U.S. patent application number 10/402344 was filed with the patent office on 2004-04-22 for vacuum insulation panels and method for making same.
This patent application is currently assigned to Advantek, Inc.. Invention is credited to Nelson, Bryan Peter, Olson, Eric Scott.
Application Number | 20040074208 10/402344 |
Document ID | / |
Family ID | 32094267 |
Filed Date | 2004-04-22 |
United States Patent
Application |
20040074208 |
Kind Code |
A1 |
Olson, Eric Scott ; et
al. |
April 22, 2004 |
Vacuum insulation panels and method for making same
Abstract
A method of forming an insulation panel with an insulating core
sealed within an envelope. The envelope formed from a single sheet
of highly flexible material with a pair of opposing edge portions
sealed together contiguously along the entire respective lengths
thereof to form a sleeve with a single and two open ends. The
sleeve may be folded to define sides. A longitudinal pleat may be
formed in at least one of the sides of the envelope. One open end
is sealed to form an envelope and a core of insulation material is
inserted. The remaining open end is sealed and the envelope is
evacuated.
Inventors: |
Olson, Eric Scott;
(Shorewood, MN) ; Nelson, Bryan Peter; (Chaska,
MN) |
Correspondence
Address: |
VIDAS, ARRETT & STEINKRAUS, P.A.
6109 BLUE CIRCLE DRIVE
SUITE 2000
MINNETONKA
MN
55343-9185
US
|
Assignee: |
Advantek, Inc.
|
Family ID: |
32094267 |
Appl. No.: |
10/402344 |
Filed: |
March 28, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10402344 |
Mar 28, 2003 |
|
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|
09580841 |
May 30, 2000 |
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Current U.S.
Class: |
52/794.1 |
Current CPC
Class: |
F16L 59/065 20130101;
B65D 81/3897 20130101; Y02B 80/10 20130101; B65D 81/3823 20130101;
Y02A 30/242 20180101; E04B 1/803 20130101; Y02B 80/12 20130101 |
Class at
Publication: |
052/794.1 |
International
Class: |
E04C 002/34 |
Claims
What is claimed is:
1. A vacuum insulation panel made by a process comprising steps of:
providing a core portion from a quantity of insulation material,
said core portion shaped as a generally rectangular polyhedron with
a top, a bottom, a pair of opposing side surfaces, and a pair of
opposing end surfaces; sealing together 2 opposing margins of a
rectangular sheet of flexible material to form a sleeve having a
pair of opposing open ends, only one longitudinal seam, and
presenting a longitudinal axis therethrough, each open end having a
periphery, said sleeve adapted to closely conform to the top,
bottom, and side surfaces of the core portion when the core portion
is inserted therein; forming at least one pair of inwardly directed
opposing creases in the sleeve, said creases being oriented
substantially parallel with the longitudinal axis of the sleeve and
dividing the periphery of each open end into a top portion and a
bottom portion; sealing one of the open ends of the sleeve by
sealing together the top and bottom portions of the periphery in a
flanged seam with the creases folded inward; inserting core portion
of insulation material into the sleeve through the remaining open
end, said core portion positioned with substantially all of one of
the end surfaces of the core portion confronting the inner surface
of the sealed end of the sleeve; sealing the remaining open end of
the sleeve by sealing together the top and bottom portions of the
periphery in a flanged seam with the creases folded inward, thereby
forming an envelope enclosing the core portion; evacuating the
envelope to a predetermined amount of vacuum, thereby causing the
envelope to closely conform to essentially all surfaces of the core
portion.
2. The panel of claim 1, wherein the flexible material is a
metalized polymer film.
3. The panel of claim 1, wherein the flexible material is a
polyester laminate.
4. The panel of claim 1, wherein the flexible material has
thermally insulating properties.
5. The panel of claim 1, wherein the core portion is formed from
open-celled polystyrene foam.
6. The panel of claim 1, wherein said insulation panel has at least
one aperture defined therethrough, said at least one aperture being
formed by process steps of: forming an aperture through the core
portion extending through the top and bottom surfaces, said
aperture having a periphery and an inwardly facing surface; forming
a pair of opposing apertures in the sleeve portion, said apertures
aligned with the aperture in the core portion, each aperture having
a periphery smaller than the periphery of the aperture in the core
portion; and joining and sealing together the peripheries of the
pair of opposing apertures in the sleeve so that the sleeve
substantially conforms with the inwardly facing surface of the
aperture in the core portion.
7. A vacuum insulation panel made by a process comprising steps of:
forming a plurality of elongate core portions from a quantity of
insulation material, said core portions shaped as regular elongate
polyhedrons with a top, a bottom, a pair of opposing side surfaces,
and a pair of opposing end surfaces, each core portion presenting a
longitudinal axis substantially parallel with the side surfaces;
sealing together opposing margins of a rectangular sheet of
flexible material to form a sleeve having a pair of opposing open
ends and presenting a longitudinal axis therethrough, each open end
having a periphery; forming at least one pair of inwardly directed
opposing creases in the sleeve, said creases being oriented
substantially parallel with the longitudinal axis of the sleeve and
dividing the periphery of each open end into a top portion and a
bottom portion; sealing one of the open ends of the sleeve by
sealing together the top and bottom portions of the periphery in a
flanged seam with the creases folded inward; inserting the core
portions into the sleeve through the remaining open end, said core
portions positioned adjacent side-to-side with the longitudinal
axis of the core portions transverse to the longitudinal axis of
the sleeve, and with substantially all of the side surface of the
innermost core portion confronting the inner surface of the sealed
end of the sleeve; sealing the remaining open end of the sleeve by
sealing together the top and bottom portions of the periphery in a
flanged seam with the creases folded inward, thereby forming an
envelope enclosing the plurality of core portions; evacuating the
envelope to a predetermined amount of vacuum, thereby causing the
envelope to closely conform to essentially all surfaces of the core
portions.
8. The panel of claim 7, wherein the side surfaces of each core
portion are positioned at an angle with respect to the top and
bottom surfaces.
9. The panel of claim 8, wherein the sum of the angles of the side
surfaces for all core portions in said plurality equals 360
degrees.
10. The panel of claim 7, wherein the flexible material is a
metalized polymer film.
11. The panel of claim 7, wherein the flexible material is a
polyester laminate.
12. The panel of claim 7, wherein the flexible material has
thermally insulating properties.
13. The panel of claim 7, wherein the core portion is formed from
open-celled polystyrene foam.
14. The panel of claim 7, wherein said insulation panel has at
least one aperture defined therethrough, said at least one aperture
being formed by process steps of: forming an aperture through at
least one of the core portions extending through the top and bottom
surfaces, said aperture having a periphery and an inwardly facing
surface; forming a pair of opposing apertures in the sleeve
portion, said apertures aligned with the aperture in the core
portion, each aperture having a periphery smaller than the
periphery of the aperture in the core portion; and joining and
sealing together the peripheries of the pair of opposing apertures
in the sleeve so that the sleeve substantially conforms with the
inwardly facing surface of the aperture in the core portion.
15. A process for making a vacuum insulation panel comprising steps
of: forming a core portion from a quantity of insulation material,
said core portion shaped as a rectangular polyhedron with a top, a
bottom, a pair of opposing side surfaces, and a pair of opposing
end surfaces; sealing together opposing margins of a rectangular
sheet of flexible material to form a sleeve having a pair of
opposing open ends and presenting a longitudinal axis therethrough,
each open end having a periphery, said sleeve adapted to closely
conform to the top, bottom, and side surfaces of the core portion
when the core portion is inserted therein; forming at least one
pair of inwardly directed opposing creases in the sleeve, said
creases being oriented substantially parallel with the longitudinal
axis of the sleeve and dividing the periphery of each open end into
a top portion and a bottom portion; sealing one of the open ends of
the sleeve by sealing together the top and bottom portions of the
periphery in a flanged seam with the creases folded inward;
inserting the core portion into the sleeve through the remaining
open end, said core portion positioned with substantially all of
one of the end surfaces of the core portion confronting the inner
surface of the sealed end of the sleeve; sealing the remaining open
end of the sleeve by sealing together the top and bottom portions
of the periphery in a flanged seam with the creases folded inward,
thereby forming an envelope enclosing the core portion; evacuating
the envelope to a predetermined amount of vacuum, thereby causing
the envelope to closely conform to all surfaces of the core
portion.
16. A process for making a vacuum insulation panel comprising steps
of: forming a plurality of elongate core portions from a quantity
of insulation material, said core portions shaped as regular
elongate polyhedrons with a top, a bottom, a pair of opposing side
surfaces, and a pair of opposing end surfaces, each core portion
presenting a longitudinal axis substantially parallel with the side
surfaces; sealing together opposing margins of a rectangular sheet
of flexible material to form a sleeve having a pair of opposing
open ends and presenting a longitudinal axis therethrough, each
open end having a periphery; forming at least one pair of inwardly
directed opposing creases in the sleeve, said creases being
oriented substantially parallel with the longitudinal axis of the
sleeve and dividing the periphery of each open end into a top
portion and a bottom portion; sealing one of the open ends of the
sleeve by sealing together the top and bottom portions of the
periphery in a flanged seam with the creases folded inward;
inserting the core portions into the sleeve through the remaining
open end, said core portions positioned adjacent side-to-side with
the longitudinal axis of the core portions transverse to the
longitudinal axis of the sleeve, and with substantially all of the
side surface of the innermost core portion confronting the inner
surface of the sealed end of the sleeve; sealing the remaining open
end of the sleeve by sealing together the top and bottom portions
of the periphery in a flanged seam with the creases folded inward,
thereby forming an envelope enclosing the plurality of core
portions; evacuating the envelope to a predetermined amount of
vacuum, thereby causing the envelope to closely conform to
essentially all surfaces of the core portions.
17. A method of manufacturing a vacuum insulation panel comprising
the steps of: providing a laminate sheet with two opposing edge
portion; joining the two edge portions defining a seam thereby
forming a sleeve with only one seam and two open ends; sealing one
of the two open ends to form an envelope with a closed end;
inserting a core of insulation material into the open end until it
abuts against the closed end; sealing the open end and evacuating
the envelope.
18. The method of claim 17 further comprising the step of providing
2 pairs of outward folds after joining the edge portions.
19. The method of claim 18 further comprising the step of providing
an inward fold within each of the pairs of outward folds.
Description
RELATED APPLICATION
[0001] This is a Continuation-in-Part of U.S. patent application
Ser. No. 09/580,841, filed on May 30, 2000, which is incorporated
herein in its entirety by reference.
TECHNICAL FIELD
[0002] This invention relates generally to vacuum insulation panels
and, more particularly, to a vacuum insulation panel constructed
with a gusseted receptacle.
BACKGROUND
[0003] Vacuum insulation panels are commonly used for storage and
shipping of heat sensitive items, such as perishable food products
and certain medical products. Such panels are conventionally
constructed with a core insulation material placed in a bag
constructed of a relatively thin flexible material having desirable
fluid barrier characteristics. Known bags for enclosing vacuum
panels are typically constructed with two identically sized
substantially flat, flexible, thin sheets of material placed one
atop the other with corresponding edges of the two sheets aligned.
The sheets are sealed together at the edges, forming a flange
entirely around the perimeter of the panel. A piece of core
insulation material is sandwiched between the two sheets,
approximately centrally within the area of the layered sheets. The
edges are vacuum-sealed in a conventional vacuum-imparting machine
commonly utilized in the art, thereby creating a vacuum insulation
panel having four flanged edges.
[0004] An example of such a conventional vacuum panel is depicted
herein and described more particularly with reference to FIG. 1, a
known vacuum insulation panel 100 is disclosed. Panel 100 is
created by two substantially identically sized sheets of a
relatively thin material (not shown prior to panel 100
construction) placed one atop the other with their corresponding
edges aligned and a piece of core insulation material sandwiched
therebetween. All edges of the sheets are then vacuum-sealed
together, resulting in four double thickness flaps or flanges 102,
104, 106, and 108, which flanges meet at the corners of the
conventional panel to produce a continuous perimeter flange,
protruding outwardly, ordinarily by at least one inch. Such
construction and outwardly protruding flanges, 102, 104, 106, and
108 in panel 100 are undesirable and amount to wasted material.
[0005] Prior to using such a known vacuum panel, each of the four
outwardly extending flanges is typically taped down to the surface
of the panel, in an effort to achieve continuous even panel edges
and surfaces. Taping the flanges, however, requires a considerable
amount of time and labor and the extending area of the flanges
themselves requires excessive material. The taping of the panel
flanges also requires the panel to undergo additional handling
which is now unnecessary with the new device and method. Such
handling to tape up the flanges stresses the film and thus reduces
the useful life of the panel.
[0006] Furthermore, the taping imparts undesirable uneven edges and
surfaces to the panel, and only the top and bottom surfaces thereof
retain the desired substantially flat surface. When uneven panel
edge surfaces are mated against any other substantially planar
surfaces, such as the walls of a storage or shipping container,
undesirable gaps are usually left between the panel surfaces and
the container walls. Such gaps permit significant waste by heat
transfer therethrough. In this manner, the desired temperature of
the container formed with or having separations formed by the panel
is jeopardized, or at least made more expensive to attain and
maintain. Furthermore, subsequent to taping, a vacuum panel may
sometimes not meet the dimensional specifications necessary for a
particular container in which the panel is intended for use. In
such event, over-sized panels are usually force-fit into the walls
of a container whereby the overall integrity of the panel may be
compromised.
[0007] There is additionally a recurring problem of leaving
wrinkles in the vacuum seal of bags around panels constructed in
the above-mentioned manner. The sealing surfaces with such bags are
not necessarily flat and parallel with each other, which makes the
seals susceptible to wrinkles. These wrinkles lead to leaking,
compromising the vacuum inside the panel, which in turn results in
a loss of the panel's insulation characteristics and therefore a
considerable amount of undesired heat transfer through the
particular affected vacuum insulation panel. It is known that to
avoid the problem of wrinkling in the course of forming the vacuum
seal during the conventional panel construction process, such bags
must also be oversized, length-wise, thereby further increasing the
amount of wasted material. All of such wasted material in turn
increases the costs associated with manufacturing these vacuum
panels.
[0008] For end-users that do not require the flanges to be taped,
shipping finished conventional insulation panels is difficult and
cumbersome. The flanges protrude outwardly so that stacking them
snugly and compactly in a container for shipping induces stress in
the bag film covering the panels. Such stresses may harm the
overall integrity of the vacuum insulation panel.
[0009] Accordingly, it is desirable to have a vacuum panel with a
structure and a method of manufacturing thereof that overcomes one
or more of the problems discussed above.
SUMMARY OF THE INVENTION
[0010] The new vacuum insulation panel includes a bag (receptacle)
constructed of flexible insulation material. The bag has only one
longitudinal scam and contains a core of insulation material in an
interior space thereof. The bag is vacuum sealed whereby air
communication between the interior space and the exterior thereof
is substantially restricted. Any flanges which remain on the new
bag are capable of lying down and substantially confirming to one
or more of the surfaces and edges of the vacuum panel, whereby all
surfaces and edges of the panel are substantially smooth and
even.
[0011] The new gusseted bag used with at least some embodiments of
the new panel is uniquely created from a single continuous
rectangular sheet of relatively thin, flexible film, which
preferably has some fluid barrier characteristics. Two opposed
edges of the flexible sheet are folded over and sealed together,
thereupon leaving two opposed open ends. One open end is sealed
with a formed gusset, thereby creating a bag with one open end,
like a large envelope. A core sheet or block of insulation material
is inserted into the bag through the open end, and the open end is
then vacuum-sealed, preferably with a formed gusset, in a
vacuum-imparting sealing machine. The vacuum insulation panel thus
created has only three flanges. The three flanges all naturally
conform, by virtue of the gussets, to the panel edges or a flat
surface of the core insulation material, thereby facilitating ease
of use, for example in containers for shipping or storage of heat
sensitive items, or for neatly stacking together a plurality of
such panels for storage and shipping of the panels.
[0012] The construction of a gusseted bag according to the instant
invention requires less time and material, thereby reducing
manufacturing and labor costs. The specific bag construction also
considerably reduces the problem of wrinkling of the bag material
as the vacuum is pulled on the container/bag. The end shape of a
new pane or other insulating form made with the new gusseted bag is
neat and compact, without wide, loose flanges, so that the finished
vacuum panels can easily be stacked or packed tightly together for
shipping, and so will survive shipping much better than known
vacuum dividers.
[0013] Accordingly, in furtherance of the above objects and
advantages, the present invention is, briefly, an insulation panel
which is the combination of a receptacle and an insulating core
sealed within the receptacle. The receptacle is formed from a
single sheet of highly flexible material which is sufficiently
pliable to form the shape of a bag or envelope and which has a
first pair of opposite side edges sealed together contiguously
along the entire respective lengths thereof to form a seam. A first
side of the receptacle is disposed opposite to a second side,
substantially parallel to the seam and on opposite sides thereof.
First and second opposed ends of the receptacle are substantially
transverse to the sides and a longitudinal pleat is formed in at
least one of the first and second sides of the receptacle, which
pleat intersects with at least one of the first end and the second
ends of the receptacle in a gusseted configuration. The receptacle
defines an interior space and the gusseted edge(s) enhance the
final form of the insulation panel.
[0014] These and other advantages of the present invention will be
in part apparent and in part pointed out herein below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a perspective view of one example of a
conventional vacuum insulation panel.
[0016] FIG. 2 is a perspective view of a gusseted receptacle for a
vacuum panel constructed according to the teachings of the present
invention.
[0017] FIG. 3 is a perspective view, partially broken away, of a
vacuum insulation panel constructed in accordance with the present
invention and showing the core insulation material inside the
covering receptacle.
[0018] FIG. 4 is a perspective view of the vacuum insulation panel
of FIG. 3 with the gusseted edges thereof laid over to conform to
the edges and one flat surface of the panel.
[0019] FIG. 5A is a perspective view of a sheet of flexible
material for use in forming the gusseted bag or receptacle of the
insulation panel of FIG. 3.
[0020] FIG. 5B is a perspective view of the sheet illustrated in
FIG. 5A, during the first step of forming the gusset bag of FIG.
2.
[0021] FIG. 5C is a perspective view of the sheet of FIGS. 5A and
5B after the bag of FIG. 2 has been completely formed, and the core
insulation material inserted, but before application of the vacuum
to the panel.
[0022] FIG. 6 is a perspective view of an alternative embodiment of
an insulation panel constructed in accordance with and embodying
the present invention.
[0023] FIG. 7 is a perspective view of a further alternative
embodiment of the invention.
[0024] FIG. 8 is a still further alternative embodiment of the
invention.
[0025] Throughout the drawings like parts are indicated by like
element numbers.
DESCRIPTION OF PRACTICAL EMBODIMENTS
[0026] With reference to the drawings, and particularly referring
to FIGS. 2 and 3, there is shown a gusseted-style bag (or
"envelope" or "receptacle"), generally designated 10, constructed
in accordance with and embodying an aspect of the present
invention. The construction of gusseted bag or "receptacle" 10 is
preferably from a single continuous sheet (indicated, for example,
at S in FIG. 5A), and will be described in detail later herein. A
further aspect of the invention is the new insulation panel,
generally designated 12, which, in some embodiments, is formed with
the new gusseted receptacle 10 and a core of insulation material,
generally designated 11, in FIG. 3. In other embodiments shown in
the later figures, the core of new "panel" of the invention takes
other forms and the receptacle may or may not be gusseted, as will
be described further hereafter. It is to be understood that,
throughout this document, the term "gusset" or "gusseted" refers to
the triangular area of receptacle material formed at the ends of
panel edge pleats or folds in the new receptacle, for example as
indicted at element number 18 in FIG. 2. In some embodiments
described herein the gusseted feature will be optional, but the
longitudinal seam or "spine" 16 which is disposed substantially
parallel and between two opposed sides (20, 22) of the receptacle
will always be present. In this manner the new panels are formed
with at least two completely seamless outer side edges, for a
superior snug fit of the new panels within a container or storage
unit.
[0027] Receptacle 10 is formed of a thin, highly flexible
sheet-like material, which preferably has some fluid barrier
characteristics, preventing passage of most liquids and gasses, as
is the case with materials commonly used in the art for similar
purposes. The material of bag 10 is preferably a metalized
polyester of foil polyester laminate which are commonly available
commercially. Alternatively, bag 10 can be formed of a multi-layer,
polyester-based laminate of several different, non-foil barrier
layers such as that polyester film sold under the registered
trademark MYLAR, 200 RSBL 300.
[0028] In the panel 12 embodiment of FIG. 3, the insulation
material of which core 11 is formed is substantially rectangular in
shape and about one inch in thickness. Core 11 is constructed of a
generally low mass material commonly used in the art for insulation
purposes for optimum insulation by panel 12, such as open cell
polystyrene foam material which is readily commercially available.
One example of a suitable type of such foam is sold under the
product num XUS46243.04 by The Dow Chemical Company and has a
density of ASTM D 1622-93. However, it is recognized and
anticipated that the core insulation material may be of other
shapes, thickness and materials as desired or appropriate for a
particular application or use, and construction of a bag 10 in size
and shape can therefore be modified accordingly.
[0029] The general construction of receptacle 10 from a sheet,
generally designated S, of suitable flexible material, typically a
laminate as described above, is illustrated with reference to FIGS.
5A, 5B and 5C. As shown in FIG. 5A, sheet S is generally
rectangular, has two pairs of opposed edges, S1, S2 and S3, S4 with
corresponding opposing pairs of edge portions S1.1 and S2.1, S3.1
and S4.1.
[0030] As particularly depicted in FIG. 5B, opposing edges S3 and
S4, and edge portions S3.1 and S4.1 of sheet S are brought toward
each other and contiguously joined together, creating a flanged
seam 16 which extends preferably parallel to central longitudinal
axis a of sheet S, and creating a sleeve or loop with an open end
14 and an open end 15, to transverse to seam 16 and which
correspond to edges S1, S2 of sheet S. Referring to FIGS. 2, 5C,
flange 16a of seam 16 is folded over and against the surface of
sheet S, along the length thereof and is preferably sealed airtight
by heating and crimping together side edge margins or portions S3.1
and S4.1 to the top surface of sheet S. As shown in FIGS. 2 and 5C,
the flange of seam 16 lays substantially flush with the surface of
sheet S. The resulting flat profile of the top surface 28 of bag 10
improves the utility of bag 10 for creating a vacuum insulation
panel 12 having substantially smooth, continuous and even surfaces
and edges.
[0031] Sides 20 and 22 are formed by two pairs of outwardly
directed folds with the individual outward folds 20.2, 20.3, 22.2,
22.3 ultimately forming the corners 20.4, 22.4 of the sides.
Inwardly directed folds 20.6, 22.6 are placed intermediate the
outward folds on each side 20, 22, a longitudinal axis a.
[0032] As shown in FIGS. 2 and 5C, sides 20 and 22 of the folds
define inwardly directed pleats, one each on two opposed sides of
receptacle 10 (hidden from view) on sheet S. It is, however,
recognized and anticipated that a bag 10 according to the present
invention may be created with just one pleat on one side or with
more than one pleat on each side, or one pleat each on more than
one side, as necessary or appropriate for the dimensions of a
desired core insulation material in a particular embodiment. End
15, as depicted in FIG. 2, is then sealed in a substantially
airtight seal, including inward pleats 20 and 22 extending
therethrough, which results in a receptacle 10 with open end 14, a
gusset 18, and two pleated, but seamless sides 20 and 22, as shown
in FIGS. 2 and 5C. Gusset 18 results when sheet S is folded as
described above, when end 15 is sealed. The seal is preferably an
airtight seal created by heating and crimping or pressing together
a portion of end 15 of sheet S by known methods, such as pressures,
heat and vacuum sealing.
[0033] Receptacle 10, thus created, may be folded in a
substantially flat configuration with the creases or inward folds
20.6, 22.6 defining internally directed pleated sides 20 and 22 on
each side of receptacle 10, parallel to seam 16, and an externally
protruding flange 24 at the edge. Flange 24 is readily pressed flat
against an end of receptacle 10, substantially transverse to spine
16. Bag 10 in such substantially flat configuration may be stored
or shipped fairly conveniently in a stack of similar bags. Such a
flat form of bag 10 may be easily opened or expanded to insert a
core insulation material therein when desired. In the panel
embodiment of FIG. 3, gusseted end 15 is preferably sized such that
when expanded, bag 10 permits room therein sufficient only to
accommodate a piece of core insulation material having desired
pre-determined dimensions. For example, the core material may take
the forms shown in the alternative embodiments of FIGS. 6, 7 and 8,
described hereafter, or other useful forms, such as an oval or
triangular shaped board, or any useful shape, depending upon the
site of use, but is nevertheless formed in the same general
manner.
[0034] Referring further to FIG. 3, a vacuum insulation panel 12
having a bag 10 of FIG. 2 is shown. In particular, core 11 of
insulation material having predetermined dimensions and desired
insulation characteristics is inserted into an interior space 30
within bag 10 through open first end before bag 10 is sealed closed
as will be further described herein. Upon inserting the core
insulation material therein, bag 10 is placed in a vacuum-imparting
machine between two platens, in known manner. The vacuum imparting
machine preferably creates a substantial vacuum in interior space
30 of bag 10 and then seals end 14 of bag 10, creating gusset
(gusseted edge) 32 and a flat flange 34 in the process. In the
embodiment of FIG. 3, gusseted edge 32 is preferably substantially
identical to gusseted edge 18 previously created end 26 of bag 10.
It is anticipated that end 14 of bag 10 does not have to be (but
may be) sealed with a gusseted edge. End 14 may instead be sealed
with any type of edge or shape, as desired or economically feasible
for a particular application. End 14 may be made as an ordinary,
non-gusseted edge if pleats 20 and 22 are undone (or never formed)
at end 14 prior to sealing that end of receptacle 10.
[0035] Those skilled in the art will appreciate that all seals on
the bag must be airtight in order to preserve the vacuum inside bag
10, i.e. to prevent air communication between interior space 30 of
panel 12 and an exterior of panel 12, and to thereby ensure optimum
insulation characteristics of the new panel. The airtight seals
created by heating and crimping together the edges of the sheet 10
result in a considerably durable insulation panel. Of course, even
if the vacuum under which panel 12 is preferably formed is
breached, the materials of the panel still offer considerable
insulation characteristics.
[0036] By virtue of the vacuum formed therein, bag 10 assumes the
shape of the comparatively rigid core 10 in interior space 30. The
only exceptions are flange 34 at end 14 and flange 24 at end 26 of
panel 12. Flange 24 and finally closed end 34 can simply be folded
over, flush with the outer surface of panel 12 to prevent a very
smooth other panel for optimum use. By contrast, the outer edges
102, 104, 106, 108 of the conventional panel shown in FIG. 1 create
a distinct problem in trying to provide a snug fit of the panel
against a container wall or against another known panel.
[0037] As further visible in FIG. 3, gusseted edge 32 on end 14 and
gusseted edge 18 on end 26 of bag 10 fold inwardly in partial
pleats closely aligned with the corresponding end of core 11
therein, which partial pleats result from inwardly directed pleats
20 and 22 formed in ends 14, 15 of bag 10 prior to sealing the
respective edges. The ends of core 11 therefore essentially define
the limits and shape of corresponding ends 36 and 38 of panel 12.
These edges may be at 90 degrees to the plane of the surface of a
board or brick-shaped core, or may be mitered as necessary for the
purpose. This feature of the present invention is of significance
to reduce the likelihood of undesired gaps between adjoining vacuum
panels during use thereof.
[0038] A further feature of the instant invention, in embodiments
including gusseted flanges or seams, is the accommodation of
flanges 34 at edge of panel 12, and the accommodation of flange 16a
on surface 28 of panel 12. As shown in FIG. 4, all three flanges
16a, 24 and 34 are biased in one direction or the other, so as to
readily lie down, to substantially conform to an edge or a surface,
or both of panel 12. Specifically, flange 16a lays down flat, on
top surface 28 of panel 12, and flange 24 folds over edge 38 of
panel 12. In the embodiment of FIG. 3, flange 24 is preferably no
longer in length than approximately half the thickness of the core
insulation material. In such case, flange 24 will not extend beyond
edge 38 of panel 12 when it is pressed flat against the flat end of
the core material therein. As a result, therefore, and as visible
in FIG. 4, flange 24 conforms substantially with edge surface 38 of
panel 12 whereby it does not extend outwardly in an awkward and
rigid manner as flanges 102, 104, 106, and 108 on prior-art panel
100. Flange 34 similarly lays down naturally and folds over edge 36
(hidden from view) of panel 12. Typically, the length of flange 34
will be longer than the length of flange 24, and flange 36
therefore may extend beyond edge 36 of vacuum panel 12. In such
case, as shown in FIG. 4, such overlapping portion of flange 34
will lay flat against top surface 28 of panel 12.
[0039] While the embodiment described above is preferred, there are
conceived reasonable and useful variations thereof, as evidenced by
the embodiments described below and depicted in FIGS. 6, 7 and 8.
In each of the following embodiments the core and receptacle
materials are the same as those described above with reference to
the embodiments of FIGS. 2-5C, but the shapes and overall form of
the embodiments vary.
[0040] FIG. 6 illustrates an embodiment of the present invention
wherein an insulation panel, generally designated 50, is provided
with a substantially centrally located hole (as shown, but the
position of which could vary) which permits passage therethrough
for wires or tubing in a refrigeration unit, cooler, and/or other
temperature sensitive applications or markets. In this embodiment
the core material has the same characteristics as described for
core 11 above, but a substantially centrally located aperture is
provided in the substance of the core. It is to be understood that
the core of panel 50 may be formed as a single sheet or board of
insulation material with the described aperture, or may be formed,
for example, as shown, as two similarly sized sheets for pieces,
with arcuate cutouts located to align with each other the two
sheets are placed edge to edge. Similar to the embodiments above,
in this embodiment the core material may take other forms besides a
flat board shape. For example, it may be brick-shaped or
elliptical, as long is there is an opening sized appropriately for
passage therethrough of whatever wires or tubing are required for
the proposed use.
[0041] Panel 50, like the previous embodiments, includes a
receptacle, generally designated 52, which may be gusseted, as
previously described regarding FIG. 3, or may have simple, straight
sealed flanges as shown in FIG. 6. The concept of the core of panel
50 per se with a defined opening therein is considered to be one
aspect of the invention, as is the entire panel 50, with either a
gusseted of non-gusseted-style receptacle 52. In the embodiment
depicted in FIG. 6, it will be seen that receptacle 52 is also
formed with a substantially central opening 54, which opening has a
smaller dimension than the opening of the core material and is
aligned therewith, so that when finally vacuum sealed, as shown, a
circumferential flange 56 is formed internally of the core opening,
so that receptacle 52 in final normal useful form is air tight.
[0042] It is also seen in FIG. 6 that the core of the embodiment
shown has two substantially equal, mirror-image halves, as
previously described, because a central seam 58 is seen where
receptacle 52 is drawn between the two adjacent side edges of the
core and a slight wrinkle 60 is developed in two opposed sides of
the perimeter flange 62 of receptacle 50.
[0043] FIG. 7 illustrates another embodiment of the present
invention wherein the panel is formed as a square panel, actually
four panels formed into a topless, bottomless box, generally
designated 70, with appropriately mitered corners of the core, for
a snug fit of adjacent panels. The core boards of pieces 74 may be
equally sized or non-equally sized panels with ends cut at 45
degree angles (when there are four "sub-panels") and all such
sub-panels placed into one bag, for a continuous leak proof "panel"
shaped as a box once the sealing is complete. In this embodiment
the pleated/gusseted receptacle 72 is preferred for the most
efficient airtight insulation "container" panel.
[0044] When the single bag 72 is placed into a sealing machine for
forming the insulation panel/box 70, the four core pieces 74 are
laid end to end with the four mitered edged sub-panels are disposed
all within the bag, with the open angles of the corners facing in
the same direction, and positioned parallel to one another. When
the vacuum sealing of the panel 70 takes place and the platens are
separated, the panel 70 pulls generally into the box-shape or
square sided tube shown in FIG. 7, by virtue of the receptacle 72
material being forced into the corner seams between adjacent
panels, and the adjacent mitered corners being pulled toward each
other until touching. This drawing together of adjacent sub-panel
ends pulls panel 70 into a closed-sided, albeit open-ended box. In
order to enhance the smooth folding of the material of bag 72 down
into the longitudinal joint between adjacent cored sections, it is
preferred that bag 72 be provided with transverse pleats formed
spaced apart along the length of the bag so that the fold of the
pleats will naturally pull down into the joint. While hidden from
view in the figure, the ends of the bag pleats are preferred to be
gusseted, as described in more detail in reference to previous
embodiments, to further enhance the folding of the bag 70 as the
vacuum sealing takes place.
[0045] As panel 70 is formed a flange 76 is formed in receptacle 72
along each end (non-mitered side) of each sub-panel, which flange
76, as described in regard to previous embodiments, is preferably
not more than half as wide as the thickness of any sub-panel of
core 74. Flange 76 is depicted pulled away at the end closest to
the bottom of FIG. 7, for clarity of the invention, but naturally
and ordinarily lays flat. Any excess flange material at the
sub-panel ends where the mitered corners come together is folded
back into the panel in the folding process so that each end of
panel 70 is substantially flat, because the flanges 76 lay flush
against their respective core piece ends. A flap 78 of bag material
remains, which flap 78 represents the previously open end of
receptacle 70 prior to the sealing process, and may be taped down
if desired, so as to be flush with the outer surface of an adjacent
sub-panel. The formerly closed end of bag 70 is hidden from view in
this embodiment.
[0046] FIG. 8 illustrates another embodiment of the present
invention, which embodiment is effectively a variation of that of
FIG. 7, and wherein a single receptacle 92 contains under vacuum
seal a number of pre-cut core segments 94. Segments 94 may be
shaped as elongated slats as shown, or may be shorter and block
shaped, if preferred. Regardless of the overall shape, segments 94
are disposed at preselected angles, and are positioned side by side
to form a core having the shape of a cylinder, octagon, pentagon or
other desired shape which defines an opening for pass-through of
conduit, piping, wires, etc. Panel 90 may also be used to receive a
product for shipping or storage, or to insulate a pipe, for
example. Thus, for example if the core of panel 90 is formed of ten
equally sized segments, the segments or slats would each have sides
(longitudinal edges) mitered to 36 degrees, so that place
side-by-side longitudinally, they would form a tubular shaped, or
otherwise open-ended insulation "panel" substantially as that shown
in FIG. 8. The angled edges of core segments 94 are seen at the
ends of the sealed segments at the lower left of FIG. 8.
[0047] Like the previous embodiments, the core segments 94 of each
panel 90 are all sealed within a single receptacle 92, one end of
which may be sealed or unsealed prior to filling with the segments
and the other end of which is open until the sealing process takes
place. After the sealing process, which is in the previous
embodiment creates seams between adjacent segments, there remain
end flanges 96, 98, which can be readily folded inwardly, toward
the center of panel 90 and either taped or otherwise secured, or
left free within the central opening of the panel. If necessary or
desired flanges 96, 98 may also be trimmed to any suitable length.
Also, as in the prior embodiment of FIG. 7, the folds or pleats of
bag 92 which are drawn between the core slats 94 are preferred to
be gusseted so as to more readily pull in between the adjacent
surfaces of slats 94 so as to leave panel 90 with a relative smooth
outer surface, free from a plurality of extraneous flanges or other
material extensions which would interfere with stacking or tight
fight for use.
[0048] It will also be noted in FIG. 8 that there is seen the same
seam 16 and flange 16a which was described in relation to the
receptacle 10 of FIG. 2. It is to be understood that, although
sealed seam 16 is illustrated internally of panel 90, it can also
be placed prior to sealing so as to be external to the final formed
panel, as may be preferred depending upon the intended use of panel
90. In other words, the receptacle 92 for this embodiment can be
constructed exactly the same as bag 10, but the sections of core
material inserted therein prior to sealing are a series of slats
with beveled edges, instead of a single flat panel. The shape of
the slats causes the final panel 90 conformation after sealing of
the receptacle. This can also be the case with the embodiment of
FIG. 7, and even that of FIG. 6 (with the exception of adding the
aperture), except that the seam 16 is hidden between adjacent core
sections.
[0049] Accordingly, a vacuum panel according to most embodiments of
the instant invention has substantially smooth, continuous and even
exterior edges and surfaces, and any flanges or excess bag material
on the edges thereof lie substantially evenly with adjoining
similar panels or wall surfaces, for use in containers for storage
or transportation of heat sensitive items, thereby reducing the
likelihood of heat transfer therebetween. Ordinarily, with the
described construction it is not necessary to glue or tape the
receptacle flanges into a flat position, although if desired,
gluing or taping certainly can be used in addition to the natural
tendency of the flanges to lie flat, or to be simply folded over,
flush with an other surface of the corresponding panel.
[0050] The fact, in the embodiment of FIG. 3, that the three
flanges 16a, 24 and 34 conveniently conform to the edges and
surfaces of vacuum panel 12 facilitates ease of use thereof in
box-type containers for shipping or storage of heat sensitive items
or for neatly stacking together a plurality of such panels. The
flanges of the panel do not have to be taped over when implemented
in a box-type container to insulate the contents thereof because
the flanges do not extend outwards but instead fold over smoothly
in conformance with the surface and edges of the core insulation
material. As a result, a panel constructed with a gusseted bag has
four significantly flat surfaces and edges, while the folds on the
remaining two edges lay perfectly flat against the surface of the
core insulation material contained in the interior space of the
bag, whereby all six edges and surfaces of the panel are
substantially even and flat as is desirable.
[0051] The flat surfaces on the vacuum panels allow for superior
mating joints between adjoining panels due to the substantially
smooth and even edges and surfaces on each pane, which, as
discussed above, result in improved tolerance between adjoining
vacuum panels. There is very little opportunity for heat transfer
through the joints therebetween, especially if the panels are
pressed together by as much as a small force. In the relevant art,
this factor is a critical one in producing effective and efficient
insulated containers. Further, panels constructed according to the
present invention also make it considerably easier to meet the
overall dimensional specifications of end users.
[0052] A vacuum insulation panel according to the instant invention
reduces manufacturing time, which in turn reduces manufacturing and
labor costs associated therewith. Such panels also require less
material, which further reduces costs. In testing of the embodiment
of FIG. 3, average savings of about six percent in material were
accomplished over conventional vacuum panels containing identically
sized core insulation material therein. Further, vacuum panels
according to the instant invention require less post-manufacture
handling and thus less overhead costs. The bag according to the
instant invention also considerably reduces the occurrence of
wrinkling of the bag material. The sealed surfaces of the bag are
flat and straight by virtue of the gusted edges, and typically will
not wrinkle when sealed. Furthermore, a vacuum panel made with such
a gusted bag is similar to a brick in its compactness, in that the
finished vacuum panels can be easily stacked or packed for any kind
of shipping. As a result, the new gusseted bag vacuum panels
survive shipping in much better condition than do those previously
known.
[0053] Accordingly, a vacuum insulation panel constructed from a
gusseted bag requires less material to manufacture, has improved
seams, and provides better insulation when mated with like
insulation panels to divide of line the circumference of a
container for storage or shipping of temperature sensitive
items.
[0054] In view of the foregoing, it will be seen that several
objects of the invention are achieved and other advantages are
attained. Although the foregoing includes a description of the best
mode contemplated for carrying out he invention, various
modifications are conceivable. As various modifications could be
made in the constructions and methods herein described and
illustrated without departing from the scope of the invention, it
is intended that all contained in the foregoing description or
shown in the accompanying drawings shall be interpreted as
illustrative rather than limiting.
[0055] Other aspects, objects and advantages of the present
invention can be obtained from a study of the drawings, the
disclosure and the appended claims.
* * * * *