Improved devices and manufacturing methods for thermal insulation

Abstract

To provide a reflective thermal insulation material that enables improved thermal insulation properties. [Solution] A multilayer thermal insulation product strip comprises a primary sheet 10 extending in the longitudinal and transverse directions, and an upper metallized film 20 having an adhesive layer 24 and a metallized layer 22, wherein the melting point of the material forming the adhesive layer 24 is less than or equal to the melting point of the material forming the primary sheet 10, and the upper metallized film 20 is rolled on the primary sheet 10.

Description

Technical Field

[0001] The present invention relates to a reflective heat insulating material.

Background Art

[0002] Reflective heat insulation systems are used in narrow spaces. Different from conventional bulky heat insulating materials, such reflective heat insulation systems have a small installation area, which is advantageous in terms of layout, for example, typically in a space under a roof.

[0003] However, the problems associated with such heat insulating materials mean that improving the heat insulation performance requires not simply increasing the thickness of the heat insulating material as can be achieved using conventional heat insulating materials such as rock wool, but rather improving the product.

[0004] Therefore, the proposed invention aims to improve the heat insulation characteristics of such reflective heat insulating materials.

Summary of the Invention

Means for Solving the Problems

[0005] For this purpose, the present invention provides - a primary sheet extending in the vertical and horizontal directions, - an upper metallized film having an adhesive layer, a support layer, and a metallized layer, the support layer being interposed between the adhesive layer and the metallized layer and comprising The primary sheet includes a low-density polyethylene layer, The support layer is made of high-density polyethylene, The adhesive layer includes low-density polyethylene, The upper metallized film provides a strip of a multilayer heat insulating product that is rolled onto the primary sheet such that the adhesive layer is fixed to the low-density polyethylene layer of the primary sheet.

[0006] According to an example, the heat insulating product strip further includes a lower metallized film having an adhesive layer, a support layer, and a metallized layer, the support layer being interposed between the adhesive layer and the metallized layer. The support layer is made of high-density polyethylene. The adhesive layer contains low-density polyethylene. The lower metallized film is rolled onto the primary sheet such that the adhesive layer is fixed to the low-density polyethylene layer of the primary sheet, and the primary sheet is positioned between the upper metallized film and the lower metallized film.

[0007] The present invention also relates to an assembly comprising a plurality of strips of an insulating product as defined above, wherein the strips are - Upper strip and, - Lower strip and, - Multiple intermediate strips are positioned between the upper and lower strips to form a perforated structure. To define, further relating to the assembly.

[0008] The present invention also relates to a method for manufacturing an insulating sheet, - Provides a primary sheet that extends in the longitudinal and transverse directions and comprises a low-density polyethylene layer, - A top metallized film is provided comprising an adhesive layer, a support layer, and a metallized layer, wherein the support layer is interposed between the adhesive layer and the metallized layer, the support layer is made of high-density polyethylene, and the adhesive layer contains low-density polyethylene. - The present invention relates to a method of applying an upper metallized film to the upper surface of a primary sheet using a heated cylinder in order to partially melt the adhesive layer and to roll the upper metallized film onto the primary sheet so that the adhesive layer is fixed to the low-density polyethylene layer of the primary sheet.

[0009] According to one example, - A lower metallized film is provided comprising an adhesive layer, a support layer, and a metallized layer, wherein the support layer is interposed between the adhesive layer and the metallized layer, the support layer is made of high-density polyethylene, and the adhesive layer contains low-density polyethylene. - In order to partially melt the adhesive layer material of the lower metallized film, and to roll the lower metallized film onto the primary sheet so that the adhesive layer is fixed to the low-density polyethylene of the primary sheet, and so that the primary sheet is positioned between the upper metallized film and the lower metallized film, the lower metallized film is applied to the underside of the primary sheet using a heating cylinder.

[0010] For example, before the process of providing the primary sheet, a process of perforating the primary sheet is performed. - Provides a primary sheet that extends in the vertical and horizontal directions, - Make cuts in the primary sheet so that they extend in the vertical direction. - Extend the cut and stretch the primary sheet laterally to form an opening in the primary sheet, - The stretched primary sheet is then fixed in place by heating or heat setting.

[0011] The present invention also relates to a method for forming thermal insulation product strips, - Provides a primary sheet that extends in the vertical and horizontal directions, - Make cuts in the primary sheet so that they extend in the vertical direction. - Extend the cut and stretch the primary sheet laterally to form an opening in the primary sheet, - The stretched primary sheet is fixed by heating or heat setting, - Provides an upper metallized film and a lower metallized film. - The present invention relates to a method for fixing an upper metallized film and a lower metallized film to a primary sheet such that the primary sheet is positioned between the upper metallized film and the lower metallized film.

[0012] For example, the upper and lower metallized films are fixed to the primary sheet by bonding or rolling.

[0013] For example, the primary sheet is perforated so that the opening ratio is 10% to 80%, or 40% to 60%.

Brief Description of the Drawings

[0014] The present invention and its advantages will be better understood by reading the following detailed description of various embodiments of the present invention, which are presented as non-limiting examples.

[0015] [Figure 1] FIG. 1 schematically shows an example of a product according to one aspect of the present invention. [Figure 2] FIG. 2 schematically shows another example of a product according to one aspect of the present invention. [Figure 3] FIG. 3 schematically shows another example of a product according to one aspect of the present invention. [Figure 4] FIG. 4 schematically shows an example of a heat insulation system formed using the product according to the present invention. [Figure 5] FIG. 5 schematically shows another example of a heat insulation system formed using the product according to the present invention. [Figure 6] FIG. 6 schematically shows another example of a heat insulation system formed using the product according to the present invention. [Figure 7] FIG. 7 schematically shows an example of an apparatus for manufacturing the product according to the present invention. [Figure 8] FIG. 8 schematically shows an example of the steps of a method for forming a concave region in a primary strip. [Figure 9] FIG. 9 schematically shows an example of a primary strip having a recess. <​​​​​​​​​​​​​​​​​The illustrated product is a strip or plate-shaped thermal insulation product comprising a primary sheet 10 extending in the vertical and horizontal directions and an upper metallized film 20.

[0019] In the illustrated example, the primary sheet 10 has one layer, on which the upper metallized film 20 is placed.

[0020] In this context, the terms "upper" and "lower" are merely referential, not restrictive, and are simply intended to facilitate understanding.

[0021] The upper metallized film 20 comprises an adhesive layer 24, a support layer 23, and a metallized layer 22. The support layer 23 is interposed between the adhesive layer 24 and the metallized layer 22.

[0022] The primary sheet 10 is usually made of foam, typically low-density polyethylene (LDPE). In the case of multilayer sheets, other materials may be further included, especially high-density polyethylene (HDPE).

[0023] The upper metallized film 20 is typically a metallized film based on polyethylene or polypropylene, and its emissivity, measured on the metallized surface according to the EN16012 standard, is typically 0.02 to 0.2, more specifically 0.05 to 0.07. The metallized layer is made of aluminum, for example. The thickness of the metallized layer is typically about 100 angstroms. Therefore, the adhesive layer 24 is typically made of low-density polyethylene (LDPE). The support layer 23 is typically made of high-density polyethylene (HDPE).

[0024] The upper metallized film 20 is fixed to the upper surface of the primary sheet 10 via the adhesive layer 24, such that the adhesive layer 24 made of LDPE is fixed to the LDPE layer of the primary sheet 10.

[0025] Figure 2 schematically shows another example of product 1 according to one aspect of the present invention.

[0026] This embodiment includes, in addition to the elements already shown with reference to Figure 1, the elements detailed below.

[0027] In this exemplary embodiment, the product further comprises a lower metallized film 30, which is fixed by rolling to the lower surface of the primary sheet 10, i.e., the lower surface of the lower layer 300.

[0028] The lower metallized film 30 comprises an adhesive layer 34, a support layer 33, and a metallized layer 32. The support layer 33 is interposed between the adhesive layer 34 and the metallized layer 32.

[0029] The lower metallized film 30 is typically a metallized film based on polyethylene or polypropylene, and its emissivity, measured on the metallized surface according to the EN16012 standard, is typically 0.02 to 0.2, more specifically 0.05 to 0.07. The metallization is made, for example, with aluminum. Therefore, the adhesive layer 34 is typically made of low-density polyethylene (LDPE). The support layer 33 is typically made of high-density polyethylene (HDPE).

[0030] The lower metallized film 30 is fixed to the lower surface of the primary sheet 10 via the adhesive layer 34, such that the adhesive layer 34 made of LDPE is fixed to the LDPE layer of the primary sheet 10.

[0031] Figure 3 schematically shows another example of product 1 according to one aspect of the present invention.

[0032] This embodiment includes, in addition to the elements already shown with reference to Figures 1 and 2, the elements detailed below.

[0033] In this embodiment, the primary sheet 10 is formed from three laminated layers, sequentially designated as 102, 101, and 103, in the direction from the upper metallized film 20 toward the lower metallized film 30. Layers 101, 102, and 103 are typically made of low-density polyethylene (LDPE), or typically made primarily of low-density polyethylene (LDPE).

[0034] More generally, the primary sheet 10 may be formed from a laminate consisting of any number of layers. The layers forming the primary sheet 10 may or may not be arranged symmetrically.

[0035] The proposed products are thin, typically with a thickness of 2 to 10 mm.

[0036] Figure 4 schematically shows an example of an insulation system formed using the product according to the present invention.

[0037] In this example, four products, indicated by reference numerals 1A, 1B, 1C, and 1D, are stacked. These products may be identical or different. For example, they may be four identical products, each having the structure described above for any of Figures 1 to 3.

[0038] The resulting assembly defines an insulating board or panel, and its rigidity depends particularly on the number of laminated products and the structure of each product.

[0039] By laminating such products, a set with improved thermal insulation properties can be obtained.

[0040] Figure 5 schematically shows another example of an insulation system formed using the product according to the present invention.

[0041] In this embodiment, two products 1F and 1G form two horizontal panels, while product 1H is positioned between these two products 1F and 1G to form a perforated structure. In the illustrated example, product 1H is positioned to form a wavy, crossing, or sawtooth structure, thereby defining a recess between products 1F and 1G.

[0042] This structure makes it possible to create panel-type products that have air pockets that contribute to heat insulation.

[0043] The illustrated embodiments are not limiting, and in particular, it is possible to stack multiple assemblies formed in this manner, or to stack different layers of the product to form a perforated structure. In particular, it is possible to alternately arrange multiple layers of product 1H between products 1F and 1G.

[0044] Figure 6 schematically shows another example of an insulation system formed using the product according to the present invention.

[0045] This figure shows an insulation system with an outer film 4, typically a metallized film, to which multiple assemblies are bonded, each assembly consisting of the product 1 and film 5, typically a metallized film. Such assemblies are typically called "simplexes." The first assembly is fixed to the outer film 4 such that the product is between the outer film 4 and film 5 of the assembly.

[0046] The second assembly can be assembled to the first assembly such that the product 1 of the second assembly is between the two films 5. Several assemblies can be laminated in this way to obtain a system with a desired thickness and desired thermal insulation properties.

[0047] In the illustrated example, product 1 forms a wavy, intersecting, or sawtooth structure. In a system composed of multiple laminated assemblies, the different assemblies are typically arranged alternately so that the undulations or patterns formed by product 1 are offset by half a pitch during assembly.

[0048] Figure 7 schematically shows an example of equipment for manufacturing the aforementioned product.

[0049] This diagram schematically shows a device for rolling metallized films 20 and 30 onto both sides of a primary sheet 10. It should be understood that the device can be modified according to the desired product structure, and in particular, it can be modified to apply only one of the metallized films 20 or 30.

[0050] Therefore, the presented device comprises two sets of rollers, namely a first pair of rollers R11 and R12, and a second pair of rollers R21 and R22. The direction of movement of the product is indicated by an arrow.

[0051] The primary sheet 10 is transported between each pair of rollers.

[0052] The upper metallized film 20 is supplied to the first roller pair R11 and R12. In the illustrated example, the upper metallized film 20 is driven by roller R11 of the first roller pair.

[0053] The roller R11 of the first roller pair is typically a heating roller suitable for applying thermal energy to the contact element.

[0054] Rollers R11 and R12 are positioned to define a gap through which the primary sheet 10 and the first metallized film 20 can pass.

[0055] The gap between roller R11 and roller R12, and the heating effect generated by roller R11, are sized to at least partially melt the adhesive layer 22 of the upper metallized film 20, thereby fixing the upper metallized film 20 to the primary sheet 10.

[0056] The heating temperature of roller R11 is defined based in particular on the rotation speed of roller R11, the materials forming the upper metallized film 20 and the primary sheet 10, and the dimensions of roller R11.

[0057] The heating temperature of the roller R11 is typically set so as not to melt the support layer 23 of the upper metallized film 20.

[0058] The passage between roller R11 and roller R12 allows the upper metallized film 20 to be assembled onto the primary sheet 10 by the rolling process.

[0059] Similarly, the lower metallized film 30 is supplied to the second roller pair R21, R22. In the illustrated example, the lower metallized film 30 is driven by roller R21 of the second roller pair.

[0060] The roller R21 of the first roller pair is typically a heating roller suitable for applying thermal energy to the contact element.

[0061] Rollers R21 and R22 are positioned to define a gap for the primary sheet 10 and the second metallized film 30 to pass through.

[0062] The gap between roller R21 and roller R22, and the heating effect generated by roller R21, are sized to at least partially melt the adhesive layer 32 of the lower metallized film 30, thereby fixing the lower metallized film 30 to the primary sheet 10.

[0063] The heating temperature of roller R21 is defined based on the rotational speed of roller R21, the materials forming the lower metallized film 30 and the primary sheet 10, and the dimensions of roller R21. The heating temperature of roller R11 is typically defined so as not to melt the support layer 33 of the lower metallized film 30.

[0064] The passage between roller R21 and roller R22 allows the lower metallized film 30 to be assembled onto the primary sheet 10 by the rolling process.

[0065] According to another aspect of the present invention, the primary sheet 10 may be perforated.

[0066] The primary sheet 10 is typically made of a foamed sheet, typically polyethylene. This foamed sheet is typically solid (or unperforated) during molding and is then typically perforated by an appropriate method, particularly the method described later.

[0067] Figure 8 shows an example of a primary sheet 10. In this example, the primary sheet 10 is provided with notches 54 in a typically alternating pattern. The illustrated notches 54 are provided in the vertical or longitudinal direction XX of the primary sheet 10.

[0068] Subsequently, the primary sheet 10 can be extended in the horizontal direction YY perpendicular to the vertical direction XX, i.e., in the horizontal direction shown in Figures 8 and 9.

[0069] The effect of this stretching is shown in Figure 9. Here, stretching of the primary sheet 10 in the lateral direction YY and contraction of the primary sheet 10 in the lateral direction XX are observed. The pre-formed cuts 54 in the primary sheet open up, forming an opening 52 having a square or rhombic shape as shown here.

[0070] The stretched primary sheet 10 is typically heated to fix its shape.

[0071] The resulting primary sheet 10 is a perforated sheet, and its opening ratio depends in particular on the cuts provided and the stretching performed.

[0072] Obtaining a perforated foam-shaped primary sheet 10 is advantageous from the viewpoint of thermal insulation. In fact, when the primary sheet 10 is wrapped on both sides, for example, with metallized films, typically the upper metallized film 20 and lower metallized film 30 described above, the perforated areas form air layers or bubbles, which exhibit superior thermal insulation properties compared to foam. Bonding with the metallized film can be carried out in particular by adhesive or by the rolling process described above.

[0073] Figure 10 schematically shows an example of a product obtained in this manner. The upper metallized film 20 and the lower metallized film 30 are fixed to the primary sheet 10 in the non-perforated area.

[0074] For example, the primary layer 10 has an aperture ratio of 10% to 80%, or 40% to 60%.

[0075] The aperture ratio is defined as the surface area of ​​the recess relative to the total surface area of ​​the primary sheet 10, viewed along a plane defined by the longitudinal direction XX and the transverse direction YY of the primary sheet 10.

[0076] Although the present invention has been described with reference to certain exemplary embodiments, it is evident that modifications and changes can be made to these examples without departing from the general scope of the invention as defined in the claims. In particular, individual features of the various embodiments shown / referenced may be combined in additional embodiments. Therefore, this specification and the drawings should be considered illustrative rather than restrictive.

[0077] Furthermore, it is clear that all features described in relation to the method can be transferred to the device, either individually or in combination, and conversely, all features described in relation to the device can be transferred to the method, either individually or in combination.

Claims

1. Multilayer insulation product strip, - A primary sheet (10) extending in the vertical and horizontal directions, - An upper metallized film (20) comprising an adhesive layer (24), a support layer (23), and a metallized layer (22), wherein the support layer (23) is interposed between the adhesive layer (24) and the metallized layer (22) Equipped with, The primary sheet (10) comprises a low-density polyethylene layer, and the support layer (23) is made of high-density polyethylene. The adhesive layer (24) contains low-density polyethylene. The upper metallized film (20) is a multilayer thermal insulation product strip rolled on the primary sheet (10) such that the adhesive layer (24) is fixed to the low-density polyethylene layer of the primary sheet (10).

2. The present invention further comprises an adhesive layer (34), a support layer (33), and a metallized layer (32), wherein the support layer (33) is interposed between the adhesive layer (34) and the metallized layer (32) and the lower metallized film (30), The support layer (23) is made of high-density polyethylene, and the adhesive layer (24) contains low-density polyethylene. The thermal insulation product strip according to claim 1, wherein the lower metallized film (30) is rolled on the primary sheet (10) such that the adhesive layer (34) is fixed to the low-density polyethylene layer of the primary sheet (10) and the primary sheet (10) is positioned between the upper metallized film (20) and the lower metallized film (30).

3. An assembly comprising a plurality of strips of the thermal insulation product according to claim 1 or 2, wherein the plurality of strips are - Upper strip and, - Lower strip and, - An assembly comprising a plurality of intermediate strips positioned between the upper strip and the lower strip, which form a perforated structure.

4. A method for manufacturing an insulating sheet, - Provides a primary sheet (10) that extends in the vertical and horizontal directions and has a low-density polyethylene layer, - Provides an upper metallized film (20) comprising an adhesive layer (24), a support layer (23), and a metallized layer (22), wherein the support layer (23) is interposed between the adhesive layer (24) and the metallized layer (22), the support layer (23) is made of high-density polyethylene, and the adhesive layer (24) contains low-density polyethylene. A method of applying the upper metallized film (20) to the upper surface of the primary sheet (10) by a heating cylinder (R11) in order to partially melt the adhesive layer (24) and to roll the upper metallized film (20) onto the primary sheet (10) so that the adhesive layer (24) is fixed to the low-density polyethylene layer of the primary sheet (10).

5. - A lower metallized film (30) is provided, comprising an adhesive layer (34), a support layer (33), and a metallized layer (32), wherein the support layer (33) is interposed between the adhesive layer (34) and the metallized layer (32), the support layer (23) is made of high-density polyethylene, and the adhesive layer (24) contains low-density polyethylene. The method according to claim 4, wherein the lower metallized film (30) is applied to the lower surface of the primary sheet (10) by a heating cylinder (R21) in order to partially melt the material of the adhesive layer (34) of the lower metallized film (30), and to roll the lower metallized film (30) onto the primary sheet (10) so that the adhesive layer (34) is fixed to the low-density polyethylene of the primary sheet (10) and the primary sheet (10) is positioned between the upper metallized film (20) and the lower metallized film (30).

6. Prior to the step of providing the primary sheet (10), a step of perforating the primary sheet (10) is performed. - Provides a primary sheet (10) that extends in the vertical and horizontal directions, - A cut (54) is made in the primary sheet (10) so as to extend in the vertical direction, - The primary sheet (10) is stretched laterally so as to extend the cut and form an opening (52) in the primary sheet. - The method according to claim 4 or 5, wherein the stretched primary sheet (10) is fixed by heating or heat setting.

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