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.

Description

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.

Claims

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.