Insulated Panel and Method of Manufacturing an Insulated Panel

Abstract

The invention relates to an insulated panel, in particular a wall panel or roof panel, including a foamed core layer and a cover layer affixed to the foamed core layer. The invention also relates to an insulating covering, in particular a wall covering or floor covering, including a plurality said insulated panels.

Claims

1-41. (canceled)

42. An insulated panel, in particular a wall panel or roof panel, comprising: a core comprising at least one foamed core layer, wherein the foamed core layer is at least partially made of wood foam, wherein the core comprises at least one intermediate layer, and at least one cover layer affixed, either directly or indirectly, to the core, in particular to at least one foamed core layer of the core.

43. The panel according to claim 42, wherein at least one intermediate layer is at least partially enclosed at least one foamed core layer.

44. The panel according to claim 42, wherein at least one intermediate layer is embedded in a foamed core layer or in between two adjacent foamed core layers.

45. The panel according to claim 42, wherein the intermediate layer is configured to act as reinforcement layer.

46. The panel according to claim 42, wherein the intermediate layer comprises fibres chosen from the group consisting of: glass fibres, carbon fibres, and/or aramid fibers.

47. The panel according to claim 42, wherein the intermediate layer comprises natural fibres chosen from the group consisting of: flax, jute, hemp, abaca, ramie, cellulose, and/or kenaf.

48. The panel according to claim 42, wherein at least one foamed core layer penetrates the intermediate layer.

49. The panel according to claim 42, the core comprises at least two foamed core layers which are mutually connected via through-holes in said intermediate layer.

50. The panel according to claim 42, wherein the core has a thickness T, and wherein the core comprises a plurality of embedded reinforcement layers, in particular, glass fiber layers, situated on both sides of the center line, defined by 0.5T, of the core.

51. The panel according to claim 42, wherein at least one foamed core layer has a density between 30 and 300 kg/m3, preferably between 40 and 250 kg/m3.

52. The panel according to claim 42, wherein the wood foam of the foamed core layer consists of chemically bound wood fibers, and wherein the wood fibers are additionally bound by physical anchorage and entanglement of wood fibers and/or strands of wood fibers.

53. The panel according to claim 42, wherein at least one foamed core layer has a thickness of 0.5 to 20 cm, preferably 1 to 15 cm, more preferably 2 to 10 cm.

54. The panel according to claim 42, wherein the cover layer has a density of at least 800 kg/m3, preferably at least 900 kg/m3, more preferably at least 1000 kg/m3.

55. The panel according to claim 42, wherein the cover layer has a thickness of 1 to 10 mm, preferably 2 to 7 mm.

56. The panel according to claim 42, wherein at least one foamed core layer and at least one cover layer are glued together.

57. The panel according to claim 42, comprising at least one pair, and preferably a plurality of pairs, of opposite side edges which are provided with interconnecting coupling means.

58. The panel according to claim 42, wherein each layer of the panel is a substantially waterproof layer.

59. The panel according to claim 42, wherein at least one panel layer comprises and/or is coated with at least one antimicrobial agent.

60. An insulating covering, in particular a wall covering or floor covering, comprising a plurality of insulated panels according to claim 42.

61. A method of manufacturing an insulated panel, in particular a wall panel or roof panel, preferably according to claim 42, comprising the steps of: a) providing at least one foamed core layer comprising an upper side and a lower side, wherein the foamed core layer comprises wood foam, b) providing at least one decorative cover layer comprising densified wood, and c) affixing at least one cover layer onto the upper side and/or lower side of the foamed core layer.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0088] The invention will be elucidated on the basis of non-limitative exemplary embodiments shown in the following figures. Herein shows:

[0089] FIG. 1 a perspective view of a first possible embodiment of an insulated panel according to the present invention;

[0090] FIG. 2 a perspective view of a second possible embodiment of an insulated panel according to the present invention;

[0091] FIG. 3 a cross-sectional view of a third possible embodiment of an insulated panel according to the present invention;

[0092] FIG. 4 a cross-sectional view of a fourth possible embodiment of an insulated panel according to the present invention; and

[0093] FIG. 5 a cross-sectional view of a fifth possible embodiment of an insulated panel according to the present invention.

DESCRIPTION OF THE INVENTION

[0094] FIG. 1 shows an insulated panel 100 comprising a foamed core layer 101 which is at least partially made of wood foam, and a cover layer 102 affixed to the foamed core layer 101. The panel 100 could for example be used as wall panel or roof panel. The foamed core layer 101 comprises an upper side 101a and a lower side 101b. The cover layer 102 is affixed on said upper side 101a of the foamed core layer 101. The foamed core layer 101 comprises wood foam, the wood foam has preferably a substantially open pore structure. The cover layer 102 comprises densified wood. In the shown embodiment, the cover layer 102 is directly attached to the foamed core layer 101, in particular via fusion.

[0095] FIG. 2 shows a perspective view of a second possible embodiment of an insulated panel 200 according to the present invention. The panel 200 comprises a wood foam core layer 201 and two cover layers 202a, 202b. The core layer 201 is in fact substantially enclosed between the cover layers 202a, 202b. In the shown embodiment, the cover layers 202a, 202b are made of a metal material. Hence, the wood foam of the foamed core layer 201 is shielded by the cover layer 202a, 202b. The metal cover layers 202a, 202b in fact form a metal casing surrounding the core layer 201. Each cover layer 202a, 202b has an upper surface area exceeding an upper surface of the foamed core layer 201. The panel 200, and in particular the cover layers 202a, 202b is provided with interconnecting coupling means 203 allowing easier installation of the panel. The panel 200 of the shown embodiment is provided with a structured upper surface, and also the lower surface of the panel is slightly structured. This may also contribute to the ease of use of the insulating panel 200, for example in the application as roof panel 200.

[0096] FIG. 3 shows a cross-sectional view of a third possible embodiment of an insulated panel 300 according to the present invention. The panel 300 comprises a foamed core layer 301 comprising wood foam and a cover layer 302 which is attached to the foamed core layer via an adhesive layer 304. Optionally, the panel 300 comprises a backing layer 305 attached to a lower side of the foamed core layer 301. Also optionally, the panel 300 may comprise a print layer 306 and/or at least one protective layer 307.

[0097] FIG. 4 shows a cross-sectional view of a fourth possible embodiment of an insulated panel 400 according to the present invention. The foamed core layer 401 comprising wood foam is attached to a cover layer 402 made of metal foil. It can be seen that the thickness d,f of the foamed core layer 401 is substantially larger than the thickness d,c of the cover layer 402.

[0098] FIG. 5 shows a cross-sectional view of a fifth possible embodiment of an insulated panel 500 according to the present invention. The panel 500 comprises a cover layer 502. The panel 500 also comprises at least one intermediate layer 508 which is enclosed between two foamed core layers 501a, 501b. The intermediate layer 508 may comprises densified wood and/or a fiber-based reinforcement layer, and can be provided with interconnecting coupling profiles (not shown). It is also conceivable that the intermediate layer 508 comprises another natural material, like e.g., preferably interconnected, natural fibres chosen from the group consisting of: flax, jute, hemp, abaca, ramie, cellulose, and/or kenaf. Instead of natural fibers also synthetic fibers, like glass fibers, carbon fibers, and/or aramid fibers may be used. In case the intermediate layer 508 comprises, preferably interconnected, fibers and constitutes an open and/or porous layer, preferably a woven or non-woven mat, in which one or both of the foamed core layers 501a, 501b are penetrated. Preferably, the foamed core layers 501a, 501b are mutually connected via through-holes formed in the intermediate layer 508. In this embodiment, it is shown that the intermediate layer 508 is positioned at the center line of the core of the panel 500, wherein the core is formed by the laminate of the lower foamed core layer 501b, the intermediate layer 508, and the upper foamed core layer 501a.

[0099] The above-described inventive concepts are illustrated by several illustrative embodiments. It is conceivable that individual inventive concepts may be applied without, in so doing, also applying other details of the described example. It is not necessary to elaborate on examples of all conceivable combinations of the above-described inventive concepts, as a person skilled in the art will understand numerous inventive concepts can be (re)combined in order to arrive at a specific application.

[0100] It will be apparent that the invention is not limited to the working examples shown and described herein, but that numerous variants are possible within the scope of the attached claims that will be obvious to a person skilled in the art. When the term insulated panel is used, it could also be referred to an insulating panel. The insulated panel according to the present invention is typically also suitable for use as floor panel.

[0101] The verb “comprise” and conjugations thereof used in this patent publication are understood to mean not only “comprise”, but are also understood to mean the phrases “contain”, “substantially consist of”, “formed by” and conjugations thereof.