Insulation panel

Abstract

An insulation panel (18) comprises a core (30) made of thermally insulating polymer foam, and two facings. The core is located between the two facings (32). The facings are multilayered. The facings comprise at least a polymeric gas barrier film (40). The facings preferably comprise at least one or more paper layers or one or more nonwoven layers (44).

Description

[0001] Insulation panel

[0002] The invention relates to insulation panels comprising a core made of thermally insulating polymer foam and two facings, the core being located between the two facings, the facings being multilayered.

[0003] Such insulation panels are described in WO2023 / 079467A1. WO2023 / 079467A1 states that the multilayered facing of the insulation panel can comprise a polymer film, one or more aluminum layers and one or more paper layers, preferably Kraft paper layers. The aluminum layers ensure gas-tightness of the insulation panel.

[0004] EP4385702A1 describes a method for producing such thermally insulating polyisocyanurate insulation panels.

[0005] The facing in such insulation panels must meet various requirements. The facing must be gas-tight to prevent escaping of thermally insulating gases from the closed foam cells of the insulation panel, must be sufficiently dimensionally stable and may absorb only little or even no moisture. In addition, the facing must ensure sufficient fire resistance of the insulation panel.

[0006] It is a disadvantage that state-of-the-art insulation panels comprise one or more aluminum layers. The use of these aluminum layers is troublesome from a sustainability perspective. The production of aluminum not only requires a lot of energy; the aluminum layer(s) also complicate the recycling of insulation panels made of polymer foam (for example made of polyurethane foam, made of polyisocyanurate foam, or made of phenolic foam).

[0007] It is an object of the invention to solve one or more problems of state-of-the-art insulation panels. The first aspect of the invention relates to an insulation panel. The insulation panel comprises a core made of thermally insulating polymer foam, and two facings. The core is located between the two facings and preferably contacts them. The facings are multilayered. The facings comprise at least a polymeric gas barrier film. The facings preferably comprise at least one or more paper layers (preferably Kraft paper) or one or more nonwoven layers.

[0008] It is an advantage of such insulation panels that sufficient gas tightness is obtained without the need for aluminum foil. This allows the facings, and therefore the insulation panel, to be produced in a more sustainable way than if the facings were to comprise an aluminum foil to make the facing sufficiently gas tight.

[0009] Sufficient gas tightness is important to limit escaping of thermally insulating gas from the cells of the thermally insulating polymer foam (for example thermally insulating polyurethane foam, thermally insulating polyisocyanurate foam, or thermally insulating phenolic foam). Escaping of this gas would reduce the thermal insulation value of the insulation panel over time.

[0010] Embodiments wherein the facings comprise at least one or more paper layers (preferably Kraft paper) and / or one or more nonwoven layers have the advantage that these layers provide for a greater rigidity and dimensional stability of the insulation panel. This compensates for the loss of rigidity and dimensional stability by replacing the traditional aluminum foil with polymeric gas barrier film to obtain the required gas tightness of the facings.

[0011] The polymeric gas barrier film preferably comprises a gas barrier forming film made of ethylene vinyl alcohol, for example laminated between two polyethylene films.

[0012] Such polymeric gas barrier films are known as packaging materials in the food industry and can be incorporated into the facing by means of lamination. This can be achieved by using a suitable adhesive, for example a polyurethane adhesive, possibly after corona pre-treatment of the polymeric gas barrier film to improve adhesion during lamination. The polymeric gas barrier film preferably comprises or consists of a polymer selected from polyamide, polyethylene terephthalate, polyvinyl naphthalate, polyvinylidene chloride, polyethylene furanoate, or polyvinyl chloride.

[0013] The use of a polymeric gas barrier film that comprises or consists of polyethylene furanoate is particularly interesting, as polyethylene furanoate can be produced out of vegetable raw materials. The use of polyethylene furanoate improves the sustainability score of the insulation panel.

[0014] A preferred embodiment is characterized in that the polymeric gas barrier film comprises a polymer film on which an inorganic layer - for example, an aluminum oxide layer or a silicon oxide layer - is applied. The polymer film can be, for example, a polyester film (for example a polyethylene furanoate film or a polyethylene terephthalate film) or a polyolefinic film.

[0015] The use of a polymeric gas barrier film comprising a polymer film on which an inorganic layer is applied, has the advantage that a complex multilayered polymer film is not required.

[0016] Polymeric gas barrier films comprising a polymer film on which an inorganic layer is applied, are known from the packaging industry.

[0017] The inorganic layer improves the fire resistance of the insulation panel.

[0018] The inorganic layer can be applied on the polymer film by means of vacuum deposition techniques.

[0019] Preferably, the inorganic layer has a thickness of less than 50 nanometers.

[0020] A polymeric gas barrier film comprising a polymer film on which an inorganic layer is applied, can be incorporated into the facing by means of lamination techniques. The gas tightness of a gas barrier film or of the facing as a whole can be determined by measuring the Oxygen Transmission Rate (OTR) according to ASTM D 3985 - 17 'Standard Test Method for Oxygen Gas Transmission Rate Through Plastic Film and Sheeting Using a Coulometric Sensor'. The measured value for the OTR is expressed in cm3 / (m2.24h) and is measured in the context of the invention with oxygen and at 50% relative humidity and at a temperature of 23 °C. The samples are first conditioned and then measured until stabilization of the OTR value.

[0021] Preferably the facing has an OTR of less than 4.5 cm3 / (m2.24 hours). More preferably less than 2 cm3 / (m2.24h), more preferably less than 1 cm3 / (m2.24 hours), more preferably less than 0.5 cm3 / (m2.24 hours), more preferably less than 0.25 cm3 / (m2.24 hours).

[0022] Preferably, the polymeric gas barrier film forms the bottom side of the facing, meaning that the polymeric gas barrier film contacts the core. This ensures high efficiency of retention of the gaseous blowing agents in the core.

[0023] More preferably, the side of the polymeric gas barrier film that contacts the core comprises an adhesion layer, for example a polyurethane layer. This improves the adhesion of the facing with the polymer foam of the core.

[0024] Preferably, the side of the polymeric gas barrier film that contacts the core is corona treated. This improves the adhesion of the facing with the polymer foam of the core.

[0025] The second aspect of the invention relates to an insulation panel. The insulation panel comprises a core made of thermally insulating polymer foam, and two facings. The core is located between the two facings and preferably contacts them. The facings are multilayered. The insulation panel is characterized in that the facings comprise a polymer film on their external surface, wherein the polymer film comprises a metal coating, so that infrared (IR) radiation on the surface of the facing is at least partly reflected by the metal coating. The facings preferably comprise at least a paper layer or a nonwoven layer. The insulation panel of the second aspect has the advantage that good reflection of infrared radiation on the surface of the insulation panel is obtained without the need for an aluminum foil on the surface of the insulation panel. Since no aluminum foil is required for infrared reflection, the facing - and therefore also the insulation panel - can be produced in a more sustainable way.

[0026] The polymer film comprising the metal coating is preferably a polyester film, more preferably a polyethylene terephthalate film or a polyethylene furanoate film.

[0027] The metal coating is preferably selected from aluminum, titanium, copper, nickel, silver, gold, chrome; or combinations thereof. These metal coatings have the advantage that they provide good reflection and are easily applied on a polymer film.

[0028] An embodiment of the second aspect of the invention is characterized in that the metal coating is applied on the polymer film by means of sputtering or by means of vacuum deposition.

[0029] The thickness of the metal coating is preferably less than 50 nanometers.

[0030] The metal coatings on the polymer film are thin, making their impact on sustainability very small compared to a polymer film without metal coating.

[0031] The insulation panel of the second aspect of the invention is preferably an insulation panel such as in the first aspect of the invention.

[0032] The third aspect of the invention relates to an insulation panel. The insulation panel comprises a core made of thermally insulating polymer foam, and two facings. The core is located between the two facings and preferably contacts them. The facings are multilayered. The insulation panel is characterized in that the facings comprise a layer with thermosetting resin. These facings with a layer comprising a thermosetting resin ensure a good dimensional stability of the insulation panel, due to their rigidity after curing of the thermosetting resin and due to their limited shrinkage under the influence of temperature changes.

[0033] The layer with thermosetting resin preferably forms neither an inner nor an outer side of the facings.

[0034] Preferably, the thermosetting resin is cured during production of the core between the two facings. Because the thermosetting resin is only fully cured during the production of the rigid foam core, the facings can be unwound from rollers. This simplifies the production process to a great extent.

[0035] A preferred embodiment is characterized in that the facing comprises a carrier, wherein the thermosetting resin is coated onto the carrier, or wherein the carrier is impregnated with the thermosetting resin.

[0036] This carrier is preferably a paper layer or multiple paper layers, a textile nonwoven or multiple textile nonwovens, or a polymer film or multiple polymer films, or combinations thereof.

[0037] The carrier can be a paper layer, for example coated on one or both sides with the thermosetting resin.

[0038] The carrier can be a paper layer - or multiple paper layers - impregnated with the thermosetting resin. For example, a non-filled paper layer made of alpha-cellulose is very suitable for this.

[0039] The carrier can be a textile nonwoven - or multiple textile nonwovens - impregnated with or coated on one or both sides with the thermosetting resin.

[0040] Preferably, the thermosetting resin is an aminoplast, an epoxy, an acrylate, a polyurethane, or a polyester resin, or combinations thereof. Preferably, the thermosetting resin layer comprises at least 40 grams per square meter of thermosetting resin, and more preferably at least 100 grams per square meter of thermosetting resin.

[0041] These embodiments ensure good values for the rigidity and dimensional stability of the insulation panel.

[0042] The insulation panel of the third aspect of the invention is preferably an insulation panel such as in the first aspect of the invention and / or according to the second aspect of the invention.

[0043] The fourth aspect of the invention relates to an insulation panel. The insulation panel comprises a core made of thermally insulating polymer foam, and two facings. The core is located between the two facings and preferably contacts them. The facings are multilayered. The insulation panel is characterized in that the facing comprises a textile nonwoven layer.

[0044] Such insulation panels have the advantage that the textile nonwoven can provide the necessary rigidity and good dimensional stability of the insulation panel. Textile nonwovens are less susceptible to the effects of moisture than paper, which is known as a reinforcement layer in facings for polymer foam insulation panels.

[0045] The facings can also each comprise multiple textile nonwovens.

[0046] Preferably, the textile nonwoven layer - or the textile nonwoven layers - is impregnated with a polymer binder. This further increases the rigidity and dimensional stability of the facing, and therefore of the insulation panel.

[0047] The polymer binder is preferably a thermosetting resin. This further increases the rigidity and dimensional stability of the facing, and therefore of the insulation panel. Preferred thermosetting resins are aminoplasts, epoxies, acrylates, polyurethanes, ethylene vinyl acetates, styrene acrylate copolymers, or polyester resins.

[0048] It is preferable that the impregnated textile nonwoven comprises a flame retardant. This improves the fire resistance of the insulation panel. This can be particularly important for insulation panels with facings that do not comprise aluminum foils, as aluminum foils provide resistance to fire.

[0049] The flame retardant can preferably be an ammonium polyphosphate based flame retardant.

[0050] A preferred embodiment is characterized in that the textile nonwoven comprises fibers selected from glass fibers, cellulose fibers, polyester fibers, modacrylic fibers, aramid fibers, or combinations thereof.

[0051] The textile nonwoven layer preferably comprises cellulose or lignocellulose, for example cellulose fibers or lignocellulose fibers.

[0052] This embodiment is particularly advantageous when the impregnated textile nonwoven comprises a flame retardant, more preferably an ammonium polyphosphate based flame retardant. In the event of fire, the interaction between the fire retardant and the cellulose or lignocellulose causes the formation of a carbon layer which provides further resistance to fire. This carbon layer in the facing also ensures that flammable gaseous components from the foam (for example physical blowing agents such as pentane) can not, or at least can not quickly, come into contact with the flames, and are therefore not ignited or only ignited late.

[0053] The textile nonwoven can, for example, comprise or consist of viscose fibers or cotton fibers. It is also possible that the textile nonwoven comprises wood pulp or wood fibers, for example between two textile nonwoven layers. The textile nonwoven can be, for example, a glass fleece, preferably with a coating or an impregnating agent.

[0054] The insulation panel of the fourth aspect of the invention is preferably an insulation panel such as in the first aspect of the invention and / or according to the second aspect of the invention and / or according to the third aspect of the invention.

[0055] The fifth aspect of the invention relates to an insulation panel. The insulation panel comprises a core made of thermally insulating polymer foam, and two facings. The core is located between the two facings. The facings are multilayered. The facings comprise at least a paper layer. The insulation panel is characterized in that the paper layer comprises a flame retardant.

[0056] It is an advantage of insulation panels according to the fifth aspect of the invention that these have a better fire resistance. This is especially important for insulation panels that do not comprise aluminum foil. Aluminum foils in facings of polymer foam insulation panels (for example in polyurethane, polyisocyanurate or phenolic insulation panels) provide fire-retardant properties. Adding a flame retardant to the paper layer therefore allows insulation panels to be made from polymer foam with facings without aluminum foil and still having a good fire resistance.

[0057] Preferably, the paper layer comprises an ammonium polyphosphate based flame retardant.

[0058] Ammonium polyphosphate based flame retardants have the advantage that acid is released in the event of fire. This acid acts on the cellulose paper fibers, forming a fire- retardant carbon layer. Because of this, better fire-retardant properties are obtained.

[0059] A preferred embodiment of an insulation panel according to any of the described aspects is characterized in that the facings comprise at least a polymeric gas barrier film; that the facings comprise at least a paper layer or one nonwoven layer, wherein the paper layer or the nonwoven layer comprises a flame retardant; that the facings comprise a polymer film, wherein the polymer film comprises a metal coating, so that IR radiation on the surface of the facing is at least partially reflected by the metal coating.

[0060] This embodiment has the advantage that an insulation panel can be produced with excellent properties without the facings comprising an aluminum foil. Due to the high energy requirement to produce aluminum foils, and because the aluminum layer or layers make recycling of insulation panels difficult, it is desirable to produce insulation panels without aluminum foils.

[0061] The polymeric gas barrier film in the facing is preferably located closer to the core made of thermally insulating polymer foam than the paper layer or nonwoven layer. This embodiment ensures a better gas tightness of the insulation panel. The gas tightness is important to prevent blowing agents from escaping from the foam, which would be detrimental to the thermal insulation value of the insulation panel.

[0062] Preferably the insulation panel does not comprise aluminum foil.

[0063] An insulation panel according to the invention is preferably between 15 mm and 260 mm thick.

[0064] A preferred embodiment of an insulation panel according to any aspect of the invention is characterized in that the facing is less than 1 mm thick, and preferably less than 0.5 mm thick, and more preferably less than 0.3 mm thick.

[0065] Such facings have the advantage of being flexible, which means they are available on a roller and can be unrolled during production of the insulation panel.

[0066] The insulation panel preferably comprises a tongue on one side and a groove on an opposite side, the tongue and groove being provided for coupling such insulation panels.

[0067] The insulation panel can also comprise tongue and groove on two pairs of opposite sides for coupling of the insulation panels. The insulation panel according to any aspect of the invention can have a straight finish on all edges.

[0068] The insulation panel according to any aspect of the invention can comprise an L-rabbet on at least two opposite edges, for the coupling of such insulation panels.

[0069] The side of the facings that contacts the core preferably comprises a polyurethane layer. This improves the adhesion of the facing with the polymer foam of the core, especially with polyurethane foam and with polyisocyanurate foam.

[0070] The side of the facing that contacts the core is preferably corona treated. This improves the adhesion of the facing with the polymer foam of the core.

[0071] The insulation panel of the fifth aspect of the invention is preferably an insulation panel such as in the first aspect of the invention and / or according to the second aspect of the invention and / or according to the third aspect of the invention and / or according to the fourth aspect of the invention.

[0072] The different layers of the facing can be laminated through known techniques to form the facing. For this purpose, adhesive layers or resin present in the facing can be used.

[0073] Preferably, the facings according to the different aspects of the invention comprise one or more layers of Kraft paper, more preferably Kraft paper between 60 and 200 grams per square meter.

[0074] The insulation panel according to any of the aspects already mentioned preferably comprises closed foam cells.

[0075] The polymer foam of the insulation panel according to any of the aspects already mentioned can be a polyurethane foam, a polyisocyanurate foam, a phenolic foam, or a polystyrene foam - for example an expanded polystyrene foam. The insulation panel according to the different aspects of the invention comprises two facings between which the core is located. The two facings can be identical; however, this is not necessarily the case. The facing on the two sides of the insulation panel can be different, even different in construction.

[0076] An independent aspect relates to a facing with features as mentioned for the insulation panels of the already mentioned aspects of the invention.

[0077] Such facings have the advantage that polymer foam insulation panels can be produced with a more sustainable material usage. The recycling of such panels is also more straightforward.

[0078] One aspect of the invention relates to a method for producing an insulation panel. The method comprises the steps of

[0079] - providing a first facing and a second facing;

[0080] - depositing a wet composition onto the first facing for forming a thermally insulating polymer foam - for example for forming a thermally insulating polyurethane foam, a thermally insulating polyisocyanurate foam, or a thermally insulating phenolic foam -; and

[0081] - depositing the second facing on top of the wet composition; so that in the method the wet composition reacts to form a rigid foam which forms a core between the first facing and the second facing. The first and the second facings comprise an uncured or only partially cured thermosetting resin, wherein in the method the thermosetting resin is cured during the forming of the rigid foam.

[0082] This curing can occur under the temperature conditions at which the chemical reactions of foam formation take place.

[0083] This method has the advantage that insulation panels with rigid facings are obtained. These facings ensure a good dimensional stability of the insulation panel, due to their rigidity after curing of the thermosetting resin and their limited shrinkage under the influence of temperature changes. Because the thermosetting resin is only fully cured during the production of the rigid foam core, the facings can be unwound from rollers. This simplifies the production process to a great extent.

[0084] Preferably, the first facing and the second facing are unwound from rollers.

[0085] Preferably, the method produces an insulation panel as in any embodiment of the first aspect, the second aspect, the third aspect, the fourth aspect or the fifth aspect of the invention.

[0086] Preferably, the facings comprise a carrier. The thermosetting resin can be coated on the carrier. The carrier can be impregnated with the thermosetting resin.

[0087] In the method according to the invention, the carrier can be a paper layer or multiple paper layers, for example coated on one side or on both sides with the thermosetting resin.

[0088] The carrier can be a paper layer impregnated with the thermosetting resin. For example, a non-filled paper layer made of alpha-cellulose is very suitable for this.

[0089] The carrier can be a textile nonwoven or multiple textile nonwovens, impregnated with or coated on one or both sides with the thermosetting resin.

[0090] The carrier can also be a combination of one or more paper layers and one or more textile nonwovens.

[0091] The thermosetting resin used in the method according to the invention can be an aminoplast, an epoxy, an acrylate, a polyurethane, a vinyl acetate, a styrene acrylate copolymer or a polyester resin, or combinations thereof.

[0092] Preferably, the carrier for carrying out the method according to the invention comprises a flame retardant, preferably an ammonium polyphosphate based flame retardant. In the method preferably facings can be used such as described in any embodiment of the first aspect, the second aspect, the third aspect, the fourth aspect or the fifth aspect of the invention.

[0093] With a view to better demonstrating the characteristics of the invention, the following, as an example without any restrictive character, describes some preferred embodiments, with reference to the accompanying drawings, wherein:

[0094] Figure 1 shows a wall thermally insulated with insulation panels according to the invention;

[0095] Figure 2 illustrates an insulation panel according to the invention;

[0096] Figure 3 shows a facing, for use in insulation panels, which combines the different aspects of the invention; and

[0097] Figure 4 represents a method according to the invention.

[0098] Figure 1 shows a wall 10 comprising an inner wall 12, an outer wall 14 and thermal insulation 16. The inner wall 12 and the outer wall 14 can be brick walls. The thermal insulation 16 is formed by insulation panels 18 according to the invention. An insulation panels according to the different aspects of the invention can be used for this. The insulation panels 18 are rectangular and have a thickness T.

[0099] The insulation panels 18 are rectangular and are provided on their opposite sides with tongue 20 and groove 22 for coupling the insulation panels. However, other options of coupling means are also possible, such as L-shaped rabbets.

[0100] On the side of the outer wall 14 a sealing tape 24 is applied on the insulation panels 18, such that the sealing tape covers the joint between coupled insulation panels 18.

[0101] Figure 2 illustrates the construction of an insulation panel 18 according to the different aspects of the invention. The insulation panel comprises a core 30 made of thermally insulating polymer foam (for example made of thermally insulating polyurethane foam, made of thermally insulating polyisocyanurate foam, made of thermally insulating phenolic foam, or made of thermally insulating polystyrene foam); and two facings 32. The core made of thermally insulating polymer foam is located between the two facings 32 and consists of closed foam cells. As will be illustrated in the example of Figure 3, the facings 32 are multilayered. On opposite sides the insulation panel 18 is provided with tongue 20 and groove 22 for coupling the insulation panels. However, other options of coupling means are also possible.

[0102] Figure 3 illustrates a facing 32 for use in insulation panels 18. The facing 32 of Figure 3 combines the different aspects of the invention; however, this need not be the case for the invention.

[0103] The facing 32 of Figure 3 comprises a polymeric gas barrier film 40, which in the example forms the bottom side of the facing 32. This is the side that contacts the foam core of the insulation panel.

[0104] The polymeric gas barrier film 40 can comprise a barrier forming film made of ethylene vinyl alcohol, for example laminated between two polyethylene films.

[0105] The polymeric gas barrier film 40 can comprise or consist of a polymer selected from polyamide, polyethylene terephthalate, polyvinyl naphthalate, polyvinylidene chloride, polyethylene furanoate, or polyvinyl chloride.

[0106] The polymeric gas barrier film 40 can comprise a polymer film (for example a polyester film or a polyolefinic film) on which an inorganic layer - for example, an aluminum oxide layer or a silicon oxide layer - is applied.

[0107] The polymeric gas barrier film 40 can be provided with a polyurethane layer on the bottom side, to obtain better adhesion with the core made of thermally insulating polymer foam during production of the insulation panel (e.g., with the core made of thermally insulating polyurethane or made of thermally insulating polyisocyanurate foam). The polymeric gas barrier film 40 can be corona treated on the bottom side, to obtain better adhesion with the core made of thermally insulating polymer foam during production of the insulation panel.

[0108] Other treatments or adhesion layers are possible to obtain better adhesion with the core made of thermally insulating polymer foam.

[0109] On its external surface the facing 32 of Figure 3 comprises a polymer film 42 comprising a metal coating, so that IR radiation on the surface of the facing is at least partially reflected by the metal coating.

[0110] The polymer film 42 comprising the metal coating can be a polyethylene terephthalate film. The metal coating can be selected from aluminum, titanium, copper, nickel, silver, gold, chrome.

[0111] The facing 32 of the example comprises a carrier layer 44. The carrier layer 44 can be formed by one or more paper layers or by one or more textile nonwoven layers, or by combinations of one or more paper layers and one or more textile nonwoven layers.

[0112] The carrier layer 44 of the example comprises a thermosetting resin. This thermosetting resin can be coated onto the carrier layer 44, or the carrier layer 44 can be impregnated with the thermosetting resin. It is preferable that the thermosetting resin is not fully cured until the insulation panel between the two facings is produced.

[0113] The thermosetting resin can be selected from, for example, an aminoplast, an epoxy, an acrylate, a polyurethane, an ethylene vinyl acetate, a styrene acrylate copolymer, or a polyester resin, or even combinations of these resins.

[0114] The carrier can comprise a flame retardant, for example an ammonium polyphosphate based flame retardant. The flame retardant can for example be applied by mixing the flame retardant into the resin with which the carrier is coated or impregnated. It is also possible to scatter the flame retardant on the carrier after coating or impregnating the carrier with the resin, while the resin is still wet.

[0115] Figure 4 represents an example of the method according to the invention. A wet composition 41 for forming a thermally insulating polyisocyanurate foam is deposited on a first facing 42 by means of spray units 43. This first facing 42 is unwound from a roller 44.

[0116] At the position where wet composition 41 is deposited on first facing 42, the first facing 42 is supported by a table 45. Table 45 is installed permanently.

[0117] The first facing42 - with the wet composition 41 on it - is continuously fed through the production line in the production direction 46 of the insulation panel.

[0118] After the table 45, the first facing 42 - with the wet composition 41 on it - is guided through an oven by means of and between a double belt 48. The wet composition 41 for forming a thermally insulating polyisocyanurate foam will expand and chemical reactions will start.

[0119] Before the oven - and therefore before the double belt 48 - a second facing 50 is unwound from a roller and supplied. The second facing 50 is positioned above the first facing 42 with the wet composition 41 thereon. The first facing 42 with the wet composition 41 thereon and the second facing 50 are guided through the oven by means of and between the double belt 48. In the oven, the wet composition 41 further expands and reacts to form a rigid polyisocyanurate foam core 30 bonded to the first facing 42 and to the second facing 50. Hereby an insulation panel 18 is produced which comprises a core 30 made of thermally insulating polyisocyanurate foam and two facings 42, 50, the core 30 being located between the two facings 42, 50 and adhering thereto. In the example of Figure 4, the first facing 42 and the second facing 50 are identical to each other; however, this is not essential to the invention. The first facing 42 and the second facing 50 comprise a carrier comprising an uncured or only partially cured thermosetting resin. This uncured or only partially cured resin is cured in the oven. This provides rigidity and dimensional stability to the facings and to the produced insulation panel 18.

[0120] The carrier of the facings 42, 50 can comprise one or more paper layers or textile nonwoven layers that are coated or impregnated with the uncured or only partially cured thermosetting resin. The carrier can also comprise a flame retardant, for example an ammonium polyphosphate based flame retardant.

[0121] The present invention is by no means limited to the embodiments described hereinbefore, but such facings, insulation panels and methods can be implemented according to different variants without departing from the scope of the present invention.

Claims

Claims1 An insulation panel, wherein the insulation panel (18) comprises a core (30) made of thermally insulating polymer foam and two facings (32), the core being located between the two facings, the facings being multilayered, characterized in that the facings comprise at least a polymeric gas barrier film (40), preferably wherein the facings comprise at least one or more paper layers or one or more nonwoven layers (44).2.- The insulation panel as in claim 1, characterized in that the polymeric gas barrier film (40) comprises a gas barrier forming film of ethylene vinyl alcohol, preferably laminated between two polyethylene films.3.- The insulation panel as in claim 1, characterized in that the polymeric gas barrier film (40) comprises or consists of a polymer selected from polyamide, polyethylene terephthalate, polyvinyl naphthalate, polyvinylidene chloride, polyethylene furanoate, or polyvinyl chloride.4.- The insulation panel as in claim 1, characterized in that the polymeric gas barrier film (40) comprises a polymer film on which an inorganic layer - for example, an aluminum oxide layer or a silicon oxide layer - is applied, preferably wherein the polymer film is a polyester film or a polyolefinic film.5.- The insulation panel as in claim 4, characterized in that the inorganic layer has a thickness of less than 50 nanometers.6.- An insulation panel, preferably an insulation panel as in any of the preceding claims, wherein the insulation panel (18) comprises a core (30) made of thermally insulating polymer foam and two facings (32), the core being located between the two facings,the facings being multilayered, characterized in that the facings comprise a polymer film (42) on their external surface and that the facings preferably comprise at least a paper layer or a nonwoven layer (44), wherein the polymer film comprises a metal coating, so that IR radiation on the surface of the coating is at least partially reflected by the metal coating.7.- The insulation panel as in claim 6, characterized in that the polymer film (42) comprising the metal coating is a polyester film, preferably a polyethylene terephthalate film, or a polyethylene furanoate film.8.- The insulation panel as in any of the preceding claims 6 - 7, characterized in that the metal coating is selected from aluminum, titanium, copper, nickel, silver, gold, chrome; or combinations thereof.9.- The insulation panel as in any of the preceding claims 6 - 8, characterized in that the metal coating is applied on the polymer film by means of sputtering or by means of vacuum deposition.10.- The insulation panel as in any of the preceding claims 6 - 9, characterized in that the thickness of the metal coating is less than 50 nanometers.11.- An insulation panel, preferably an insulation panel as in any of the preceding claims, wherein the insulation panel (18) comprises a core (30) made of thermally insulating polymer foam and two facings (32), the core being located between the two facings, characterized in that the facings comprise a layer with thermosetting resin.12.- The insulation panel as in claim 11, characterized in that the thermosetting resin is cured during the production of the core between the two facings.13.- The insulation panel as in any of the preceding claims 11 - 12, characterized in that the facing comprises a carrier, wherein the thermosetting resin is coated on the carrieror wherein the carrier is impregnated with the thermosetting resin, preferably the carrier can be a paper layer, a textile nonwoven, or a polymer film.14.- The insulation panel as in any of the preceding claims 11 - 13, characterized in that the thermosetting resin is an aminoplast, an epoxy, an acrylate, a polyurethane, an ethylene vinyl acetate, a styrene acrylate copolymer or a polyester resin, or combinations thereof.15.- An insulation panel, preferably an insulation panel as in any of the preceding claims, wherein the insulation panel (18) comprises a core (30) made of thermally insulating polymer foam and two facings (32), the core being located between the two facings, the facings being multilayered, characterized in that the facing comprises a textile nonwoven layer.16.- The insulation panel as in claim 15, characterized in that the textile nonwoven layer is impregnated with a polymer binder - preferably a thermosetting resin - preferably with an aminoplast, an epoxy, an acrylate, a polyurethane, or a polyester resin.17.- The insulation panel as in claim 16, characterized in that the impregnated textile nonwoven comprises a flame retardant, preferably an ammonium polyphosphate based flame retardant.18.- The insulation panel as in any of the preceding claims 15 - 17, characterized in that the textile nonwoven comprises fibers selected from glass fibers, cellulose fibers, polyester fibers, modacrylic fibers, aramid fibers, or combinations thereof.19.- The insulation panel as in any of the preceding claims 15 - 18, characterized in that the textile nonwoven layer comprises cellulose or lignocellulose, for example cellulose fibers or lignocellulose fibers.20.- An insulation panel, preferably an insulation panel as in any of the preceding claims, wherein the insulation panel (18) comprises a core (30) made of thermally insulating polymer foam and two facings (32), the core being located between the two facings, the facings being multilayered, the facings comprising at least a paper layer, characterized in that the paper layer comprises a flame retardant, preferably an ammonium polyphosphate based flame retardant.21.- The insulation panel (18) as in any of the preceding claims, characterized in that the facings (32) comprise at least a polymeric gas barrier film (40); in that the facings comprise at least a paper layer or a nonwoven layer (44), wherein the paper layer or the nonwoven layer comprises a flame retardant; and in that the facings comprise a polymer film (42), wherein the polymer film comprises a metal coating, so that IR radiation on the surface of the facing is at least partially reflected by the metal coating.22.- The insulation panel as in claim 21, characterized in that the polymeric gas barrier film (40) in the facing is located closer to the core made of thermally insulating polymer foam than the paper layer or nonwoven layer.23.- The insulation panel as in any of the preceding claims, characterized in that the insulation panel does not comprise any aluminum foil.24.- The insulation panel as in any of the preceding claims, characterized in that the insulation panel is between 15 mm and 260 mm thick.25.- The insulation panel as in any of the preceding claims, characterized in that the facing is less than 1 mm thick, and preferably less than 0.5 mm thick.26.- The insulation panel as in any of the preceding claims 1 - 25, characterized in that the insulation panel (18) comprises a tongue (20) on one side and a groove (22) onan opposite side, the tongue and the groove being provided for coupling such insulation panels.27.- The insulation panel as in any of the preceding claims 1 - 25, characterized in that the insulation panel comprises a straight finish on all edges; or in that the insulation panel comprises an L-rabbet on at least two opposite edges, for coupling such insulation panels.28.- The insulation panel as in any of the preceding claims, characterized in that the side of the facings that contacts the core comprises a polyurethane layer and / or is corona treated.29.- The insulation panel as in any of the preceding claims, characterized in that the thermally insulating polymer foam is a polyurethane foam, a polyisocyanurate foam, a phenolic foam, or a polystyrene foam - for example, an expanded polystyrene foam.30.- A method for producing an insulation panel (18), preferably an insulation panel(18) as in any of the preceding claims, the method comprising the steps of- providing a first facing (42) and a second facing (50);- depositing a wet composition (41) onto the first facing (42) for forming a thermally insulating polymer foam - for example for forming a thermally insulating polyurethane foam, a thermally insulating polyisocyanurate foam, or a thermally insulating phenolic foam -; and- depositing the second facing (50) on top of the wet composition (41); so that in the method the wet composition reacts to form a rigid foam which forms a core (30) between the first facing (42) and the second facing (50), wherein the first (42) and second (50) facings comprise an uncured or only partially cured thermosetting resin, wherein in the method the thermosetting resin is cured during the forming of the rigid foam.31.- The method as in claim 30, characterized in that the facings comprise a carrier (44), wherein the thermosetting resin is coated onto the carrier or wherein the carrier isimpregnated with the thermosetting resin, preferably the carrier can be one or more paper layers or textile nonwovens, or combinations thereof.32.- The method as in any of claims 30 - 31, characterized in that the thermosetting resin is an aminoplast, an epoxy, an acrylate, a polyurethane, an ethylene vinyl acetate, a styrene acrylate copolymer or a polyester resin, or combinations thereof.33.- The method as in any of claims 31 - 32, characterized in that the carrier comprises a flame retardant, preferably an ammonium polyphosphate based flame retardant.34.- The method as in any of the preceding claims 30 - 33, characterized in that the first facing (42) and the second facing (50) are facings as described in any of the preceding claims 1 - 29.

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