Method to produce an insulating polymer panel

Abstract

A method to produce an insulating polymer panel (10), the method comprises the steps of providing a first and a second intermediate polymer panel (111, 121), each comprising a base plate (101) on which upstanding walls(102) are provided, said walls defining a number of cells (103) with a void inner space (104) and an open top (105), the cells being distributed over the base plate according to a pattern (130); providing for at least one of the first and second intermediate polymer panel, a number of blocks (201) of insulating polymer material, the number of blocks being equal to or less than the number of cells of this at least one of the first and second intermediate polymer panel, said blocks each have two identical and parallel bases and one mantle face between the two bases, for each cell a block is provided for which the bases match the open top of the cell; for this at least one of the first and second intermediate polymer panel, inserting this number of blocks (201) in this at least one of the first and second intermediate polymer panel such the blocks are sunken in the cells to provide at least one intermediate filled polymer panels (301, 302) comprising this at least one of the first and second intermediate polymer panel; connecting the edges (106) of the walls (102) of the first intermediate polymer panel to the edges of the walls of the second the intermediate polymer panel.

Description

[0001] METHOD TO PRODUCE AN INSULATING POLYMER PANEL

[0002] Field of the Invention

[0003]

[0001] The present invention generally relates to methods to produce an insulating polymer panel, and polymer panels.

[0004] Background of the Invention

[0005]

[0002] Polymer panels are known in the art. Often these panels are provided as honeycomb- or similar panels, and may be used as parts of walls , ceilings or floor structures. The polymer panels comprise a cellular structure between two outer polymer walls.

[0006]

[0003] The cells in such panels are provided as hollow cells in order to reduce the weigh per square meter of panel. However there is a need to provide polymer panels which have a higher thermal insulation as compared to the presently known polymer panels with empty cells.

[0007]

[0004] There is also a need to a method to fill the cells of such polymer panels with cell structures, allowing to fill the cells with insulating material, but facilitating still the use of presently known machinery to produce these panels, and / or avoiding complex production steps to get the cells at least partially filled with insulating material.

[0008] Summary of the Invention

[0009]

[0005] According to a first aspect of the invention, a method to produce an insulating polymer panel is provided. The method comprises the steps of

[0010] • providing a first and a second intermediate polymer panel, each comprising a base plate on which upstanding walls are provided, said walls defining a number of cells with a void inner space and an open top, the cells being distributed over the base plate according to a pattern;

[0011] • providing for at least one of the first and second intermediate polymer panel, a number of blocks of insulating polymer material, the number of blocks being equal to or less than the number of cells of this at least one of the firstand second intermediate polymer panel, said blocks each have two identical and parallel bases and one mantle face between the two bases, for each cell a block is provided for which the bases match the open top of the cell;

[0012] • for this at least one of the first and second intermediate polymer panel, inserting this number of blocks in this at least one of the first and second intermediate polymer panel such the blocks are sunken in the cells to provide at least one intermediate filled polymer panels comprising this at least one of the first and second intermediate polymer panel;

[0013] • connecting the edges of the walls of the first intermediate polymer panel to the edges of the walls of the second the intermediate polymer panel.

[0014]

[0006] Preferably, the number of blocks of insulating polymer material may be equal to or less than the number of cells of this at least one of the first and second intermediate polymer panel.

[0015]

[0007] According to some embodiments, the blocks of the first number of blocks may be interconnected. These blocks of the first number of blocks may be provided as parts of an insulating polymer sheet.

[0016]

[0008] According to some embodiments, the method may comprise

[0017] • providing for the first intermediate polymer panel, a first number of blocks of insulating polymer material equal to or less than the number of cells of this first intermediate polymer panel, said blocks each have two identical and parallel bases and one mantle face between the two bases, for each cell a block is provided for which the bases match the open top of the cell;

[0018] • providing for the second intermediate polymer panel, a second number of blocks of insulating polymer material, the second number of blocks being equal to or less than the number of cells of this second intermediate polymer panel, said blocks each have two identical and parallel bases and one mantle face between the two bases, for each cell a block is provided for which the bases match the open top of the cell;

[0019] • Inserting the first number of blocks in the first intermediate polymer panels such the blocks are sunken in the cells to provide an intermediate filled polymer panels comprising this first intermediate polymer panel;

[0020] • Inserting the second number of blocks in the second intermediate polymer panels such the blocks are sunken in the cells to provide anintermediate filled polymer panels comprising this second intermediate polymer panel;

[0021]

[0009] Preferably, the first number of blocks of insulating polymer material may be equal to the number of cells of this first intermediate polymer panel. Preferably, the second number of blocks of insulating polymer material may be equal to the number of cells of this second intermediate polymer panel. Preferably, the first number of blocks of insulating polymer material may be equal to the number of cells of this first intermediate polymer panel, and the second number of blocks of insulating polymer material may be equal to the number of cells of this second intermediate polymer panel, possibly, the first number of blocks of insulating polymer material may be equal to the number of cells of this first intermediate polymer panel, the second number of blocks of insulating polymer material may be equal to the number of cells of this second intermediate polymer panel and the first number of blocks is equal to the second number of blocks.

[0022]

[0010] Preferably all blocks of the first number of blocks of insulating polymer material are similar, even identical one to the other. Preferably all blocks of the second number of blocks of insulating polymer material are similar, even identical one to the other. Most preferably, but not necessarily, all blocks of the first and the second number of blocks of insulating polymer material are similar, even identical one to the other.

[0023]

[0011] According to some embodiments, the blocks of the first number of blocks may be equal to the blocks of the second number of blocks are similar, even identical. Similar means that two blocks have the same dimensions, polymer material and / or specific density. Identical means that two blocks have the same dimensions, polymer material and specific density.

[0024]

[0012] According to some embodiments, the second number of blocks may be interconnected. According to some embodiments, the second number of blocks may be provided as parts of an insulating polymer sheet. Possibly the insulating polymer sheet providing the second number of blocks is similar, even identical to the insulating polymer sheet providing the first number of blocks.

[0025]

[0013] These methods according the present invention have the advantage that the insulating polymer panel may be provided with a high flexibility of insulation properties.In an easy way, the insulation property of the insulating polymer sheet may be changes by using more or less, and larger or smaller blocks in one or all the cells of one or both the intermediate polymer panels. By merely choosing the height of the walls of the block, the material of the block and / or the provision of blocks in one or in both intermediate polymer panels at a given spot of the insulating polymer sheet to be provided prior to connecting the edges of the walls of the first intermediate polymer panel to the edges of the walls of the second the intermediate polymer panel, the thermal insulating property of the insulating polymer sheet so obtained, can locally be varied as well. By using other blocks during production of the next insulating polymer sheet in the production line, the next produced insulating polymer sheet may be different from the one or more earlier or later produced insulating polymer sheets. Hence a wide production freedom is obtained by using the method according to the invention.

[0026]

[0014] The blocks may be provided as individual blocks, and may as such be inserted in the cells of the intermediate polymer panel, e.g. by using an automated filling step, e.g. using a robot or alike.

[0027]

[0015] According to preferred embodiments of methods according to the first aspect of the invention, the method comprises the steps:

[0028] - providing two sets of

[0029] o an intermediate polymer panel, comprising a base plate on which upstanding walls are provided, said walls defining a number of cells with a void inner space and an open top, the cells being distributed over the base plate according to a pattern;

[0030] o at least one insulating polymer sheet, comprising a number of blocks equal to or less than the number of cells of the intermediate polymer panel, said blocks each have two identical and parallel bases and one mantle face between the two bases, for each cell a block is provided for which the bases match the open top of the cell, o the blocks being interconnected such the blocks are positioned within the insulating polymer sheet according to the same pattern; - for both sets of an intermediate polymer panel and an insulating polymer sheet, inserting the insulating polymer sheets, in the intermediate polymerpanels (such the blocks are sunken in the cells to provide two intermediate filled polymer panels,

[0031] - connecting the edges of the walls of the first of the intermediate filled polymer panels to the edges of the walls of the second of the intermediate filled polymer panels.

[0032]

[0016] According to some embodiments, the height of the face may be less than or equal to the depth of the cell. Most preferably the height of the face is less than the depth of the cell, e.g. about 0.5 mm to 2.5 mm less than the depth of the cell. As such the blocks may be fully sunken in the cells. When the height of the face is more than or equal to the depth of the cell, care is to be taken that the upper sides of the blocks do not hinder the further steps of the production of this insulating polymer panel, e.g. by hindering the heating of the edges of the polymer walls in case of using thermal welding to connect the walls of the first of the intermediate filled polymer panels to the edges of the walls of the second of the intermediate filled polymer panels. This particularly when mirror welding is used. As a step to avoid melting and adhesion of molten insulating polymer to the mirror, the mirror may be a mirror having apertures at the positions of the blocks’ upper sides, or the mirror may be masked with e.g. a thermally insulating material, avoiding the melting of the insulating polymer at the blocks’ upper sides.

[0033]

[0017] In the context of the present invention, the term insulating means thermally insulating. When reference is made to insulating polymer, this means that the polymer is thermally insulation, hence may also be referred to as insulation polymer material or polymeric insulation material or polymeric insulating material.

[0034]

[0018] At the top side of the walls, the edges or upper edges define the perimeter of the open tops of the cells. Upper in this context means the edges of the wall opposite to the base plate to which the walls are connected.

[0035]

[0019] The pattern is preferably a regular pattern and / or a repetitive pattern.

[0036]

[0020] As the bases of the blocks being part of an insulating polymer sheet and to be inserted in the first or the second intermediate polymer panel, may be identical and parallel, even coplanar to each other, the bases matching the dimensions of the open top of the cell, the blocks may fit snuggly in the cell when sinking the blocks in the cells. As the blocks are interconnected and the pattern of the blocks match the pattern of thecells on the base plate of the intermediate panel, the block can be sunken simultaneously in the cells. There is no need to position the blocks one by one. The volumes of the blocks may meet the void inner space width; hence the blocks may fit in the cells and may be locked due to friction to the inner wall of the void inner space of the cells. Possibly, even alternatively, the inner sides of the cells may first be provided with a glue, e.g. a glue may be sprayed on the inner walls, some inner walls and / or the inner side of the outer wall, prior to inserting the blocks in the cells. Also in this way, the blocks may be locked due to friction to the inner wall of the void inner space of the cells.

[0037]

[0021] During the insertion of blocks as individual blocks, and in order to obtain a tight fit, the dimensions of the blocks may be identical or minimally larger than the dimensions of the cells. At least the perimeter of the radial cross section of the block and the perimeter of the radial cross section of the corresponding cell, are such that the radial cross section of the block fills the radial cross section of the corresponding cell once being inserted. Friction forces between the faces of the block and the inner surfaces of the cells may prevent the block to fallout of the cell when the so obtained intermediate filled polymer panel is manipulated, and possibly eventually turned upside down, the open sides of the filled cells facing vertically downwards, the outer surface of the base plate of the as such obtained intermediate but filled polymer panel facing upwards.

[0038]

[0022] Between the blocks being part of an insulating polymer sheet, open areas are provided to accommodate the walls of the cells when the blocks are inserted in the cells of the intermediate polymer panel. During the insertion, as such providing an intermediate but filled polymer panel, the link or interconnection between the blocks, may be broken or extended, and preferably are broken. As such, after insertion in the cells, the blocks are individualized and provided in, preferably tightly fitting in the cells. To obtain a tight fit, the dimensions of the blocks may be identical or minimally larger than the dimensions of the cells. At least the perimeter of the radial cross section of the block and the perimeter of the radial cross section of the corresponding cell, are such that the radial cross section of the block fills the radial cross section of the corresponding cell once being inserted. Friction forces between the faces of the block and the inner surfaces of the cells may prevent the block to fallout of the cell when the so obtained intermediate filled polymer panel is manipulated, and possibly eventuallyturned upside down, the open sides of the filled cells facing vertically downwards, the outer surface of the base plate of the intermediate filled polymer panel facing upwards.

[0039]

[0023] All this provides an easy filling of the cells using the one or more insulating polymer sheets or the individual blocks of insulating polymer.

[0040]

[0024] Once the two intermediate filled polymer panels are connected, e.g. by mirror welding, a panel is provided having two outer base plates, between which a cell structure is provided, each cell structure comprising at least two parts of insulation material, free of contact between the two parts of insulation material at the position of the connection between the two walls of the two intermediate filled polymer panels.

[0041]

[0025] As the two intermediate filled polymer panels have insulation material from the blocks being sunken in the cells, the two intermediate filled polymer panels may still be thermally welded one to the other using the presently known equipment, such as mirror welding equipment, without the risk that the insulation material would stick to the mirror of the mirror welding machine.

[0042]

[0026] According to some embodiments, the intermediate polymer panels, bpossibly of the sets of an intermediate polymer panel and an insulating polymer sheet, may have cells with a pattern such each edge of a wall of the first of the two intermediate polymer panels contacts edge of a second of the two intermediate polymer panels when the intermediate filled polymer panels stacked with open side cells to each other.

[0043]

[0027] As such an insulating polymer panel may be provided having two outer polymer plates, i.e. base plates, between which a plurality of cells are provided in a structure, like a honeycomb structure, a checkerboard cell structure with horizontally and vertically aligned rows of cells or alike.

[0044]

[0028] According to some embodiments, the cells have a depth, the height of the faces of the blocks may be less than the depth of the cells.

[0045]

[0029] Preferably the height of the faces of the blocks is less than or equal to the depth of the cells minus 0.5mm. Possibly the height of the faces of the blocks is less than or equal to the depth of the cells minus 1mm.

[0046]

[0030] It is understood that more than one, and even a different number of insulating polymer sheets may be used to be inserted in one or both of the intermediate polymer panels. In a similar way, a plurality of blocks of insulating polymer may be inserted inone or more of the cells of one intermediate polymer panel. The blocks will be positioned within the insulating polymer sheet in a stacked way. The blocks to become positioned within the insulating polymer sheet may be inserted, like pushed, into the cells one by one or some or all blocks, possibly the insulating polymer sheets, may first be stacked together before introducing the stack in the intermediate polymer panel.

[0047]

[0031] The depth of the cells in the two intermediate polymer panels may be different. The height of the blocks, possibly by means of one or more insulating polymer sheets, inserted in the cells may be different. As such the total thickness and / or thermal insulating properties of the final insulating polymer panel may be easily varied.

[0048]

[0032] According to some embodiments, more than one insulating polymer sheets may be inserted in one or in both of the two intermediate polymer panels, the more than one insulating polymer sheets being stacked one on top of the other in the intermediate filled polymer panel or panels.

[0049]

[0033] When using more than one insulating polymer sheets for one or both of the two intermediate polymer panels, optionally some part of the depth of one or both of the two intermediate polymer panels may be only partially filled. As such the insulation property of the final insulating polymer panel may be modified without modifying the dimension of the final insulating polymer panel, more in particular its thickness.

[0050]

[0034] In a similar way, for one or both of the two intermediate polymer panels, optionally some part of the depth of one or both of the two intermediate polymer panels may be only partially filled with one or a plurality of blocks. As such the insulation property of the final insulating polymer panel may be modified without modifying the dimension of the final insulating polymer panel, more in particular its thickness.

[0051]

[0035] In the one or more insulating polymer sheets preferably the number of blocks may be equal to the number of cells in the corresponding intermediate polymer panel. Possibly however, one or more of the cells in the corresponding intermediate polymer panel may not have a corresponding block in one or more than one of the insulating polymer sheets to be inserted in the intermediate polymer panel. Similarly, the number of cells filled by one or more blocks may equal or may be different from the total number of calls of the intermediate polymer panel. As such, locally on the final insulating polymer panel, the thermal insulation properties may be varied by locally providingless, or even no thermal insulation material via the blocks of the one or more insulating polymer sheets.

[0052]

[0036] According to some embodiments, more than one insulating polymer sheets may be inserted in one or in both of the two intermediate polymer panels, the more than one insulating polymer sheets being positioned one adjacent the other in the intermediate filled polymer panel or panels.

[0053]

[0037] The provision of insulating polymer sheets, each hence being provided to cover and to be inserted in a part of the surface of the intermediate polymer panel, has the advantage that the dimensions of the insulating polymer sheets must not necessarily match the dimensions of the intermediate polymer panel. As a mere example, the surface of the insulating polymer sheets may only be half, one third or less than the surface of the intermediate polymer panel. By arranging a plurality of insulating polymer sheets over the surface of the intermediate polymer panel, manipulation of the sheets and panels become more economic and / or easy to control.

[0054]

[0038] It is understood that the insulating polymer sheets, optionally once arranged next to the other, may be inserted in the intermediate polymer panel simultaneously or one by one.

[0055]

[0039] According to some embodiments, the cells may have a polygonal open top. The open tops of the cells, and thereby also the bases of the corresponding blocks, may be polygonal, such as triangular, square or rectangular, pentagonal, hexagonal and alike. Possibly the polygonal shapes are all identical. The polygons may be regular polygons. Preferably the polygons are hexagons, such as regular hexagons, or rectangular, such as regular rectangular, i.e. squares.

[0056]

[0040] As preferred, the polygons are rectangular with short side in the range of 30mm to 120mm, such as in the range of 50mm to 100mm, e.g. 50mm, 75mm 100mm and 3 inches. The long side is preferably in the range of 50mm to 120mm, such as in the range of 75mm to 100mm, e.g. 75mm 100mm and 3 inches. As a mere indication, the number of cells per surface unit of the insulating polymer panel is preferably in the range of 200 to 500 per m2, such as in the range of 350 to 450 per m2, e.g. 400 / m2.

[0057]

[0041] According to some embodiments, the step of inserting the insulating polymer sheets or blocks in the intermediate polymer panels may comprise pushing the insulating polymer sheets or blocks in the intermediate polymer panels.

[0042] Such pushing in may be done by pressing in the blocks in the cells after the blocks are aligned with the cell pattern, and hence the insulating polymer sheet being positioned on the intermediate polymer panels. The press used may be any suitable press, such as a static press, or a dynamic press, e.g. a double band press. The pressure used may range from 5 N / cm2to 50 N / cm2, such as in the range of 5 N / cm2to 15 N / cm2, e.g. 10 N / cm2.

[0058]

[0043] Preferably the faces of the cells, provided by the walls, are substantially perpendicular to the base plate. Hence although oblique cells may be used, preferably the cells are right cells defining right cylinders or right prisms, as said preferably having a polygonal, such as a regular polygon basis. The blocks, optionally of the one or more insulating polymer sheets also preferably have the form of a right volume defining right cylinders or right prisms, as said preferably having a polygonal, such as a regular polygon basis.

[0059]

[0044] According to some embodiments, the insulating polymer sheets may be injection molded sheets.

[0060]

[0045] The insulating polymer sheets and its blocks, or the individual bocks, may be provided from expanded polymer.

[0061]

[0046] Possibly the insulating polymer sheets may be provided from expanded polymer material, e.g. expanded preferably thermoplastic polymer, such as polyamide (PA), polyester (PES) polyethylene terephthalate (PET), or polyolefins (Pol), like polyethylene (PE) or polypropylene (PP). Preferably expanded polyolefins, more preferred expanded polypropylene are used.

[0062]

[0047] Optionally, extruded polypropylene may be used. Preferably closed cell extruded polypropylene, most preferred non-crosslinked extruded polypropylene such as closed cell non-crosslinked extruded polypropylene is used.

[0063]

[0048] Most preferably the insulating polymer sheets are injection molded sheets, provided from expanded polymer material, e.g. expanded thermoplastic polymer, such as polyamide (PA), polyester (PES) polyethylene terephthalate (PET), or polyolefins (Pol), like polyethylene (PE) or polypropylene (PP). Preferably expanded polyolefins, more preferred expanded polypropylene are used.

[0064]

[0049] According to some embodiments, the intermediate polymer panels may be injection molded panels.

[0050] Possibly the intermediate polymer panels may be provided from polymer material, preferably thermoplastic polymer, such as polyamide (PA), polyester (PES) polyethylene terephthalate (PET), or polyolefins (Pol), like polyethylene (PE) or polypropylene (PP). Preferably polyolefins, more preferred polypropylene are used.

[0065]

[0051] The insulating polymer panel preferably has a thickness, i.e. the distance from the one outer surface of the first base plate to the outer surface of the second base plate, in the range of 10mm to 150mm, more preferred in the range of 20mm to 125mm, e.g. in the range of 20mm to 100mm, e.g. 20mm, 35mm 50mm and 100mm. most preferably each intermediate filled polymer panels provides about half the thickness of the insulating polymer panel. Hence the thickness of each of the intermediate filled polymer panels, thus also the thickness of the intermediate polymer panels, is preferably in the range of 5mm to 75mm, more preferred in the range of 10mm to 65mm, e.g. in the range of 10mm to 50mm, e.g. 10mm, 17mm 25mm and 50mm, this thickness being the distance from the outer surface of the first base plate to the edge of the walls of the cells.

[0066]

[0052] The width of the insulating polymer panel may preferably be in the range of 750mm to 1500mm, such as in the range 800mm to 1000mm, e.g. 800mm, 850mm, 1000mm and 4 feet. The length of the insulating polymer panel may preferably be in the range of 750mm to 3000mm, such as in the range 1000mm to 2600mm, e.g. 800mm, 850mm, 1000mm 1200mm, 2600mm and 8 feet.

[0067]

[0053] As to the dimensions of the insulating polymer sheets, the length of the insulating polymer sheets is preferably in the range of 1000mm to 1500mm, e.g. about 1300mm. The width of the insulating polymer sheets is preferably in the range of 800mm to 1200mm, e.g. about 1000mm.

[0068]

[0054] The bases of the corresponding blocks, may be polygonal, such as triangular, square or rectangular, pentagonal, hexagonal and alike. Possibly the polygonal shapes are all identical, although for blocks, e.g. the blocks to be inserted in the cells at the outer perimeter of the insulating polymer panel, the dimensions may be just a little bit smaller to accommodate the outer peripheric walls of the intermediate polymer panels, which are usually somewhat thicker as the internal walls providing the internally positioned cells. The polygons may be regular polygons. Preferably the polygons are hexagons, such as regular hexagons, or rectangular, such as regular rectangular, i.e.squares. As preferred, the polygons are rectangular with short side in the range of 30mm to 120mm, such as in the range of 50mm to 100mm, e.g. 50mm, 75mm 100mm and 3 inches. The long side is preferably in the range of 70mm to 120mm, such as in the range of 75mm to 100mm, e.g. 75mm 100mm and 3 inches. As a mere indication, the number of blocks per surface unit of the insulating polymer sheets is preferably in the range of 200 to 500 per m2, such as in the range of 350 to 450 per m2, e.g. 400 / m2.

[0069]

[0055] Possibly additional walls are provided in the intermediate polymer panel to provide some reinforcement of other characteristic properties to the insulating polymer panel. It is understood that some blocks may be provided with slits of gaps to receive these additional walls.

[0070]

[0056] According to some embodiments, the bases of individual blocks may be connected to each other by a polymer film.

[0071]

[0057] This film may be glued to the blocks at one of the bases of each block. The film, preferably of the same or similar polymer of the blocks itself, can adhere to the bases using any appropriate glue.

[0072]

[0058] After the insulating polymer sheet is inserted in the intermediate polymer panel, the film may be removed by peeling or pulling of the film. This in particular when the film is not broken, thus the film extends over the edges of the walls of the cells in which the blocks are inserted. When the polymer film is made of polymer material compatible with the polymer of the intermediate polymer panel, this removal of the film may be omitted.

[0073]

[0059] Possibly the film may be a slit film. When the insulating polymer sheet is inserted in the intermediate polymer panel and the film is not broken due to the insertion action, only small tapes of the film may extend over the edges of the walls of the cells in which the blocks are inserted. This may cause less hindrance for connecting the edges of the walls of the intermediate filled polymer panels in a further step of the method. As such the need to remove the non-broken slit film is less needed.

[0074]

[0060] Alternatively the film is a film comprising cut out sections. The cut out sections preferably are such that at least open space is provided at the position of the open area between the block, while still leaving one or more than one, like 2 or 3, filmtapes between adjacent blocks, to interconnect the adjacent blocks. Possibly, also zones of the film covering the basis of the blocks may be cut out.

[0075]

[0061] Possibly the film, optionally with cut out sections or being slit films, may be provided from polymer material, like preferably thermoplastic polymer, such as polyamide (PA), polyester (PES) polyethylene terephthalate (PET), or polyolefins (Pol), like polyethylene (PE) or polypropylene (PP). Preferably polyolefin films more preferred polypropylene films are used. As a mere example, and not limitative, the film may have a thickness in the range of 0.05 mm to 1.25 mm, such as in the range of 0.8mm to 1.2mm, e.g.0.1mm (i.e. 100pm)

[0076]

[0062] Preferably the polymer of the insulating polymer sheet and the polymer of the intermediate polymer panel are similar, even identical. When a polymer film is used to connect blocks of insulating polymer sheet, the polymer of the insulating polymer sheet, the polymer of the intermediate polymer panel and the polymer of the film may be similar, even identical.

[0077]

[0063] Possibly the film may comprise one or more perforation lines, preferably at the sites of the film which are not connected to a base of a block. When the insulating polymer sheet is inserted in the intermediate polymer panel, the film mau be ruptured at these perforation lines due to the insertion action.

[0078]

[0064] By selecting similar or even identical polymers, the insulating polymer panel is fully recyclable and separating different materials during recycling is avoided to a large extent, hence can even avoided completely.

[0079]

[0065] For the insulating polymer sheet , the bases of the blocks may be connected by polymeric bridges between the faces of adjacent blocks.

[0080]

[0066] Between adjacent blocks, bridges may be provided, bridging the distance between the adjacent faces of two blocks. These bridges may be made during production of the blocks of insulating material. The bridges may be provided along the height of the faces of the blocks, such as e.g. at half the distance between two bases of a block.

[0081]

[0067] The bridges may have a very limited thickness. As an example, the thickness of the bridges may be less than 10mm, e.g. in the range of 1mm to 5 mm, e.g. in the range of 1.25 to 2mm, e.g. 1 ,5mm.Possibly the bridges close part or even all the space between the blocks of the insulating polymer sheets.

[0082]

[0068] When using the insulating polymer sheets being injection molded sheets, provided from expanded polymer material, e.g. expanded polypropylene, the bridges may be provided between the block of expanded polymer material during injection molding of the sheet. The mold used therefore comprises small channels between the mold cavities forming the blocks of expanded polymer material after injection.

[0083]

[0069] According to some embodiments, the step of connecting the edges of the walls of the intermediate filled polymer panels may comprise, even may be done by thermal welding of the edges of cells of the intermediate filled polymer panels.

[0084]

[0070] Although the edges may be connected by any other suitable method, like glueing or providing a snap and click structure, preferably the edges of the cells of the intermediate filled polymer panels. Thermal welding may make use of so-called mirror welding.

[0085]

[0071] The insulating polymer panel obtained by a method according to the first aspect of the invention, comprises cells between two base plates. The height of the cells are defined by the depth of the voids of the two intermediate polymer plates. The insulating polymer panel obtained by a method according to the first aspect of the invention are free of cells comprising a block of thermally insulating material, which block is present at both side of the connection line between the two intermediate polymer plates. The insulating polymer panel obtained by a method according to the first aspect of the invention may comprise cells comprising one block of thermally insulating material, which block is present between the base plate and the connection line between the two intermediate polymer plates. The insulating polymer panel obtained by a method according to the first aspect of the invention may comprise cells comprising two blocks of thermally insulating material, between each one of the base plates and the connection line between the two intermediate polymer plates, one of these two blocks is present, the two blocks being free of mutual connection at the sides oriented towards the other block.

[0086]

[0072] According to a second aspect of the invention, an insulating polymer panel is provided. The insulating polymer panel comprises two outer base plates and a cellular structure between these base plates, the cells being delimited by the baseplates and walls between the base plates, each wall comprising a first and a second wall part, the first wall part being connected to the first base plate, the second wall part being connected to the second base plate, said two wall parts being connected one to the other at a connection along a connection line, the insulation in some or all of the cells of the cellular structure comprises at least a first and a second volume, said first volume being present in the cell between the first base plate and the connection line, the second volume being present in the cell between the second base plate and the connection line.

[0087]

[0073] According to some embodiments, said first and a second volume may be mutually separated one from the other.

[0088]

[0074] The insulating polymer panel may be provided by a method according to the first aspect of the invention.

[0089]

[0075] The two insulating volumes in the cells are mutually independent and not connected to one other. Possibly, even preferred, a gap is provided between the sides of the volumes which are contained one to the other at the position of the connection lines.

[0090]

[0076] The connection lines together may be all coplanar.

[0091]

[0077] The insulating polymer panel can be provided using the two intermediate filled polymer panels, the connection between the intermediate filled polymer panels proving the connection lines of the cell walls.

[0092]

[0078] The polymer panel according to the second aspect of the invention, and the polymer panel obtained according to a method of the first aspect of the invention, may preferably be a polymer wall panel, meaning that the polymer panel can be used as a wall in a building construction or a similar facility. According to a further, third aspect of the invention, the polymer panels according to the first aspect of the invention, may be used to construct at least part of a wall or floor or ceiling, such as walls, floors or ceilings of any kind of construction, such as houses, offices, agricultural buildings like staples, e.g. for housing animals and / or livestock such as chickens, pigs, cattle, and alike.

[0093]

[0079] In relation to the invention, when reference is made to a range, the range is to be understood inclusive. Further, it is understood that a feature of one aspect of theinvention may be combined with one or more features of one or more other aspect of the invention

[0094] Brief Description of the Drawings

[0095]

[0080] Fig. 1 to 5 illustrate schematically a method to provide an insulating polymer panel.

[0096]

[0081] Fig. 6 and 7 illustrate schematically alternative insulating polymer sheets to be used in a method to provide an insulating polymer panel.

[0097]

[0082] Fig. 8 to 10 illustrate schematically another method to provide an insulating polymer panel.

[0098]

[0083] Fig.11 illustrates a detail of an insulating polymer sheet used in the method to provide an insulating polymer panel shown in figures 8 to 10.

[0099]

[0084] Fig. 12 to 14 illustrate schematically another method to provide an insulating polymer panel.

[0100]

[0085] Fig. 15 to 17 illustrate schematically still another method to provide an insulating polymer panel.

[0101]

[0086] It is understood that in different figures, the same reference signs refer to the same or a similar feature.

[0102] Detailed Description of Embodiment(s)

[0103]

[0087] Figures 1 to 5 show the consecutive steps of a method to produce an insulating polymer panel 10. In figure 1 a top view of the first set 110 of an insulating polymer sheet 112 positioned over an intermediate polymer panel 111, and a cross section according to the plane AA’ of this insulating polymer sheet 112 positioned above an intermediate polymer panel 111 is shown. Hence an insulating polymer sheet 112, and an intermediate polymer panel 111 are provided. Both may be provided by injection molding techniques.

[0104]

[0088] The insulating polymer sheet 112 comprises a number of blocks 201 of insulating material, in this embodiment expanded polypropylene. The bases 206 of the blocks are identical and coplanar to each other. These are distributed according to amatrix pattern on a polypropylene sheet 202. The intermediate polymer panel 111 comprises a base plate 101 on which substantially vertical wall 106 are provided, defining cells 103 distributed with the same pattern over the inner surface of the base plate 101. The cells in this embodiment each have the same rectangular open tops 105 defined by the edges 106 of the walls 102. The cells have a cuboid inner void space 104, with inner surfaces 107.

[0105]

[0089] The blocks 201 have a basis identical to the open tops 105, and have a regular cuboid shape as well. The dimensions of the inner void space 104 and the blocks 201 are substantially identical, although the height of the faces 204 of the blocks 201 are about 1 mm less than the height of the inner surfaces 107 of the cells 103. Between the blocks, open areas 203 are provided to accommodate the walls 102 of the cells 103.

[0106]

[0090] Once the insulating polymer sheet 112 is positioned over an intermediate polymer panel 111 with the blocks outer ends 205 directed towards the open tops 105 of the cells 102, as shown in figure 1 , the blocks 201 of the insulating polymer sheet 112 are simultaneously pushed into the inner void spaces 104 of the cells 102 through the open tops 105 as indicated with arrow 1001.

[0107]

[0091] As such a first intermediate polymer panel 301 is provided, of which a top view and a cross section according to the plane BB’ is shown in figure 2.

[0108]

[0092] the blocks 201 fit snuggly in the cell 103 when the blocks are sunken, i.e. pushed, in the cells.

[0109]

[0093] Friction forces between the faces 204 of the blocks 201 and the inner surfaces 107 of the cells 102 prevent the blocks 201 to fallout of the cell 103 when the so obtained intermediate filled polymer panel 301 is manipulated, and turned upside down, is shown in figure 3. The sheet 202, or film, may still be adhering to the bases 206 of the blocks, and may be tensioned over the edges 106 of the walls 102.

[0110]

[0094] After a second intermediate filled polymer panel 302 is provided in the same way at the first intermediate polymer panel 301 , and after the removal of the sheets 202, the first or second, in this embodiment the first intermediate filled polymer panel 301 is turned upside down as shown in figure 3. Between the outer edges 106 of the walls 102 of both intermediate polymer panels 111 and 121, a heating mirror 400 is provided to heat and partially or fully melt the edges 106 of the walls 102 of the cells103 of the intermediate polymer panels 111 and 121 of both intermediate filled polymer panels 301 and 302.

[0111]

[0095] As shown in figure 4, the heating mirror 400 is removed from between the intermediate filled polymer panels 301 and 302. Both having melted, hence sticky edges 106 at the outer ends of the cells 102. These melted, hence sticky edges 106 at the outer ends of the cells 102 are brought together by moving the two intermediate filled polymer panels 301 and 302 towards each other as indicated with arrow 1002. The molten edges are pushed one to the other and cooled to bind the intermediate filled polymer panels 301 and 302 one to the other, thereby forming the insulating polymer panel 10, a cross section of which is shown in figure 5.

[0112]

[0096] As shown somewhat exaggerated for the sake of clarity, at the interface of the outer ends 205 of the blocks 201 of both intermediate filled polymer panels 301 and 302, these outer ends 205 are free of adhering one to the other. Possibly, in case the dimensions are chosen such that the height of the inner void space 104 is slightly larger than the height of the faces 204 of the blocks 201 , a minor gap 303 may be provided between corresponding blocks in the two intermediate filled polymer panels 301 and 302. This non-linked or non-bond locks facilitate to some extent further the recycling of the insulating polymer panel 10, as smaller blocks or volumes of polymer material are to be treated, usually comminuted during the recycle process.

[0113]

[0097] In figures 6 and 7, two alternative insulating polymer sheet 113 respectively 114 are shown. Both alternative insulating polymer sheet 113 respectively 114 each comprises a number of blocks 201 of insulating material, in this embodiment expanded polypropylene. The bases 206 of the blocks are identical and coplanar to each other. The bases in figure 6 are held on a slit film 222 and are distributed according to a matrix pattern on this slit film. The bases in figure 7 are held on a perforated film 232 and are distributed according to a matrix pattern on this perforated film 232. The perforated film comprises bridges 233 in both width and length of the insulating polymer sheet 114, which bridges bridge the adjacent blocks and as such bind and hold these together in the wanted pattern. Both slit film 222 and perforated film 232 may be provided from polypropylene. Both slit film 222 and perforated film 232 may remain present after the insulating polymer sheet 113 respectively 114 is pressed in the intermediate polymer panel, and may remain present in the mirror welding step.

[0098] In figures 8 to 11 , a further alternative insulating polymer sheet 115 is used in the production of a insulating polymer panel according to the invention. Although the steps to provide the insulating polymer panel 11 are basically identical to the ones as set out in relation to figures 1 to 5, the insulating polymer sheet 115 comprises blocks 201 which are held in pattern one to the other by another holding principle. During injection molding of the insulating polymer sheet 115, i.e. while the blocks 201 are molded in the mold, between the mold cavities a thin slit is left open, such polymer material injected can pass or seep through these slits. This causes the blocks to be connected by thin bridges 210 of polymer. These bridges 210 or links are provided preferably along the height of the faces 204 of the blocks, e.g. about halfway between the basis 206 and the outer end 205.

[0114]

[0099] The insulating polymer sheet 115 is pushed into the intermediate polymer panel in a direction 1001 , to provide the intermediate filled polymer panel 311 as is shown in figure 10. As is made visible in the detail C, during pressing the blocks in the open void spaces of the cells, the bridge 210 is ruptured in two pieces, which pieces are gripped between the face side 204 of the block 201 and the inner surface 107 of the wall 102. These tiny pieces may function as barbs, and prevent the block 201 to slide out of the void space 104 again. They do increase the friction force and thereby allow the use of blocks with larger tolerances as to the dimensions of the blocks.

[0115]

[0100] In the same way as shown in figures 3, 4 and 5, two intermediate filled polymer panel 311 may be thermally welded one to the other using mirror welding, providing insulating polymer panels similar as the insulating polymer panel 10.

[0116]

[0101] In figure 10, in the same way as in figure 8, two insulating polymer sheets 115 are used in the production of a insulating polymer panel according to the invention.

[0117]

[0102] Two identical insulating polymer sheets 115 are provided side by side over one intermediate polymer panel 111. In this embodiment each of the two identical insulating polymer sheets 115 together cover the whole surface of this intermediate polymer panel 111, and each of the two insulating polymer sheets 115 will used to provide the insulation in half of the cells of the intermediate polymer panel 111, e.g. one insulating polymer sheet 115 being pushed in the one, e.g. the left half of the intermediate polymer panel 111 , the other insulating polymer sheet 115 being pushed in the other, e.g. the right half of the intermediate polymer panel 111. All further steps are identicalto steps described in view of figures 1 to 5. The result is an insulating polymer panel similar as the insulating polymer panel 10 and 11.

[0118]

[0103] In a further embodiment of the method of the invention, as shown in figures 12 to 14, alternative intermediate filled polymer panels 312 and 313 are provided. As shown in figure 12, three insulating polymer sheets 116, optional mutually different in height or insulation material or density and / or thermal insulation properties, are provided one on top of the other over one intermediate polymer panel 111. As an example, each of the insulating polymer sheets 116 is of the type as described in figure 9. As shown in figures 13, the three insulating polymer sheets 116 are all pushed in the void spaces of the cells after being positioned over the intermediate polymer panel 111. They may be pushed into the void spaces simultaneously ore one by one, to provide the intermediate filled polymer panel 312. As a mere example, another intermediate filled polymer panel 313 is provided by providing only two insulating polymer sheets 116 in an intermediate polymer panel 112.

[0119]

[0104] As shown in figure 13 and 14, after having heated the edges of the two intermediate filled polymer panels 312 and 313 by mirror welding, the two intermediate filled polymer panels 312 and 313 may be connected by bringing the molten edges together and allow to cool. As such the insulating polymer panels 12 similar as the insulating polymer panel 10 may be provided.

[0120]

[0105] In still a further embodiment of the method of the invention, as shown in figures 15 to 17, alternative intermediate filled polymer panels 314 and 315 are provided. As shown in figure 15, three insulating polymer sheets 117, 118 and 119, optional mutually different in height, are provided one on top of the other over one intermediate polymer panel 111. As an example, each of the insulating polymer sheets 117, 118 and 119 is of the type as described in figure 9. In insulating polymer sheet 117, two spaces 230 in the block patten are not provide with a block. The bridge over this open space 230 is larger to connect the blocks aside this open space 230. In insulating polymer sheet 118, two rows of blocks indicated 251 are provided from more dense expanded PP. In insulating polymer sheet 118, one row of blocks indicated 252 is provided from less dense expanded PP. It is clear that instead of rows, also locally some blocks may differ from the other.

[0106] As shown in figures 15, the three insulating polymer sheets 117, 118 and 119 are all pushed in the void spaces of the cells after being positioned over the intermediate polymer panel 111. They may be pushed into the void spaces simultaneously ore one by one, to provide the intermediate filled polymer panel 314. As a mere example, another intermediate filled polymer panel 315 is provided by providing only two insulating polymer sheets 120 in an intermediate polymer panel 112.

[0121]

[0107] As shown in figure 16 and 17, after having heated the edges of the two intermediate filled polymer panels 314 and 315 by mirror welding, the two intermediate filled polymer panels 314 and 315 may be connected by bringing the molten edges together and allow to cool. As such insulating polymer panels 13 similar as the insulating polymer panel 10, 11 and 12 may be provided. This polymer panel may have locally different thermal insulating properties dependent the presence locally of a more or less dense block or blocks of insulation material, or even the absence of insulation material.

[0122]

[0108] Although the present invention has been illustrated by reference to specific embodiments, it will be apparent to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied with various changes and modifications without departing from the scope thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. In other words, it is contemplated to cover any and all modifications, variations or equivalents that fall within the scope of the basic underlying principles and whose essential attributes are claimed in this patent application. It will furthermore be understood by the reader of this patent application that the words "comprising" or "comprise" do not exclude other elements or steps, that the words "a" or "an" do not exclude a plurality, and that a single element may fulfil the functions of several means recited in the claims. Any reference signs in the claims shall not be construed as limiting the respective claims concerned. The terms "first", "second", third", "a", "b", "c", and the like, when used in the description or in the claims are introduced to distinguish between similar elements or steps and are not necessarily describing a sequential or chronological order. Similarly, the terms "top", "bottom","over", "under", and the like are introduced for descriptive purposes and not necessarily to denote relative positions. It is to be understood that the terms so used are interchangeable under appropriate circumstances and embodiments of the invention are capable of operating according to the present invention in other sequences, or in orientations different from the one(s) described or illustrated above.

Claims

- 23 -CLAIMS1.- A method to produce an insulating polymer panel (10), the method comprises the steps:- providing a first and a second intermediate polymer panel (111, 121), each comprising a base plate (101) on which upstanding walls(102) are provided, said walls defining a number of cells (103) with a void inner space (104) and an open top (105), the cells being distributed over the base plate according to a pattern (130);- providing for at least one of the first and second intermediate polymer panel, a number of blocks (201 ) of insulating polymer material, the number of blocks being equal to or less than the number of cells of this at least one of the first and second intermediate polymer panel, said blocks each have two identical and parallel bases and one mantle face between the two bases, for each cell a block is provided for which the bases match the open top of the cell;- for this at least one of the first and second intermediate polymer panel, inserting this number of blocks (201 ) in this at least one of the first and second intermediate polymer panel such the blocks are sunken in the cells to provide at least one intermediate filled polymer panels (301 , 302) comprising this at least one of the first and second intermediate polymer panel,- connecting the edges (106) of the walls (102) of the first intermediate polymer panel to the edges of the walls of the second the intermediate polymer panel.2.- A method to produce an insulating polymer panel (10) according to claim 1 , wherein the blocks of the first number of blocks are interconnected.3.- A method to produce an insulating polymer panel (10) according to any of the claims 1 to 2, wherein the blocks of the first number of blocks are provided as parts of an insulating polymer sheet (112).4.- A method to produce an insulating polymer panel (10) according to any of the claims 1 to 3, wherein the method comprises- providing for the first intermediate polymer panel, a first number of blocks (201) of insulating polymer material equal to or less than the number of cells of this first intermediate polymer panel, said blocks each have two identical and parallel bases and one mantle face between the two bases, for each cell a block is provided for which the bases match the open top of the cell;- providing for the second intermediate polymer panel, a second number of blocks (201) of insulating polymer material, the second number of blocks being equal to or less than the number of cells of this second intermediate polymer panel, said blocks each have two identical and parallel bases and one mantle face between the two bases, for each cell a block is provided for which the bases match the open top of the cell;- Inserting the first number of blocks (201 ) in the first intermediate polymer panels (111) such the blocks are sunken in the cells to provide an intermediate filled polymer panels (301) comprising this first intermediate polymer panel;- Inserting the second number of blocks (201) in the second intermediate polymer panels (121) such the blocks are sunken in the cells to provide an intermediate filled polymer panels (302) comprising this second intermediate polymer panel;5.- A method to produce an insulating polymer panel (10) according to claim 4, wherein the blocks of the first number of blocks are equal to the blocks of the second number of blocks are identical.6.- A method to produce an insulating polymer panel (10) according to any of claims 4 to 5, wherein the blocks of the second number of blocks are interconnected.7.- A method to produce an insulating polymer panel (10) according to claim 6, wherein the blocks of the second number of blocks are provided as parts of an insulating polymer sheet (122).8.- A method to produce an insulating polymer panel (10) according to any of the claims 4 to 7, wherein blocks of the first number of blocks are identical to the blocks of the second number of blocks.9.- A method to produce an insulating polymer panel (10) according to claim 8, wherein the cells of the first and second intermediate polymer panel are identical.10.- A method to produce an insulating polymer panel (10) according to claim 9, wherein the height of the face is less than or equal to the depth of the cell.11.- A method to produce an insulating polymer panel (10) according to any of the claims 9 to 10, wherein the intermediate polymer panels of the sets of an intermediate polymer panel and an insulating polymer sheet, have cells with a pattern such each edge of a wall of the first of the two intermediate polymer panels contacts edge of a second of the two intermediate polymer panels when the intermediate filled polymer panels stacked with open side cells to each other.12.- A method to produce an insulating polymer panel (10) according to any of the claims 9 to 11 , wherein the cells have a depth, the height of the faces of the blocks being less than the depth of the cells.13.- A method to produce an insulating polymer panel (10) according to any of the claims 9 to 12, wherein the first and / or the second number of blocks are provided as parts of a plurality of insulating polymer sheet (122), the plurality of insulating polymer sheets are inserted in the first and / or the second intermediate polymer panels, the plurality of insulating polymer sheets being stacked one on top of the other in the intermediate polymer panel or panels.14.- A method to produce an insulating polymer panel (10) according to any of the claims 9 to 13, the first and / or the second number of blocks are provided as parts of a plurality of insulating polymer sheet (122), the plurality of insulating polymer sheets are are positioned one adjacent the other in the intermediate polymer panel or panels.15.- A method to produce an insulating polymer panel (10) according to any of the claims 9 to 14, wherein the cells have a polygonal open top.16.- A method to produce an insulating polymer panel (10) according to any of the claims 9 to 15, wherein the step of inserting the insulating polymer sheets (112, 122) in the intermediate polymer panels (111, 121) comprises pushing the insulating polymer sheets (112, 122) in the intermediate polymer panels (111, 121).- 26 -17.- A method to produce an insulating polymer panel (10) according to any of the claims 9 to 16, wherein the insulating polymer sheets are injection molded sheets.18.- A method to produce an insulating polymer panel (10) according to any of the claims 9 to 17, wherein the insulating polymer sheets are provided from expanded polymer.19.- A method to produce an insulating polymer panel (10) according to any of the claims 9 to 18, wherein the intermediate polymer panels are injection molded panels.20.- A method to produce an insulating polymer panel (10) according to any of the claims 9 to 19, wherein the bases of the blocks are connected to each other by a polymer film.21.- A method to produce an insulating polymer panel (10) according to any of the claims 9 to 20, wherein the bases of the blocks are connected by polymeric bridges between the faces of adjacent blocks.22.- A method to produce an insulating polymer panel (10) according to any of the claims 9 to 21 , wherein connecting the edges of the walls of the intermediate polymer panels is done by thermal welding of the edges of cells of the intermediate polymer panels.23.- An insulating polymer panel (10), comprising two outer base plates and a cellular structure between these base plates, the cells being delimited by the base plates and walls between the base plates, each wall comprising a first and a second wall part, the first wall part being connected to the first base plate, the second wall part being connected to the second base plate, said two wall parts being connected one to the other at a connection along a connection line, the insulation in some or all of the cells of the cellular structure comprises at least a first volume, said first volume being present in the cell between the first base plate and the connection line.24.- An insulating polymer panel according to claim 24, wherein the insulation in some or all of the cells of the cellular structure comprises at least a second volume, the second volume being present in the cell between the second base plate and the connection line.- 27 -25.- An insulating polymer panel according to claim 24, wherein said first and a second volume being mutually separated one from the other.

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