[특허]Alternative core material based vacuum insulated panels

UNITED STATES GYPSUM COMPANY

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Alternative core material based vacuum insulated panels

국가/구분	United States(US) Patent 등록
국제특허분류(IPC7판)	F16L-059/065 F17C-003/08 B29C-070/58 B29C-070/88 E04C-002/284 E04C-002/30 E04B-002/00 B29K-105/00 B29K-105/04 B29K-105/16 B29L-031/00
출원번호	US-0040413 (2016-02-10)
등록번호	US-10012348 (2018-07-03)
발명자 / 주소	Ray, Suman Sinha Rao, Ajith
출원인 / 주소	UNITED STATES GYPSUM COMPANY
대리인 / 주소	Marshall, Gerstein & Borun LLP
인용정보	피인용 횟수 : 0 인용 특허 : 7

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A vacuum insulated panel (VIP) and a method of manufacturing a VIP includes a rigid core material having high insulation and low conductivity properties. The rigid core may be made of an inorganic material that effectively mimics a porous silica core material. The core material includes large particles of an inorganic material having a diameter in a range of 10 μm to 50 μm. A portion of these large particles may be ground into small particles having a diameter of less than 1 μm. The small particles are mixed with a portion of the large particles to form ...

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1. A vacuum insulated panel comprising: a core having a porosity defined by pores having a size in a range of approximately 10 nm to approximately 1 μm, wherein the core comprises:a plurality of large particles of an inorganic material with a diameter in a range of greater than 10 μm to approximately 50 μm;a plurality of small particles of the inorganic material with a diameter in a range of approximately 0.01 μm to less than 10 μm, at least some of the small particles attached to at least some of the large particles;a plurality of fibers intermixed with the large and small particles; andan envelope having a cavity, wherein the core is disposed within the cavity and vacuum compacted. 2. The vacuum insulated panel of claim 1, wherein the inorganic material is at least one of (a)-(g); (a) perlite, (b) pumice, (c) natural gypsum, (d) calcium sulfate hemi hydrate, (e) anhydrite calcium sulfate, (f) calcium sulfate di-hydrate, and (g) wollastonite. 3. The vacuum insulated panel of claim 1, wherein the plurality of fibers are at least one of (a)-(e): (a) mineral fiber, (b) high density glass fiber, (c) mineral oxide fiber, (d) loose microfiber, and (e) woven fiber. 4. The vacuum insulated panel of claim 1, wherein each of the plurality of small particles has a diameter in a range of approximately 0.01 μm to approximately 1 μm. 5. The vacuum insulated panel of claim 1, wherein the envelope is a metallic coated polymer. 6. The vacuum insulated panel of claim 1, wherein each of the plurality of large particles is at least partially covered by a portion of the plurality of small particles. 7. The vacuum insulated panel of claim 1, wherein the core has a core material to fibers weight ratio of at least 1:1. 8. The vacuum insulated panel of claim 1, wherein the core consists of the large particles, small particles, and the plurality of fibers. 9. A vacuum insulated panel comprising: a pair of barrier walls;a core sandwiched between the pair of barrier walls, the core including a core material and a plurality of fibers mixed with the core material forming a porous structure;wherein the core material is an inorganic material and includes a first class of particles with a diameter in a range of greater than 10 μm to approximately 50 μm and a second class of particles with a diameter in a range of approximately 0.01 μm to less than 10 μm;wherein the porous structure includes a plurality of the first class of particles mixed with a plurality of the second class of particles, wherein each of the plurality of first class particles is at least partially covered by a portion of the plurality of second class particles;wherein the porous structure has a porosity defined by pores having a size in a range of approximately 10 nm to approximately 1 μm when compacted under vacuum. 10. The vacuum insulated panel of claim 9, wherein the inorganic material is at least one of (a)-(g); (a) perlite, (b) pumice, (c) natural gypsum, (d) calcium sulfate hemi hydrate, (e) anhydrite calcium sulfate, (f) calcium sulfate di-hydrate, and (g) wollastonite. 11. The vacuum insulated panel of claim 9, wherein the plurality of fibers are at least one of (a)-(e); (a) mineral fiber, (b) high density glass fiber, (c) mineral oxide fiber, (d) loose microfiber, and (e) woven fiber. 12. The vacuum insulated panel of claim 9, wherein the pair of barrier walls is metallic coated polymer. 13. The vacuum insulated panel of claim 9, wherein the porous structure includes a core material to fibers weight ratio of at least 1:1. 14. The vacuum insulated panel of claim 9, wherein each of the small particles has a diameter in a range of approximately 0.01 μm to approximately 1 μm. 15. The vacuum insulated panel of claim 9, wherein the core consists of the large particles, small particles, and the plurality of fibers. 16. A vacuum insulated panel comprising: a core having a porosity defined by pores having a size in a range of approximately 10 nm to approximately 1 μm, wherein the core comprises:a plurality of large particles of an inorganic material with a diameter in a range of approximately 10 μm to approximately 50 μm;a plurality of small particles of the inorganic material with a diameter in a range of approximately 0.01 μm to approximately 1 μm, at least some of the small particles attached to at least some of the large particles;a plurality of fibers intermixed with the large and small particles; andan envelope having a cavity, wherein the core is disposed within the cavity and vacuum compacted. 17. The vacuum insulated panel of claim 16, wherein the envelope is a metallic coated polymer. 18. The vacuum insulated panel ot claim 16, wherein each of the plurality of large particles is at least partially covered by a portion of the plurality of small particles. 19. The vacuum insulated panel of claim 16, wherein the core has a core material to fibers weight ratio of at least 1:1.

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