Honeycomb transparent insulation with improved insulating ability

• US 6,699,559 B1
• Filed: 07/19/2002
• Issued: 03/02/2004
• Est. Priority Date: 09/27/1999
• Status: Expired due to Term

• Current Assignee: Advanced Glazing Technologies Ltd.
• Original Assignee: Advanced Glazings Ltd.
• Inventors: Milburn, Douglas I.
• Primary Examiner(s): Jones, Deborah
• Assistant Examiner(s): BOSS, WENDY L
• Application Number:
  US10/089,160
• Time in Patent Office: 592 Days
• Field of Search: 428/116, 428/117, 428/118, 428/73, 428/34, 428/119, 428/188, 428/220, 428/402, 428/465, 428/446, 428/426, 428/688, 428/689, 428/702, 428/913, 181/284, 181/288, 181/289, 181/296, 359/350, 359/559, 359/361, 359/591, 359/596, 359/601, 359/614, 427/162, 427/164, 427/165, 427/212, 427/209, 427/221, 427/230, 264/176.1, 264/177.2
• US Class Current: 428/73
• CPC Class Codes: E04C 2/365 by honeycomb structures
• CPC Class Codes: F24S 80/525 made of plastics
• CPC Class Codes: Y02E 10/40 Solar thermal energy, e.g. solar towers
• CPC Class Codes: Y10S 428/913 Material designed to be responsive to temperature, light, moisture
• CPC Class Codes: Y10T 428/236 Honeycomb type cells extend perpendicularly to nonthickness layer
• CPC Class Codes: Y10T 428/24149 Honeycomb-like
• CPC Class Codes: Y10T 428/24174 including sheet or component perpendicular to plane of web or sheet
• CPC Class Codes: Y10T 428/2982 Particulate matter [e.g., sphere, flake, etc.]
• CPC Class Codes: Y10T 428/2991 Coated

Abstract

An inorganic particulate, having strong absorption in the thermal infrared region of the radiative spectrum and low absorption in the solar or visible portion of the radiative spectrum, is combined with a plastic resin, to create a composite material. This composite is used in whole or in part to manufacture a honeycomb transparent insulation material, or is applied as a coating to a honeycomb transparent insulation material. The resulting honeycomb transparent insulation can have similar visible or solar light transmittance, and will have improved thermal radiant suppression relative to an identical honeycomb made of plastic resin only.

Claims

1. In a glazing system comprising a honeycomb transparent insulation sandwiched between glass and comprising an array of open-ended cell whose axes are oriented normal to the plane of the insulation, the improvement wherein said cells have walls comprising a composite material consisting essentially of inorganic particles having strong absorption/emissivity in the thermal infrared wavelength regions and negligible absorption in the visible (400 nm to 700 nm regions) dispersed in a plastic resin binder, said inorganic particles and said plastic resin binder have substantially matching refractive indices for visible light, and said inorganic particles have a size selected from the group consisting of a first range less than 200 nm and a second range between 1 and 30 μ

m, whereby said honeycomb insulation is substantially clear.

2. A glazing system as claimed in claim 1, wherein the walls of said cells are made of a plastic sheet coated with said composite material.

3. A glazing system as claimed in claim 1, wherein the walls of said cells are made of said composite material.

4. A glazing system as claimed in claim 1, wherein said inorganic particles comprise a combination of inorganic materials selected such that their maximum absorption bands cover different parts of the infrared spectrum so they work together to maximize absorption per unit mass or volume of material.

5. A glazing system as claimed in claim 1, wherein said plastic resin binder is selected from the group consisting of:

polypropylene, polyethylene, polyvinyl chloride, acrylic, polycarbonate, polyurethane, polyester, fluoropolymers, UV or thermal stabilizers, and UV absorbers.

6. A glazing system as claimed in claim 1, wherein said inorganic particles are selected from the group consisting of:

silica (natural or synthetic, fused or crystalline, in pyrolytic (fumed), precipitated, or milled forms), glass (soda lime, borosilicate, or other compositions, in microsphere, fibre, and milled form), kaolin, alumnia, various aluminosilicate compounds, and titanium dioxide.

7. A glazing system as claimed in claim 1, wherein said inorganic particles are surface-treated with a compatibility-enhancing agent.

8. A glazing system as claimed in claim 7, wherein said compatibility-enhancing agent is vinyl-functional silane.

9. A glazing system as claimed in claim 1, wherein said size lies in the range 1-10 μ

m.

10. A glazing system as claimed in claim 1, wherein said inorganic particles are borosilicate glass microspheres.

11. A method of making a glazing system comprising:

providing a plastic resin and plurality of inorganic particles, said plastic resin and said inorganic particles having substantially matching refractive indices, said inorganic particles having strong absorption/emissivity in the thermal infrared wavelength regions and negligible absorption in the visible (400 nm to 700 nm regions) and said inorganic particles having a size selected from the group consisting of a first range less than 200 nm and a second range between 1 and 30 μ

m;

blending said inorganic particles with said plastic resin to form a substantially clear composite film; and

manufactureing from said film a honeycomb insulation sheet comprising an array of radiation absorbing open-ended cells whose axes are oriented normal to the plane of the insulation; and

sandwiching said honeycomb sheet between glass.

12. A method as claimed in claim 11, wherein said composite film is co-extruded with a laminate layer to form a composite film that is used to make said array of open-ended cells.

13. A method as claimed in claim 12, wherein said composite film is formed into said film by curing.

14. A method as claimed in claim 11, wherein said composite film is coated onto a pre-existing honeycomb of open-ended cells.