel 32 is thus indirectly supported against the bottom of the housing 42 with glue interposed between them. Alternatively, the vacuum insulation panel 32 can be fixed by any other suitable means, for example by adhesive.

[0061] In the mounted position of the vacuum insulation panel 32 inside the base 34, only the main face 32a of the panel is left free by the base. The base 34 covers the main face 32b of the vacuum insulation panel and the various transverse sections linking this face to the opposite face 32a.

[0062] Furthermore, in the illustrated embodiment, the vacuum insulation panel 32 is centered on the median longitudinal plane 43 of the module 30. By median longitudinal plane of the module 30, we mean the longitudinal plane which is in the middle of the total thickness of the module.

[0063] The base 34 also includes internally a shoulder 44 peripheral to the housing 42. The shoulder 44 is located on the periphery of the housing 42. The shoulder 44 is offset from the bottom of the housing 42 on the side of the cover 36. In other words, the shoulder 44 is offset upwards relative to the bottom of the housing 42 with respect to the axis X-X'. The shoulder 44 extends horizontally outwards from a lateral peripheral edge of the housing 42. The shoulder 44 is oriented vertically upwards with respect to the axis X-X'. The shoulder 44 is offset downwards relative to the upper face of the base 34 with respect to the axis X-X'.

[0064] As previously stated, the main face 32b of the vacuum insulation panel rests against the bottom of the housing 42 of the base. The opposite main face 32a of the panel is vertically flush with the shoulder 44.

[0065] The shoulder 44 forms a stop surface for mounting the cover 36. In the illustrated embodiment, the cover 36 is in the form of a rectangular plate. The cover 36 is advantageously made of expanded polyurethane. The cover 36 can be obtained by machining or by molding.

[0066] In the mounted position of the cover 36 on the base 34, the cover covers the main face 32a of the vacuum insulation panel, which is left free by the base. The cover 36 covers the vacuum insulation panel 32 so that it is entirely enclosed between the cover and the base 34, and inaccessible from the outside. The cover 36 presses against the vacuum insulation panel 32. The upper face of the cover 36 is vertically flush with the upper face of the base 34.

[0067] The sealing means 38 extends over the entire shoulder 44 of the base. The sealing means 38 extends continuously over the shoulder 44. The sealing means 38 extends over the entire periphery of the vacuum insulation panel 32 and the housing 42.

[0068] The sealing means 38 is interposed between the base 34 and the cover 36. The cover 36 is indirectly supported against the shoulder 44 of the base with the sealing means 38 interposed. The sealing means 38 is disposed in the bearing area of ​​the cover 36 on the base 34.

[0069] In the illustrated embodiment, the sealing means 38 is located only on the horizontal part of the shoulder 44, considering the X-X' axis. Alternatively, the sealing means 38 could be located on both the horizontal and vertical parts of the shoulder 44, or even located only on the vertical part of shoulder 44.

[0070] For the reasons which will be indicated later, the sealing means 38 fulfills a sealing function for the vacuum insulation panel 32, but also a thermal bridge breaking function within the body module 30.

[0071] The following method can be used to manufacture module 30.

[0072] In a first step, the vacuum insulation panel 32 is fixed inside the housing 42 of the base which has been manufactured beforehand. To do this, glue is applied to the bottom of the housing 42 and / or to the main face 32b of the vacuum insulation panel, and the panel 32 is positioned against the housing 42.

[0073] Next, in a second step, glue is applied to the main face 32a of the vacuum insulation panel left free by the base 34, and / or to the lower surface of the cover 36 intended to rest against this face 32a.

[0074] Then, in a third step, the sealing means 38 is deposited onto the shoulder 44 of the base so that it extends along the shoulder over the entire periphery of the vacuum insulation panel 32 and the housing 42. The sealing means 38 can be deposited in the form of a bead of material. The sealing means 38 can, for example, be applied by spray gun in the form of a ring. The sealing means 38 can, for example, be an adhesive. This allows the sealing means 38 to contribute to the function of securing the cover 36 to the base 34. Alternatively, the sealing means 38 can, for example, be an adhesive or a rubber, an elastomer, an unexpanded polyurethane, etc.

[0075] Alternatively, the order of the second and third steps can be reversed.

[0076] Next, in a fourth step, the previously manufactured lid 36 is pressed, against the main face 32a of the vacuum insulation panel and against the sealing means 38 placed on the shoulder 44 of the base. During this step, the sealing means 38 is crushed between the cover 36 and the shoulder 44 of the base.

[0077] The pressing step of the lid 36 can advantageously be carried out under vacuum. This allows the evacuation of any air that may be present between the vacuum insulation panel 32, the base 34, and the lid 36. This also allows the lid 36 to perfectly conform to the shape of the main face 32a of the vacuum insulation panel, which may be irregular due to folds in the encapsulation membrane 40. Furthermore, this vacuum pressing technique allows for a homogeneous application of pressure on the lid 36, regardless of any irregularities in thickness. Vacuum pressing can, for example, be carried out using a flexible and deformable counter-mold.

[0078] Finally, in a fifth step, the unit module 30 formed by the base 34, the vacuum insulation panel 32, the cover 36, and the sealing means 38 can, if necessary, be thickened. This thickening can, for example, be carried out by machining if it is necessary to adjust the upper face of the cover 36 to that of the base 34.

[0079] To manufacture a body panel forming the side 16 by assembling body modules 30, the following procedure can be used.

[0080] A horizontal support is used, the dimensions of which are at least equal to the dimensions of the side panel 16 to be manufactured. First, the support is coated with synthetic wax to facilitate subsequent demolding of the side panel. Next, a polymerizable finishing layer 50 (Figure 2) is applied over the wax, followed by a polymerizable coating layer 52 comprising glass fibers on the finishing layer 50. The body modules 30 are then applied against this coating layer 52 so as to be aligned and positioned in close proximity to one another, leaving a slight gap between two immediately successive modules.

[0081] New polymerizable coating layers 52 are then deposited so as to completely coat each of the body modules 30. A polymerizable topcoat 53 is then deposited on the coating layers 52 on the side opposite the topcoat 50. The assembly thus obtained is then placed under pressure until the layers have hardened.

[0082] After demolding, the side 16 of the refrigerated body is obtained. After assembly of the body, the cover 36 of each body module is located on the inner side, i.e. on the side of the inner loading space 26.

[0083] During the manufacture of the body panel, the sealing means 38 of each body module forms upstream of the vacuum insulation panel 32 a preliminary seal, which prevents any migration of catalyzed resin from the finishing layers 50, 53 and coating 52 between the base 34 and the cover 36 towards the housing 42 and the panel 32.

[0084] Thus, the sealing means 38 also ensures a thermal bridge breaking function inside the body module 30 by preventing filaments or cords of catalyzed resin from passing through the thickness of the module.

[0085] In the embodiment described above, a single vacuum insulation panel 32 is used to manufacture a body module 30. Alternatively, it is also possible to provide a plurality of vacuum insulation panels 32 within the same module 30.

[0086] For example, as illustrated in Figure 5, in which the identical elements bear the same references, the module 30 comprises two vacuum insulation panels 32, each housed inside a separate housing 42 provided on the base 34 and covered by a cover 36.

[0087] In the preceding embodiments, each shoulder 44 of the base extends over the entire periphery of the associated housing 42 and the insulation panel 32 vacuum-sealed and mounted in this housing.

[0088] The embodiment shown in Figure 6, in which the identical elements bear the same reference numerals, differs from the first embodiment in that the housing 42 of the base is also open at its opposite longitudinal edges. The base 34 here covers the main face 32b and the opposite transverse edges of the short sides of the vacuum insulation panel.

[0089] Unlike the first illustrated embodiment, the base 34 here does not have a single peripheral shoulder around the housing 42, but two opposing lateral shoulders 54. The shoulders 54 are offset upwards relative to the bottom of the housing 42, considering the X-X' axis. The shoulders 54 are offset downwards relative to the upper face of the base 34. The two shoulders 54 are located in the same horizontal plane.

[0090] The sealing means 38 extends continuously over the base 34. The sealing means 38 extends over the shoulders 54 and over the bottom of the housing 42. The sealing means 38 extends over the entire periphery of the vacuum insulation panel 32. The sealing means 38 is disposed on the surface of the base which forms a stop for the cover 36. This stop surface is formed by the shoulders 54 and the portions of the bottom of the housing 42 left free by the vacuum insulation panel 32.

[0091] Indeed, in this embodiment example, the lateral dimension of the housing 42 of the base is greater than that of the vacuum insulation panel 32 so as to leave two opposing lateral strips on the bottom of said housing allowing the removal of the sealing means 38.

[0092] In the mounted position of the cover 36 on the base 34, the cover covers the vacuum insulation panel 32 so that it is inaccessible from the outside, similarly to the first embodiment. Here, the cover 36 covers the main face 32a and the longitudinal transverse edges of the vacuum insulation panel, which are left free by the base 34.

[0093] In the embodiment shown in Figure 7, where identical elements bear the same reference numerals, the housing 42 of the base is open vertically upwards along the X-X' axis and at its opposite edges of short sides. The base 34 here covers the main face 32b and the opposite longitudinal transverse edges of the vacuum insulation panel.

[0094] The housing 42 of the base is here the same size as the vacuum insulation panel 32. The cover 36 rests vertically against the upper face and laterally against the edges of the short sides of the base 34.

[0095] The sealing means 38 is disposed on the stop surface for the cover 36 which is provided on the base. The sealing means 38 thus extends here over the upper face and the edges of the short sides of the base 34. The sealing means 38 extends continuously on the base 34. The sealing means 38 extends over the entire periphery of the vacuum insulation panel 32 and the housing 42.

[0096] In the mounted position of the cover 36 on the base 34, the cover covers the vacuum insulation panel 32 so that it is inaccessible from the outside. The cover 36 here covers the main face 32a and the transverse edges of the short sides of the vacuum insulation panel, which are left free by the base 34.

[0097] In the examples described above, the body modules are used to manufacture a vertical side panel of the body. The floor and / or the ceiling, and / or the front panel, and / or the rear door forming the walls of the refrigerated body can also be manufactured from such elementary body modules.

[0098] The invention has been illustrated by way of example on the basis of a semi-trailer type road transport vehicle body. The invention is also applicable to a rigid truck or trailer type road transport vehicle body.

Claims

Demands

1. Body module for refrigerated vehicle, in particular for road goods transport vehicle, comprising at least one vacuum insulation element (32) having a core (39) and a gas-tight encapsulation membrane (40) for said core, characterized in that it further comprises: - a base (34) delimiting at least one housing (42) within which said vacuum insulation element (32) is disposed, - at least one closing cover (36) fixed to the base (34) and mounted against said vacuum insulation element (32), said vacuum insulation element (32) being entirely housed between the base and said closing cover, and - at least one sealing means (38) which is interposed between the base (34) and said closing cover (36) and which is peripheral to said vacuum insulation element (32).

2. Module according to claim 1, wherein the sealing means (38) covers at least in part the abutment surface which is provided on the base (34) and against which said closing cover (36) is mounted in support.

3. Module according to claim 1 or 2, wherein the base (34) comprises at least one shoulder (44, 54) offset laterally outwards from said housing (42) and offset towards said closing cover (36) from the bottom of said housing, the peripheral sealing means (38) extending at least along said shoulder (44, 54).

4. Module according to any one of the preceding claims, wherein said vacuum insulation element (32) is centered on the median longitudinal plane (43) of said module.

5. Module according to any one of the preceding claims, wherein said closing cover (36) has a different colour and / or texture from that of the base (34).

6. Module according to any one of the preceding claims, wherein the base (34) and said closing cover (36) are each made of a thermally insulating material.

7. Module according to any one of the preceding claims, wherein the base (34) is made of expanded polyurethane.

8. Module according to any one of the preceding claims, in said closing cover (36) is made of expanded polyurethane.

9. Module according to any one of the preceding claims, wherein the base (34) delimits a plurality of housings (42) within each of which is disposed a vacuum insulation element (32), the module comprising a plurality of closing covers (36) each associated with a vacuum insulation element (32).

10. Body panel for refrigerated vehicle, in particular for road freight vehicle, comprising a plurality of body modules (30) according to any one of the preceding claims aligned longitudinally with respect to each other.

11. Refrigerated vehicle body, in particular for road goods transport vehicles, comprising an interior loading space delimited by walls forming vertical sides, a floor and a ceiling, in which at least one of said walls comprises a body panel according to claim 10.

12. A method for manufacturing a body module according to any one of claims 1 to 9, comprising: - a step of mounting said vacuum insulation element inside said housing of the base, - a step of depositing the sealing means on a surface of the base which is peripheral to said housing of the base, and - a step of pressing the cover against said vacuum insulation element and against said sealing means deposited on the surface of the base peripheral to said housing.

13. A method according to claim 12, wherein the lid pressing step is carried out under vacuum.

Images