U.S. patent application number 12/227855 was filed with the patent office on 2009-09-24 for composite insulating panel.
Invention is credited to James Carolan, Gregory Flynn.
Application Number | 20090236074 12/227855 |
Document ID | / |
Family ID | 38319157 |
Filed Date | 2009-09-24 |
United States Patent
Application |
20090236074 |
Kind Code |
A1 |
Flynn; Gregory ; et
al. |
September 24, 2009 |
Composite Insulating Panel
Abstract
A composite insulating panel (17) comprises a profiled external
sheet (2) having a plurality of raised crowns (3) of generally
trapezoidal form, an inner liner sheet (4) and a body of insulating
foam (5) between the sheets (2, 4). The panel (1) has an integral
heat collecting means for transfer of heat from one source to
another. In one case there are inner conduit (21) through which a
heat transfer medium is circulated to extract heat from inside a
building and outer conduits (8) for collection of solar heat (9).
The panel (17) may be used as part of a heating/cooling/ventilation
system.
Inventors: |
Flynn; Gregory; (County
Louth, IE) ; Carolan; James; (County Cavan,
IE) |
Correspondence
Address: |
JACOBSON HOLMAN PLLC
400 SEVENTH STREET N.W., SUITE 600
WASHINGTON
DC
20004
US
|
Family ID: |
38319157 |
Appl. No.: |
12/227855 |
Filed: |
June 12, 2007 |
PCT Filed: |
June 12, 2007 |
PCT NO: |
PCT/IE2007/000057 |
371 Date: |
December 1, 2008 |
Current U.S.
Class: |
165/53 ; 165/165;
165/168 |
Current CPC
Class: |
Y02B 10/20 20130101;
Y02E 10/44 20130101; E04D 3/358 20130101; Y02E 10/40 20130101; E04D
3/352 20130101; F24S 20/66 20180501; F24S 80/60 20180501; E04D
3/357 20130101; F24S 70/60 20180501; Y02A 30/60 20180101; F24S
20/67 20180501; E04D 3/355 20130101; E04C 2/525 20130101 |
Class at
Publication: |
165/53 ; 165/168;
165/165 |
International
Class: |
F24H 9/06 20060101
F24H009/06; F28F 3/12 20060101 F28F003/12; F28D 7/00 20060101
F28D007/00 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 13, 2006 |
IE |
2006/0443 |
Mar 6, 2007 |
IE |
2007/0145 |
Claims
1-43. (canceled)
44. A composite insulating panel comprising a first sheet, a second
sheet, insulating foam between the first and second sheets, and
heat collecting means within the panel for transfer of heat from
one source to another.
45. The panel as claimed in claim 44 wherein the heat collecting
means comprises conduit means for containing a heat transfer
medium.
46. The panel as claimed in claim 45 wherein the conduit means
comprises a plurality of tubes extending through the panel.
47. The panel as claimed in claim 46 wherein the conduit means are
located adjacent to the first sheet.
48. The panel as claimed in claim 46 wherein the conduit means are
located adjacent to the second sheet.
49. The panel as claimed in claim 44 wherein the first sheet is
profiled to define a plurality of recesses, the heat collecting
means extending through at least portion of at least some of the
recesses.
50. The panel as claimed in claim 44 wherein the second sheet is
profiled to define a plurality of recesses, the heat collecting
means extending through at least portion of some of the crowns.
51. The panel as claimed in claim 49 wherein at least some of the
recesses contain the heat collection means.
52. The panel as claimed in claim 49 wherein conduit means extend
through at least some of the recesses.
53. The panel as claimed in claim 49 wherein at least some of the
recesses define a pathway for air circulation.
54. The panel as claimed in claim 49 wherein the recess defined by
at least some of the profile is substantially free of insulating
foam.
55. The panel as claimed in claim 49 wherein the recess is defined
by a crown formed in an external sheet of the panel.
56. The panel as claimed in claim 55 wherein the external sheet
comprises a plurality of laterally spaced-apart crowns.
57. The panel as claimed in claim 49 wherein the recess has a cross
sectional area of at least 0.002 m.sup.2.
58. The panel as claimed in claim 49 wherein the recess has a cross
sectional area of at least 0.0025 m.sup.2.
59. The panel as claimed in claim 49 wherein the recess has a cross
sectional area of approximately 0.003 m.sup.2.
60. The panel as claimed in claim 49 wherein the profile defining
the recess has an exposed surface, the width of the exposed surface
being from 150 mm to 200 mm.
61. The panel as claimed in claim 60 wherein the width of the
exposed surface is from 160 mm to 180 mm.
62. The panel as claimed in claim 60 wherein the width of the
exposed surface is about 170 mm.
63. The panel as claimed in claim 60 wherein the exposed surface
comprises an outer face and a pair of side faces which diverge
inwardly from the outer face.
64. The panel as claimed in claim 63 wherein the angle between the
outer face and each side face is from 115.degree. to
125.degree..
65. The panel as claimed in claim 64 wherein the angle between the
outer face and each side face is from 118.degree. to
123.degree..
66. The panel as claimed in claim 64 wherein the angel between the
outer face and each side face is about 121.degree..
67. The panel as claimed in claim 63 wherein the width of the outer
face is from 50 mm to 60 mm.
68. The panel as claimed in claim 67 wherein the width of the outer
face is about 55 mm.
69. The panel as claimed in claim 63 wherein the width of each side
face is from 50 mm to 60 mm.
70. The panel as claimed in claim 69 wherein the width of each side
face is about 57 mm.
71. The panel as claimed in claim 49 wherein the panel comprises at
least 3 crowns.
72. The panel as claimed in claim 49 wherein the panel comprises at
least 4 crowns.
73. The panel as claimed in claim 54 comprising a barrier between
the recess and the insulating foam.
74. The panel as claimed in claim 73 wherein the barrier extends
across the inwardly facing opening of the recess.
75. The panel as claimed in claim 73 wherein the barrier comprises
a seal.
76. The panel as claimed in claim 73 wherein the barrier comprises
a tape.
77. The panel as claimed in claim 44 wherein the panel comprises a
roof panel.
78. The panel as claimed in claim 44 wherein the panel comprises a
wall panel.
79. The panel as claimed in claim 44 wherein the panel comprise a
floor panel.
80. The heating or cooling system comprising at least one panel as
claimed in claim 44.
Description
INTRODUCTION
[0001] With increasing energy costs there is a need for optimizing
heat transfer to and from a building.
[0002] This invention is directed towards providing an improved
insulating panel which will address this issue.
STATEMENTS OF INVENTION
[0003] According to the invention there is provided a composite
insulating panel comprising a first sheet, a second sheet,
insulating foam between the first and second sheets, and heat
collecting means within the panel for transfer of heat from one
source to another.
[0004] In one embodiment the heat collecting means comprises
conduit means for containing a beat transfer medium. The conduit
means may comprise a plurality of tubes extending through the
panel. The conduit means may be located adjacent to the first sheet
and/or adjacent to the second sheet.
[0005] In one case the first sheet is profiled to define a
plurality of recesses, the heat collecting means extending through
at least portion of at least some of the recesses. Alternatively or
additionally the second sheet may be profiled to define a plurality
of recesses, the heat collecting means extending through at least
portion of some of the recesses.
[0006] Preferably at least some of the recesses contain the heat
collection means.
[0007] Conduit means may extend through at least some of the
recesses.
[0008] In one embodiment at least some of the recesses define a
pathway for air circulation.
[0009] The recess defined by at least some of the profiles may be
substantially free of insulating foam.
[0010] In one case the profile is formed in an external sheet of
the panel. The external sheet may comprise a plurality of laterally
spaced-apart crowns.
[0011] In a preferred embodiment the recess has a cross sectional
area of at least 0.002 m.sup.2, most preferably at least 0.0025
m.sup.2, and about 0.003 m.sup.2.
[0012] In one embodiment the recess has an exposed surface, the
width of the exposed surface being from 150 mm to 200 mm,
preferably from 160 mm to 180 mm, and about 170 mm.
[0013] In one embodiment the exposed surface comprises an outer
face and a pair of side faces which diverge inwardly from the outer
face.
[0014] The angle between the outer face and each side face may be
from 115.degree. to 125.degree., preferably from 118.degree. to
123.degree., and about 121.degree..
[0015] In one embodiment the width of the outer face is from 50 mm
to 60 mm. The width of the outer face may be about 55 mm.
[0016] In one embodiment the width of each side face is from 50 mm
to 60 mm. The width of each side face may be about 57 mm.
[0017] Preferably, the panel comprises at least 3 crowns. The panel
may comprise at least 4 crowns.
[0018] There may be a barrier between the recess and the insulating
foam. The barrier may extend across the inwardly facing opening of
the recess. The barrier may be a seal, a tape, or the like.
[0019] In one case the panel comprises a roof panel.
[0020] In another case the panel comprises a wall panel.
[0021] The panel may also be a floor panel.
[0022] The invention also provides a heating or cooling system
comprising at least one panel of the invention.
[0023] In one embodiment a heat transfer medium is circulated
through the panel. The heat transfer medium may be air.
[0024] The system may comprise duct means for collecting and
directing air which is passing through the panel. The system may
have air circulating means such as a fan for circulating air to or
from the panel or duct.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The invention will be more clearly understood from the
following description thereof given by way of example only, in
which:--
[0026] FIG. 1 is a cross sectional view of an insulating panel of
the invention;
[0027] FIG. 2 is an enlarged view of portion of the panel of FIG.
1;
[0028] FIG. 3 is a cross sectional view of an insulating panel
according to another embodiment of the invention;
[0029] FIG. 4 is a cross sectional view of a further panel
according to the invention;
[0030] FIG. 5 is a cross sectional view of a composite insulating
panel according to the invention;
[0031] FIG. 5(a) is a cross sectional view of another composite
panel;
[0032] FIG. 5(b) is an enlarged view of a crown of the panel of
FIG. 5;
[0033] FIGS. 6 and 7 are cross sectional views illustrating an
overlap joint between adjacent panels of FIG. 5;
[0034] FIG. 8 is a plan cross sectional view of a building
comprising a plurality of panels of the invention;
[0035] FIG. 9 is a cross sectional view of a top corner of the
building of FIG. 8; and
[0036] FIG. 10 is a cross sectional view of another corner of the
building of FIG. 8.
DETAILED DESCRIPTION
[0037] Referring to the drawings and initially to FIGS. 1 and 2
thereof there is illustrated an insulating panel according to the
invention which in this case is a roof panel 1. The roof panel 1
comprises a first sheet which in this case is a profiled external
sheet 2 which may be of painted galvanized steel. The profile
defines recesses. The profile in this case comprises a plurality of
raised crowns 3 which in this case are of generally trapezoidal
form and extend longitudinally along the length of the panel. The
panel also comprises a second sheet which in this case is an inner
metal liner sheet 4. There is insulating foam 5 between the inner
and outer sheets 2, 4.
[0038] The panel has an integral heat collecting means for transfer
of heat from one source to another. In this case the heat
collecting means are provided in the crowns 3 of the external sheet
which may be devoid of insulation 5. Conduits 8 in this case extend
through the crowns 3 and a heat transfer medium such as water is
circulated through the conduits 8. In this way solar heat
illustrated diagrammatically as 9 is transferred and used, for
example, to provide hot water for washing and the like. The heat
transfer medium may be any suitable fluid such as water,
refrigerant or anti-freeze solution. The conduits 8 run through the
roof in the external envelope of the building and the medium
absorbs solar energy. The warmed medium may be pumped back through
the system into the building to provide heat to the building space.
Once the medium passes through the building and transfers its
energy, it flows back to the roof conduit and the process is
repeated in a closed loop.
[0039] Referring to FIG. 3 there is illustrated another panel 20
according to the invention. In this case the heat collecting means
is in the form of conduits 21 through which a heat transfer medium
is circulated. The conduits 21 are in this case located adjacent to
the internal liner 4. The system may be used to extract heat 22
rising from the building, especially in environments where
equipment and machines give off heat, causing the internal
temperature to rise. This system can be used to help keep the
building cool in summer and heat it up in winter. In the
summertime, a coolant may be circulated. A valving system may be
provided to switch from heating to cooling cycles. Extracted heat
can be used as described above to heat a supply of hot water.
[0040] Referring to FIG. 4 there is illustrated another panel 17
according to the invention which is similar to the panels of FIGS.
1 to 3 and like parts are assigned the same reference numerals. In
this case there are inner conduits 21 through which a beat transfer
medium is circulated (for example to extract heat from inside a
building) and outer conduits 8 for collection of solar heat 9. Such
a system may be used as part of a heating/cooling/ventilation
system for a building.
[0041] Referring to FIGS. 5, 5b, 6 and 7 there is illustrated
another panel 29 according to the invention which is similar to the
panel of FIGS. 1 and 2 and like parts are assigned the same
reference numerals. In this case the recess is defined by the
crowns. Air is circulated through crowns 3 which are not filled
with insulating foam and thereby define passageways 19. The
circulating air is again heated by solar energy. This hot air is
captured and may be blown by small fans into the
heating/ventilation ductwork of the building, again assisting in
heating the building. The heated air may also or alternatively be
circulated through a heat exchanger for transfer of solar heat to
another heat collector. Another panel of this type is illustrated
in FIG. 5(a) but with smaller crowns 3.
[0042] Air is circulated through the crowns 3 which are not filled
with insulating foam. Such panels are usually manufactured by
leading the profiled outer sheet 2 along a flat bed with the
recesses defined by the crowns 3 facing upwards. The profiled sheet
is let to a lay-down area at which liquid foam reactants are spread
across the sheet using a lay-down poker or the like. As the foam
rise the backing sheet is applied over the foam and the sandwich
this formed is then led through an oven and subsequently cut to
length. The manufacturing technology is described in our
UK-A-2227712, UK-A-2257086, and UK-A-2325640.
[0043] In the panels of the invention foam is excluded from at
least some of the recesses defined by the crowns 3. This may be
achieved in a number of ways. For example, a seal or tape 25 may be
laid across the recesses defined by the crowns 3 prior to foam
lay-down. Alternatively a lost core may be inserted into the
recesses defined by the crowns 3 and subsequently removed leaving
the recesses substantially fee of foam.
[0044] We have found that the panel of FIG. 5 is particularly
suitable for roofs, walls and for floors. The panel has a
relatively large exposed surface area and a relatively high large
internal void space whilst maintaining structural and insulation
properties. The width L of the panel in this case is 1 metre. For
optimum thermal efficiency there should be at least 3 and
preferably at least 4 crowns 3. Referring especially to FIG. 5(b),
each of the crowns 3 defines an area which is devoid of foam. The
void area A is preferably at least 0.002 m.sup.2, most preferably
greater than 0.0025 m.sup.2, and in this case about 0.003
m.sup.2.
[0045] The faces of the crown 3 which are exposed to the external
environment comprise an outer face x and two side faces y which
diverge inwardly from the outer face x. The angle .alpha. between
the faces x, y is preferably 115.degree. to 125.degree., most
preferably 118.degree. to 123.degree. and in this case about
121.degree..
[0046] The width of the exposed surface of each crown 3 is from 150
mm to 200 mm, most preferably 160 mm to 180 mm, and in this case
about 170 mm. the outer face x has a width Wx of from 50 mm to 60
mm, in this case about 55 mm. Each side facing has a width Wy of
from 50 mm to 60 mm, in this case about 57 mm.
[0047] In the panel of FIG. 5 each of the foam-free crowns has a
cross sectional area of 0.002906 m.sup.2.
[0048] By way of comparison, in the panel of FIG. 5(a) the
foam-free crowns each have a cross sectional area of 0.001603
m.sup.2.
[0049] The energy production possible using panels with crowns of
this type was calculated using RET screen International Clean
Energy Project Analysis software available at www.retscreen.net.
The following assumptions were made:
TABLE-US-00001 Building Location: North West England Building Size:
10 m .times. 100 m .times. 100 m = 10,000 m.sup.2 floor space South
Facing Wall: 100 m (W) .times. 10 m (H) Fan Air Speed: 10 m/sec
[0050] Using the panels to construct the south facing wall of the
building and circulating air through the foam-free passageways
results in the following energy production:
TABLE-US-00002 Panel of FIG. 5(a) with two crowns: 125,569 kWh per
year based on local weather data. Panel of FIG. 5 with four crowns:
347,647 kWh per year based on local weather data.
[0051] Using a panel with enlarged foam-free crowns greatly
enhances energy production.
[0052] The panels may be used to construct part of or all of the
building envelope including the roof, walls and/or floor. One such
building is illustrated in FIGS. 8 to 10. Each of the walls and the
roof of the building comprise a plurality of the panels such as the
panels 29 of FIG. 5. Air circulating through the passageways
defined by the crowns 3 is directed into ducting 30 as shown by the
arrows. The flow of air may be controlled using one or more fans
31. The ducting may have a venting system 32 which may be motorized
to facilitate ease of operation and control. The circulating air is
heated by solar energy. This hot air is captured and may be passed
into the heating/ventilation ductwork of the building, again
assisting in heating the building. The heated air may also
alternatively be circulated through a heat exchange for transfer of
solar heat to another heat collector. The system may be set to take
air from the warmest or coldest elevations depending on the
internal and external temperatures. The system can be used for
heating and/or cooling.
[0053] Referring especially to FIGS. 9 and 10 suitable insulated
cappings 35 may be provided. The building may also have insulated
flashings 36.
[0054] May variations on the embodiments described will be readily
apparent. Accordingly the invention is not limited to the
embodiments hereinbefore described which may be varied in
detail.
* * * * *
References