PROTECTIVELY FRAMED AND COVERED THERMAL INSULATION PANEL

Abstract

A protectively enclosed panel of frangible thermal insulation having a panel of frangible thermal insulation with C-channel binding bars fitted over each edge of the panel and wear protective cover sheets covering the first and second major surface of the panel with the peripheral margin of the cover sheets adhered to the C-channel binding bars.

Claims

1. A protectively enclosed panel of frangible thermal insulation, comprising an assembly of separately and independently formed components that include at least: (a) a panel of frangible thermal insulation having first and second major surfaces and a plurality of edges, (b) a C-channel binding bar fitted over each of the edges, and (c) first and second wear protective cover sheets each with a peripheral margin and pliable in a direction normal to the plane of the sheet, wherein: (i) the first cover sheet covers the first major surface of the thermal insulation panel with the peripheral margin of the first cover sheet adhered to the C-channel binding bars, and (ii) the second cover sheet covers the second major surface of the thermal insulation panel with the peripheral margin of the second cover sheet adhered to the C-channel binding bars.

2. The protectively enclosed panel of frangible thermal insulation of claim 1, wherein the panel of frangible thermal insulation has a corner at the intersection of each pair of edges, and the protectively enclosed panel of frangible thermal insulation further includes wear protective corner protectors over each corner with each corner protector in overlapping engagement with the C-channel binding bars fitted over the intersecting edges and adhered to at least one of the first and second impact protective cover sheets.

3. The protectively enclosed panel of frangible thermal insulation of claim 1, wherein the panel of frangible thermal insulation is a vacuum insulated panel comprising a core material sealingly wrapped under vacuum within a gas resistant film.

4. The protectively enclosed panel of frangible thermal insulation of claim 1, wherein the C-channel binding bars are secured to the panel of frangible thermal insulation by interference fit.

5. A protectively enclosed set of frangible thermal insulation panels, comprising: (a) a planar set of separately and independently formed, edge-abutting frangible thermal insulation panels wherein the set defines an integrated thermal insulation panel having first and second major surfaces and a plurality of peripheral edges, (b) a C-channel binding bar fitted over each of the peripheral edges of the integrated thermal insulation panel, and (c) first and second wear protective cover sheets each with a peripheral margin and pliable in a direction normal to the plane of the sheet, wherein: (i) the first cover sheet covers the first major surface of the integrated thermal insulation panel with the peripheral margin of the first cover sheet adhered to the C-channel binding bars, and (ii) the second cover sheet covers the second major surface of the integrated thermal insulation panel with the peripheral margin of the second cover sheet adhered to the C-channel binding bars.

6. The protectively enclosed set of frangible thermal insulation panels of claim 5, wherein the set of frangible thermal insulation panels comprises at least two vacuum insulation panels.

7. The protectively enclosed set of frangible thermal insulation panels of claim 5, wherein the set of frangible thermal insulation panels comprises at least three thermal insulation panels.

8. The protectively enclosed set of frangible thermal insulation panels of claim 5, wherein the integrated thermal insulation panel has a corner at the intersection of each pair of peripheral edges, and the protectively enclosed set of frangible thermal insulation panels further includes wear protective corner protectors over each corner with each corner protector in overlapping engagement with the C-channel binding bars fitted over the intersecting peripheral edges and adhered to at least one of the first and second wear protective cover sheets.

9. The protectively enclosed set of frangible thermal insulation panels of claim 5, wherein each panel of frangible thermal insulation, each C-channel binding bar, and the first and second cover sheets are formed as separate and independent components.

10. The protectively enclosed set of frangible thermal insulation panels of claim 5, wherein the C-channel binding bars are secured to the panels of frangible thermal insulation by interference fit.

11. A kit comprising several separate and independent components for protectively enclosing a panel of frangible thermal insulation, the components including at least: (a) a plurality of C-channel binding bars, each configured and arranged for engagement over an edge of a panel of frangible thermal insulation so as to cover a peripheral margin on both a first major surface and a second major surface of the panel of frangible thermal insulation and leave an exposed central area on each of the first and second major surfaces of the panel of frangible thermal insulation framed by the C-channel binding bars, and (b) first and second wear protective cover sheets, each pliable in a direction normal to the plane of the sheet, wherein: (i) the first cover sheet is operable for overlapping the first major surface of the panel of frangible thermal insulation so as to (A) completely cover an exposed central area of the first major surface of the panel of frangible thermal insulation formed when a plurality of the C-channel binding bars are installed over the edges of the panel, and (B) overlap each of the plurality of C-channel binding bars installed onto the panel, and (ii) the second cover sheet is operable for overlapping the second major surface of the panel of frangible thermal insulation so as to (A) completely cover an exposed central area of the second major surface of the panel of frangible thermal insulation formed when a plurality of the C-channel binding bars are installed over the edges of the panel, and (B) overlap each of the plurality of C-channel binding bars installed onto the panel, and (c) further including: (i) a first layer of pressure sensitive adhesive operable for adhering a peripheral margin of the first cover sheet to each C-channel binding bar installed onto the panel of frangible thermal insulation, with the first layer of pressure sensitive adhesive provided on the first cover sheet, the C-channel binding bars or as a separate and independent component, and (ii) a second layer of pressure sensitive adhesive operable for adhering a peripheral margin of the second cover sheet to each C-channel binding bar installed onto the panel of frangible thermal insulation, with the second layer of pressure sensitive adhesive provided on the second cover sheet, the C-channel binding bars or as a separate and independent component.

12. A kit comprising several separate and independent components from which a protectively enclosed panel of frangible thermal insulation may be assembled, the components including at least: (a) a panel of frangible thermal insulation having (i) a first major surface that includes a peripheral margin and a central area bounded by the peripheral margin, (ii) a second major surface that includes a peripheral margin and a central area bounded by the peripheral margin, and (iii) a plurality of edges, (b) a plurality of C-channel binding bars, each configured and arranged for engagement over one of the plurality of edges of the panel of frangible thermal insulation so as to cover the peripheral margins of the first major surface and the second major surface of the panel, and (c) first and second wear protective cover sheets each having side edges, wherein: (i) the first cover sheet is operable for completely covering the central area and extending a distance on all side edges into the peripheral margin of the first major surface of the thermal insulation panel, and (ii) the second cover sheet is operable for completely covering the central area and extending a distance on all side edges into the peripheral margin of the second major surface of the thermal insulation panel, and (d) further including: (i) a first layer of pressure sensitive adhesive operable for adhering a peripheral margin of the first cover sheet to each C-channel binding bar when the bars are installed over the edges of the panel of frangible thermal insulation, with the first layer of pressure sensitive adhesive provided on the first cover sheet, the C-channel binding bars or as a separate and independent component, and (ii) a second layer of pressure sensitive adhesive operable for adhering a peripheral margin of the second cover sheet to each C-channel binding bar when the bars are installed over the edges of the panel of frangible thermal insulation, with the second layer of pressure sensitive adhesive provided on the second cover sheet, the C-channel binding bars or as a separate and independent component.

13. The kit of claim 12, wherein the panel of frangible thermal insulation has a corner at the intersection of each pair of edges, and the kit further includes a plurality of wear protective corner protectors configured and arranged for engagement over each corner of the panel of frangible thermal insulation in overlapping arrangement with C-channel binding bars installed onto the panel.

14. The kit of claim 12, wherein the panel of frangible thermal insulation is a vacuum insulated panel comprising a core material sealingly wrapped under vacuum within a gas resistant film.

15. The kit of claim 12, wherein the C-channel binding bars are configured and arranged for interference fit onto the panel of frangible thermal insulation.

16. A kit comprising several separate and independent components from which a protectively enclosed set of frangible thermal insulation panels may be assembled, the components including at least: (a) a set of at least two separately and independently formed frangible thermal insulation panels capable of forming an integrated thermal insulation panel when placed in a planar edge-abutting arrangement, whereby an integrated thermal insulation panel formed from the set of at least two frangible thermal insulation panels defines (i) a first major surface that includes a peripheral margin and a central area bounded by the peripheral margin, (ii) a second major surface that includes a peripheral margin and a central area bounded by the peripheral margin, and (iii) a plurality of edges, (b) a plurality of C-channel binding bars, each configured and arranged for engagement over one of the plurality of edges of the integrated thermal insulation panel so as to cover the peripheral margins of the first major surface and the second major surface of the integrated panel, and (c) first and second wear protective cover sheets each having side edges, wherein: (i) the first cover sheet is operable for completely covering the central area and extending a distance on all side edges into the peripheral margin of the first major surface of the integrated thermal insulation panel, and (ii) the second cover sheet is operable for completely covering the central area and extending a distance on all side edges into the peripheral margin of the second major surface of the integrated thermal insulation panel, and (d) further including: (i) a first layer of pressure sensitive adhesive operable for adhering a peripheral margin of the first cover sheet to each C-channel binding bar when the bars are installed over the edges of the integrated thermal insulation panel, with the first layer of pressure sensitive adhesive provided on the first cover sheet, the C-channel binding bars or as a separate and independent component, and (ii) a second layer of pressure sensitive adhesive operable for adhering a peripheral margin of the second cover sheet to each C-channel binding bar when the bars are installed over the edges of the integrated thermal insulation panel, with the second layer of pressure sensitive adhesive provided on the second cover sheet, the C-channel binding bars or as a separate and independent component.

17. The kit of claim 16, wherein the frangible thermal insulation panels comprise vacuum insulation panels.

18. The kit of claim 16, wherein the set of frangible thermal insulation panels comprises at least three vacuum insulation panels.

19. The kit of claim 16, wherein the C-channel binding bars are configured and arranged for interference fit onto the edges of the integrated panel of frangible thermal insulation.

20. A method of assembling a protectively enclosed panel of frangible thermal insulation, comprising the sequential steps of: (a) installing a C-channel binding bar over each edge of a panel of frangible thermal insulation so as to form a frame of C-channel binding bars around the panel of frangible thermal insulation with a central exposed area on a first major surface of the panel surrounded by the frame and a central exposed area on a second major surface of the panel surrounded by the frame, (b) placing a first wear protective cover sheet over the central exposed area on the first major surface of the panel and adhering a peripheral margin of the first wear protective cover sheet onto each C-channel binding bar comprising the frame, and (c) placing a second wear protective cover sheet over the central exposed area on the second major surface of the panel and adhering a peripheral margin of the second wear protective cover sheet onto each C-channel binding bar comprising the frame.

21. The method of claim 20 further comprising the step of installing wear protective corner protectors over each edge intersecting corner on the panel of frangible thermal insulation prior to step (b).

22. The method of claim 20 wherein the panel of frangible thermal insulation is an integrated panel of frangible thermal insulation formed by an initial step of placing a plurality of panels of frangible thermal insulation in planar, edge-abutting arrangement.

23. The method of claim 20 wherein the panel of frangible thermal insulation is a vacuum insulation panel.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] FIG. 1 is an exploded perspective view of one embodiment of the invention.

[0007] FIG. 2 is an exploded perspective view of a second embodiment of the invention.

[0008] FIG. 3 is a perspective view of one of the C-channel binding bars depicted in FIGS. 1 and 2.

[0009] FIG. 4 is a perspective view of one of the corner protectors depicted in FIGS. 1 and 2.

[0010] FIG. 5 is a perspective view of one of the corners on the embodiments of the invention depicted in FIGS. 1 and 2.

[0011] FIG. 6 is an enlarged cross-sectional view of the top and bottom edge portions of the invention depicted in FIG. 5 taken along line 6-6.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

[0012]

TABLE-US-00001 Nomenclature Table REF. NO. NAME 100 Protectively Enclosed Frangible Thermal Insulation Panel 101 Protectively Enclosed Individual Panel of Frangible Thermal Insulation 102 Protectively Enclosed Set of Frangible Thermal Insulation Panels 110 Individual Panel of Frangible Thermal Insulation 110a First Major Surface of Individual Panel of Frangible Thermal Insulation 110b Second Major Surface of Individual Panel of Frangible Thermal Insulation 110c Corners at Edge Intersections on Individual Panel of Frangible Thermal Insulation 110e Edge of Individual Panel of Frangible Thermal Insulation 120 Integrated Set of Frangible Thermal Insulation Panels 120a First Major Surface of Integrated Set of Thermal Insulation Panels 120b Second Major Surface of Integrated Set of Thermal Insulation Panels 120c Corners at Intersections of Peripheral Edges of Integrated Set of Thermal Insulation Panels 120e Peripheral Edges of Integrated Set of Thermal Insulation Panels 140 C-channel Binding Bars 140a First Leg of C-channel Binding Bar 140b Second Leg of C-channel Binding Bar 150 Adhesive Layer 160 Wear Protective Cover Sheets (collective reference) 161 First Wear Protective Cover Sheet 161p Peripheral Margin of First Wear Protective Cover Sheet 162 Second Wear Protective Cover Sheet 162p Peripheral Margin of Second Wear Protective Cover Sheet 180 Corner Protector 181 Flange on Corner Protector

[0013] We have discovered that the useful life of rigid thermal insulation, particularly and hereinafter referenced as a vacuum insulated panel 110 can be significantly increased by reducing abrasive and impact wear of the rigid thermal insulation, such as experienced by the airtight outer film (not individually numbered) on vacuum insulated panels 110.

Construction

[0014] Referring to FIGS. 1 and 2, the invention is directed to a wear-protected rigid thermal insulation panel 100 particularly suited for use in assembly of an insulated container (not shown) such as those shown and described in U.S. Pat. Nos. 4,145,895; 4,579,170; 4,923,077; 4,931,333; 5,626,936; 5,899,088; 6,209,343; 6,718,776; 7,257,963; 7,422,143; 7,500,593 and 8,424,335, and United States Patent Application Publications 2002/0050147; 2005/0188714; 2011/0248038; and 2013/0228583, hereby incorporated by reference.

[0015] Referring to FIG. 1, a first embodiment of the wear-protected frangible thermal insulation panel 100 is a wear-protected frangible thermal insulation panel 101 that includes a single frangible thermal insulation panel 110, such as a vacuum insulated panel, a C-channel binding bar 140 for covering each edge 110e of the frangible thermal insulation panel 110, a coating of pressure-sensitive adhesive 150 on both the first 140a and second 140b legs of each C-channel binding bar 140, and a paired set of a first 161 and a second 162 wear-protective cover sheets (collectively 160).

[0016] Referring to FIG. 2, a second embodiment of the wear-protected frangible thermal insulation panel 100 is a wear-protected set of frangible thermal insulation panels 102 that includes a plurality of frangible thermal insulation panels 110, such as vacuum insulated panels, forming an integrated set of frangible thermal insulation panels 120, a C-channel binding bar 140 for covering each peripheral edge 120e of the integrated set of frangible thermal insulation panels 120, a coating of pressure-sensitive adhesive 150 on both the first 140a and second 140b legs of each C-channel binding bar 140, and a paired set of a first 161 and a second 162 wear-protective cover sheets (collectively 160). The C-channel binding bars 140 and cover sheets 160 used in this second embodiment provide not only wear-protection but also conformational stability.

[0017] Frangible thermal insulation panels 110 suitable for use include any of the well-known and widely used frangible thermal insulation materials available and deployed as rigid panels, such as sheets of foamed polystyrene and vacuum insulated panels. Each of the frangible thermal insulation panels 110 have a first major surface 110a, an opposed second major surface 110b, edges 110e, and corners 110c at the intersection of each pair of edges 110e.

[0018] The invention is particularly suited for wear-protection of vacuum insulated panels (VIPs). VIPs are a technologically advanced insulation product consisting of a cell foam core material surrounded by a gas tight outer film to which a vacuum has been applied. VIPs are highly efficient thermal insulators so long as the integrity of the vacuum is not compromised. Once the vacuum is lost, the panel provides modest insulating value at best. VIPs suffer from a frequent loss of vacuum, with concomitant loss of insulating value, due to the fragile nature of the gas tight outer film.

[0019] Referring to FIG. 3, the C-channel binding bars 140 are linearly elongated C-channels constructed from any structurally rigid yet slightly elastic material such as aluminum, polyethylene, polypropylene, polyurethane, nylon, etc. The C-channel binding bar 140 should be sufficiently flexible to allow the legs 140a and 140b of the bar 140 to readily flex a distance away from one another so as to allow slide fitting of the C-channel binding bars 140 over the edges 110e of a frangible thermal insulation panel 110 without damaging the panel 110, but with sufficient elasticity to effect an interference fit of the C-channel binding bars 140 to the frangible thermal insulation panel 110 once fitted. The C-channel binding bars 140 should have a length sufficient to cover the entire length of a corresponding edge on the frangible thermal insulation panel 110.

[0020] Referring to FIG. 4, corner protectors 180 may optionally be included for protectively covering the corners 110c of the frangible thermal insulation panel 110. The corner protectors 180 are preferably constructed from the same material as the C-channel binding bars 140, and preferably include a peripheral flange 181 for facilitation overlapping engagement of the C-channel binding bars 140 with the corner protectors 180.

[0021] Referring to FIGS. 1 and 2, the cover sheets 160 may be pliable in a direction normal to the plane of the sheet, but should provide dimensional stability within the plane of the sheet, and be abrasion and puncture resistant. Suitable materials include specifically but not exclusively, sheet metal such as aluminum or steel, plastics such a polycarbonate, polyvinyl chloride, polypropylene and polyethylene, and paper such as card stock, with a preference for plastics. Referring to FIGS. 5 and 6, the peripheral margins 161p of a first cover sheet 161 are adhered to the first legs 140a of the C-channel binding bars 140 fitted onto the frangible thermal insulation panel 110, and adhered to any corner protectors fitted onto the frangible thermal insulation panel 110 by an adhesive layer 150. In similar fashion the peripheral margins 162p of a second cover sheet 162 are adhered to the second legs 140b of the C-channel binding bars 140 fitted onto the frangible thermal insulation panel 110, and adhered to any corner protectors fitted onto the frangible thermal insulation panel 110 by an adhesive layer 150. The adhesive layers 150 are preferably a coating of a pressure sensitive adhesive or a layer of double-sided adhesive tape.

[0022] Referring to FIG. 2, the embodiment 102 that includes a set of frangible thermal insulation panels 110 is constructed in a fashion very similar to the embodiment 101 having a single frangible thermal insulation panel 110. The major distinctions are that the set of frangible thermal insulation panels 110 form an integrated set 120 that defines a first major surface 120a and a second major surface 120b of the integrated set 120, and only the peripheral edges 120e and corners 120c of the integrated set 120, rather than all of the edges and corners of each individual frangible thermal insulation panel 110, are covered by C-channel binding bars 140 and corner protectors 180.