GB2626526A

GB2626526A - Insulation apparatus

Info

Publication number: GB2626526A
Application number: GB2219148.0A
Authority: GB
Inventors: Browne-Wilkinson Oliver
Original assignee: MODERNISE UK Ltd
Current assignee: MODERNISE UK Ltd
Priority date: 2022-12-19
Filing date: 2022-12-19
Publication date: 2024-07-31
Also published as: GB202219148D0

Abstract

A relatively simple to install and relatively low-cost to manufacture insulation apparatus comprising a plurality of individual cells (100, 200, 300 figs 4, 9, 10) wherein each cell (100 fig 4) comprises a base 10 and a removably replaceable lid 60. The base and lid are configured such that when fitted together an interior air-tight space is formed. Each cell further comprises a first set of internal walls (40 fig 2) extending from the base of the cell to the lid of the cell. The internal walls are configured to separate the interior air-tight space into a plurality of substantially air- tight sub-cells. The insulation apparatus may be used in building walls or windows.

Description

Insulation apparatus The present invention relates generally to insulation apparatus and a method of insulating a window and finds particular, although not exclusive, utility in providing a relatively low cost, modular, do-it-yourself insulation system.

Many buildings or other structures have walls and/or windows with poor insulation characteristics. There are already many products available for increasing the insulation characteristics of walls and windows, however, many arc either relative expensive or require a skilled installer to implement. Although there are some relatively low-cost systems which may be installed with no training required, these are often of poor quality.

It is desirable to have a relatively low-cost and simple to install insulation system which provides relatively better U-values of a higher quality.

In a first aspect, the present invention provides insulation apparatus comprising a plurality of individual cells, wherein each cell comprises a base and a removably replaceable lid, the base and lid configured such that when fitted together an interior airtight space is formed, each cell further comprising a first set of internal walls extending from the base of the cell to the lid of the cell, the internal walls configured to separate the interior air-tight space into a plurality of substantially air-tight sub-cells.

The plurality of cells may, in use and as described herein, may be placed across a planar substrate such as a wall, ceiling or window to create a layer of air-tight cells, each comprising alt-tight sub-cells. It is well known that air is a relatively good thermal insulator as long as it can be kept stationary. Accordingly, the cells and sub-cells form containers for relatively small amounts of air; the containers being substantially air-tight such that the air therein is maintained in a stationary manner.

The insulation apparatus may further comprise a spacer element configured to fit between the lid and the base to increase the distance between them, said spacer element configured such that when placed betyvcen the lid and the base, the interior remains airtight.

In this way, the thickness of the cell may be increased.

The insulation apparatus may further comprise a second set of internal walls and an intermediate floor, the second set of internal walls extending from the floor, the floor configured to lie against the first set of internal walls, the first and second sets of internal walls and the floor configured to further separate the interior into individual air-tight sub-cells.

Tn this way, additional layers of sub-cells may be formed within the increased thickness cell.

The insulation apparatus may further comprise one or more spacer elements configured to fit between the lid and the base to increase the distance between them, said spacer elements configured such that when placed between the lid and the base, the interior remains air-tight; the apparatus further comprising one or more further sets of internal walls 'and further intermediate floors, each of the further sets of internal walls extending from one of the further intermediate floors, the further intermediate floors configured to separate each cell into air-tight layers, the further set of internal walls configured to further separate each layer into individual air-tight sub-cells.

In this way, the thickness of the cell may be further increased. Even more additional spacer elements may be included, as desired, such that the overall thickness of the cell is adjustable. Additional internal walls and intermediate floors may be included as desired such that additional layers of sub-cells may be formed within the increased thickness cell.

The insulation apparatus may further comprise positioning HICUTIS configured to releasably hold adjacent cells immediately adjacent one another.

The positioning means may comprise elements configured to attach to the base or lid of two adjacent cells. Each cell may have one or more positioning means releasably attachable thereto such that each cell may be releasably held immediately adjacent one or more other cells. In this way the layer of cells may be formed such that no air gaps are formed between adjacent cells, such air gaps potentially reducing the overall insulation characteristics of the apparatus when in use.

The elements may comprise projections and each cell may comprise sockets on the lid or base, the projections and sockets may be configured to provide a close fit when connected together.

Each base or lid may comprise a rebate for accommodating the positioning means such that, in use, each base or lid may be placeable immediately against a planar substrate without any gap therebetween. Alternatively, the positioning means (or "elements") may be slightly thinker than the depth of the rebate such that the base or lid may be placeable against a planar substrate with a predefined gap therebetween. The insulation apparatus may further comprise attachment means for releasably attaching the cells to a substrate to thereby provide a layer of insulation. For instance, the attachment means may include adhesive, such as double-sided tape.

The attachment means may be arranged on one side of the positioning means.

The base, lid and internal walls may comprise dear plastics. For instance, dear polycarbonate may be employed. As polycarbonate has relatively good clarity characteristics (it is optically clear) it allows daylight to pass through the cells when placed on windows, which maybe desirable. Polycarbonate may also reduce ultra-violet radiation passing through, which may be desirable.

The base, lid and internal walls may comprise relatively rigid materials.

The corners of each cell may have sharp corners for allowing adjacent cells to be positioned tightly against one another.

Each base or lid may have a square shape, although other shapes are contemplated such as rectangular, or hexagonal.

The base, lid and internal walls may comprise clear plastics.

Tn a second aspect, the invention provides a method of insulating a planar surface, such as a window, comprising the steps of providing insulation apparatus according to the first aspect, and arranging the cells immediately adjacent one another in a layer across the window. In this regard, the "window" may he the window pane.

The method may further comprise the step of using the positioning means to releasably align adjacent cells relative to one another.

The method may further comprise the step of using the attachment means to releasably attach the cells to the window.

The above and other characteristics, features and advantages of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention. This description is given for the sake of example only, without limiting the scope of the invention. The reference figures quoted below refer to the attached drawings.

Figure 1 is a perspective vim of a base including internal walls; Figure 2 is a perspective view of a base and a second set of internal walls and an intermediate floor; Figure 3 is a perspective view of a base including internal walls, a second set of internal walls, an intermediate floor and a lid; Figure 4 is a perspective view of an assembled unit including a base with internal walls a second set of internal walls, an intermediate floor and a lid; Figures 5 and 6 are perspective views of a base including internal walls, a second set of internal walls, an intermediate floor, and a spacer element; Figures 7 and 8 are perspective views of a base including internal walls, a second set of internal walls, an intermediate floor, a spacer element, and a further set of internal walls, an intermediate floor; Figure 9 is a perspective view of an assembled unit including a base with internal walls, two sets of additional of internal walls and intermediate floors and a lid; Figure 10 is a perspective view of an assembled unit including a base with aternal walls, three sets of additional of internal walls and intermediate floors and a lid; Figure 11 is a perspective view of the external side of four bases; Figure 12 is a perspective view of the assembled unit of Figure 4 including edge members; Figure 13 is a plan view of a base with one set of internal walls; Figure 14 is a plan view of a base with two sets of internal walls; and Figure 15 is a perspective view of a frame with three assembled units and edge members.

The present invention will be described with respect to certain drawings but the invention is not limited thereto but only by the claims. The drawings described are only schematic and are non-limiting. Each drawing may not include all of the features of the invention and therefore should not necessarily be considered to be an embodiment of the invention. In the drawings, the size of some of the elements may be exaggerated and not drawn to scale for illustrative purposes. The dimensions and the relative dimensions do not correspond to actual reductions to practice of the invention Furthermore, the terms first, second, third and the like in the description and in the claims, are used for distinguishing between similar elements and not necessarily for describing a sequence, either temporally, spatially, in ranking or in any other manner. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that operation is capable in other sequences than described or illustrated herein. Likewise, method steps described or claimed iii a particular sequence may be understood to operate in a different sequence.

Moreover, the terms top, bottom, over, under and the like in the description and the claims are used for descriptive purposes and not necessarily for describing relative positions. it is to be understood that the terms so used are interchangeable under appropriate circumstances and that operation is capable in other orientations than described or illustrated herein.

Tt is to be noticed that the term "comprising" used used in the claims, should not be interpreted as being restricted to the means listed thereafter; it does not exclude other elements or steps. It is thus to be interpreted as specifying the presence of the stated features, integers, steps or components as referred to, but does not preclude the presence or addition of one or more other features, integers, steps or components, or groups thereof Thus, the scope of the expression "a device comprising means A and B" should not be limited to devices consisting only of components A and B. It means that with respect to the present invention, the only relevant components of the device are A and B. Reference throughout this specification to "an embodiment" or "an aspect" means that a particular feature, structure or characteristic described in connection with the crribodirricrit or aspect is included in at least one en 1110Chlf lent or aspect of the present invention. Thus, appearances of the phrases "in one embodiment", "in an embodiment", or "in an aspect" in various places throughout this specification are not necessarily all referring to the same embodiment or aspect, but may refer to different embodiments or aspects. Furthermore, the particular features, structures or characteristics of any one embodiment or aspect of the invention may be combined in any suitable manner with any other particular feature, structure or characteristic of another embodiment or aspect of the invention, as would be apparent to one of ordinary skill in the art from this disclosure, in one or more embodiments or aspects.

Similarly, it should be appreciated that in the description various features of the invention are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various inventive aspects. This method of disclosure, however, is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Moreover, the description of any individual drawing or aspect should not necessarily be considered to be an embodiment of the invention. Rather, as the following &Urns reflect, inventive aspects lie in fewer than all features of a single foregoing disclosed embodiment. Thus, the claims following the detailed description are hereby expressly incorporated into this detailed description, with each claim standing on its own as a separate embodiment of this invention.

Furthermore, while some embodiments described herein include some features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the invention, and form yet further embodiments, as will be understood by those skilled in the art For example, in the following claims, any of the claimed embodiments can be used in any combination.

In the description provided herein, numerous specific details are set forth.

However, it is understood that embodiments of the invention may be practised without these specific details. In other instances, well-known methods, structures and techniques have not been shown in detail in order not to obscure an understanding of this description.

In the discussion of the invention, unless stated to the contrary, the disclosure of alternative values for the upper or lower limit of the permitted range of a parameter, coupled with an indication that one of said values is more highly preferred than the other, is to be construed as an implied staterrient that each intermediate value of said parameter, lying between the more preferred and the less preferred of said alternatives, is itself preferred to said less preferred value and also to each value lying between said less preferred value and said intermediate value.

The use of the term "at least one" may mean only one in certain circumstances.

The use of the term "any" may mean "all" and/or "each" in certain circumstances.

The principles of the invention will now be described by a detailed description of at least one drawing relating to exemplary features. It is clear that other arrangements can be configured according to the knowledge of persons skilled in the art without departing from the underlying concept (Jr technical teaching, the invention being limited only by the terms of the appended claims.

Figure 1 shows a base 10 cotnprising a square shape planar substrate 25. Towards the perimeter of the base, external side walls 30 are arranged projecting perpendicularly away from the substrate 25. Four unbroken side walls 30 are shown. Within the side walls 30, a series of internal walls 40 are shown forming a honeycomb pattern (hexagonal). 'these internal walls 40 project perpendicularly from the substrate 25 and are solid and unbroken. They do not reach the same height, or level as the tops of the side walls 30, being shorter in height. However, in one embodiment they are taller, reaching the same height or level as the side walls 30.

Positioning means 20 are also shown at each corner of the base 20. These will be explained in more detail below.

In Figure 2 an insert 50 comprising an intermediate floor 55 and internal walls 40 is shown prior to installation onto the base 20. 11he internal walls 40 have the same characteristics (shape, size, arrangement, etc.) as the internal walls 40 described above in relation to the base 10. The intermediate floor 55 includes a lug 57 at each corner; each lug having an upper planar surface.

In Figure 3 this insert 50 is shown fitted into the base 10. The intermediate floor 55 has a shape and size such that it fits snugly inside the side walls 30 of the base 10. The intermediate floor 55 rests against the top of the internal walls 40 located in the base 10. Accordingly, the intermediate floor 55 corms sub-cells between it and the substrate 25 and as defined by the internal walls 40. These sub-cells are substantially air-tight each being bounded by the substrate 25, the intermediate floor 55 and the internal walls 40 and/or side walls 30.

A lid 65 is also shown in Figure 3. The lid 65 comprises a planar surface the SaTTIC size and shape as the base 10 substrate 25, and side walls 70.

The lid 60 is fitted to the base 10 such that each of the four lugs 57 fit inside a corner of the lid such that the upper planar surface of each lug 57 rests against the inside of the lids planar surface 65. 'these lugs 57 help to strengthen the corners of the completely assembled unit.

It is to be noted that the side walls 30 of the base 10 are arranged in size and shape such that they fit snugly inside the side walls 70 of the lid 60. A completed unit 100 is shown in Figure 4, where it is noted that the external surfaces of the lid's side walls 70 form a contiguous surface with the sides 12 of the base 10 substrate 25. In this regard, a "unit" may he referred to as a "cell".

In Figure 5, the lid 60 has been removed from the base 10 and a spacer element 110 is arranged ready to be fitted to the base 10 in its place. The spacer element 110 comprises a frame-like member having a first set of four side walls 120, shaped and sized to fit snugly around the side walls 30 of the base 10, and a second set of four side walls shaped and sized to be substantially the same shape and size as the side walls or the base 10.

Figure 6 shows this spacer element 110 having been fitted to the base 10. Although not shown, the internal walls 40 will extend away from the substrate 25 and reach the height of the first set of side walls 120 An insert 50, as described above, is shown prior to installation onto the base 10 in Figure 7.

Tn Figure 8 this insert 50 is shown fitted into the base 10. The intermediate floor 55 has a shape and size such that it fits snugly inside the side walls 110 of the spacer element 110. The intermediate floor 55 rests against the top of the internal walls 40 located in the base 10. Accordingly, the intermediate floor 55 forms sub-cells between it and the substrate 25 and as defined by the internal walls 40. These sub-cells are substantially air-tight each being bounded by the two intermediate floors 552nd the internal walls 40 and/or side walls 110.

A completed unit 200 is shown in Figure 9, whereby a lid 60 has been fitted over the second set of side walls 130 such that its side walls 70 form a contiguous surface with the side walls 120 of the spacer element and the side walls 12 of the base 10 substrate 25. The lid 60 is fitted to the base 10 such that each of the four lugs 57 tit inside a corner of the lid such that the upper planar surface of each lug 57 rests against the inside of the lids planar surface 65. These lugs 57 help to strengthen the corners of the completely assembled unit.

In the unit 200 shown in Figure 9, there are three separate layers defined by the substrate 25, two intermediate floors 55, and the lid 60. Each layer is sub-divided into sub-cells by the internal walls 40.

The completed units 100, 200 are parralelepiped in shape.

Figure 10 depicts another assembled, completed unit 300 which is also parallelepiped in shape, however, this one has yet another spacer element 110 included in a similar manner to that described above with reference to Figures 5 to 9. An additional insert 50 is also included. In this unit 300, there are four separate layers defined by the substrate 25, three intermediate floors 55, and the lid 60. Each layer is sub-divided into sub-cells by the internal walls 40.

The rear of the four closely positioned bases 10 are shown in Figure 11 in a square pattern. A recess is provided at each corner of each base 10. Each recess includes a socket 15. A positioning means in the form of a plate and lug may be placed in a recess, as required. The lug and socket are arranged to fit one another such that they maintain the positioning means in position relative to the base 10. Positioning means may be provided of a size and shape to fit completely behind only one base, or two bases, or four bases. The positioning means sized and shaped to fit completely behind two bases 10 include two lugs 15 located such that the lugs will only insert correctly into the sockets of two adjacent bases 10, when the two bases are placed immediately adjacent one another. likewise, the positioning means sized and shaped to fit completely behind four bases 10 include four lugs 15 located such that the lugs will only insert correctly into the sockets of four adjacent bases 10, when the four bases are placed immediately adjacent one another in a square pattern.

In Figure 11 a positioning means 20 sized and shaped to fit completely behind the four bases 10 includes four lugs 15 located such that the lugs, arranged in the corners of the fours bases 10, are inserted correctly into the sockets of the four adjacent bases 10, with the four bases placed immediately adjacent one another in a square pattern. The positioning means 20 is arranged in the centre of the square pattern.

Means of adhering 22 the positioning means 20 to a wall, window, ceiling or other planar surface arc provided such as double-sided tape. Although not shown, it will bc understood that single-lug positioning means 20 may be placed at each outer corner of the four-base pattern. Likewise, although not shown, it will be understood that double-lug positioning means 21 (with reference to Figure 2) may be placed at the junction of the two outer corners of the two upper bases 10 and at the junction of the two outer corners of the two lower bases 10 of the four-base pattern.

Together, these positioning means and adhesive means allow the units to be stuck to the planar surface in close alignment to thereby create a layer of insulation.

When the planar surface has a size which does not lend itself to a whole number of units, smaller units may be provided to fille any gaps at the end of a row of units.

Examples of such smaller "edge" units 350 are shown in Figure 12, comprising of similarly layered parallelepiped structures including substantially air-tight sub-cells.

Tongue 360 and groove 370 retaining elements are provided for releasably clipping the smaller units together, and to an adjacent full-size unit 100.

A rectangular frame 400 is shown in Figure 13, comprising a row of three units 100 and two smaller "edge" units to completely fill the frame across its width. Further units may be positioned in rows below to completely fill the frame. The frame may be a window frame. Alternatively, it may define a planar wall or ceiling of a structure.

A plan view of the internal walls 40A is shown in Figure 14 arranged to form a plurality of hexagonal sub-cells. If a second layer of internal walls 4013 is provided, for instance by including an additional intermediate floor with internal walls, then the intermediate floor may be placed in the unit such that the hexagonal pattern has been rotated 90 degrees with respect to the first layer so as to form a different pattern of walls 40A, 4013 as shown in Figure 15. This may provide a more visually interesting pattern of walls which may be viewed through the lids if the units comprise clear materials.

Each unit 100, 200, 300 may have a dimension of 90mm by 90mm, although other dimensions are contemplated such as 50mm by 50mm, 75mm by 75nam, 100mm by 100rnm, 150rnm by 150mm, 200mm by 200mm, 300mm by 300mm, 500mm by 500mm. The thickness of each unit may lie in the range 18mm to 50mm. Each spacer element may increase the thickness by approximately omm. Each layer within each unit may have a height of approximately ornm The thickness of the side 12 and internal walls 40 may lie in the range 1 to 1.5mm, although other thicknesses are contemplated such as lnam to 5mm.

In tests, the U value of a 4timi single glazed window may be reduced from 5.0 to 1.5 with an array of two-layer units attached thereto. in tests, the U value of a 4min single glazed window may he reduced from 5.0 to 1.3 with an array of four-layer 35mtn units attached thereto. In tests, the U value of a 4mm single glazed window may be reduced to 1.5 with an array of two-layer units attached thereto. In tests, the U value of an air-filled double-glazed window may be reduced from 2.0 to 1.2 with an array of two-layer units attached thereto. In tests, the LT value of a gas-filled double-glazed window may be reduced to 1.1 with an array of four-layer units attached thereto.

Claims

CLAIMS 2. 3. 4.
Insulation apparatus comprising a plurality of individual cells, wherein each cell comprises a base and a removably replaceable lid, the base and lid configured such that when fitted together an interior air-tight space is formed, each cell further comprising a first set of internal walls extending from the base of the cell to the lid of the cell, the internal walls configured to separate the interior air-tight space into a plurality of substantially air-tight sub-cells.
The insulation apparatus of claim 1, further comprising a spacer element configured to fit between the lid and the base to increase the distance between them, said spacer element configured such that when placed between the lid and the base, the interior remains air-tight.the insulation apparatus of claim 2, further comprising a second set of internal walls and an intermediate floor, the second set of internal walls extending from the floor, the floor configured to lie against the first set of internal walls, the first and second sets of internal walls and the floor configured to further separate the interior into individual air-tight sub-cells.
The insulation apparatus of claim 3, further comprising one or more spacer elements configured to fit between the lid and the base to increase the distance between them, said spacer elements configured such that when placed between the lid and the base, the interior remains air-tight; the apparatus further comprising one or more further sets of internal walls and further intermediate floors, each of the further sets of internal walls extending from one of the further intermediate floors, the Further intermediate floors configured to separate each cell into air-tight layers, the further sets of internal walls configured to further separate each layer into individual air-tight sub-cells.
5. The insulation apparatus of any preceding claim, further comprising positioning means configured to releasably hold adjacent cells immediately adjacent one another. ii
6. The insulation apparatus of claim 5, wherein the positioning means comprise elements configured to attach to the base or lid of two adjacent cells.
7.the insulation apparatus of claim 6, wherein the elements comprise projections and each cell comprises sockets on the lid or base, the projections and sockets configured to provide a close fit when connected together.
8 The insulation apparatus of any one of claims 5 to 7, wherein each base or lid comprises a rebate for accommodating the positioning means such that, in use, each base or lid is placeable immediately against a planar substrate without any gap therebetween.
9.
10.
11.
12.
13.
14.
15.the insulation apparatus of any preceding claim, further comprising attachment means for releasably attaching the cells to a substrate to thereby provide a layer of insulation.The insulation apparatus of claim 9, wherein the attachment means includes adhesive.the insulation apparatus of either one of claims 9 and 10, when dependent directly or indirectly on any one of claims 5 to 8 wherein the attachment means are arranged on one side of the positioning means.The insulation apparatus of any preceding claim, wherein the base, lid and internal walls comprise clear plastics.The insulation apparatus of any preceding claim, wherein the base, lid and internal walls comprise relatively rigid materials.the insulation apparatus of any preceding claim, wherein the corners of each cell have sharp corners for allowing adjacent cells to be positioned tightly against one another.The insulation apparatus of any preceding claim, wherein each base or lid has a square shape.
16. The insulation apparatus any one of claims 1 to 14, wherein each base or lid has a rectangular shape.
17. the insulation apparatus of any preceding claim, further comprising wherein the base, lid and internal walls comprise clear plastics.
18. A method of insulating a planar surface window, comprising the steps of providing insulation apparatus according to any one of claims 1 to 17, and arranging the cells immediately adjacent one another in a layer across the window.
19. The method of insulating a planar surface, according to claim 18, when dependent directly or indirectly on any one of claims 5 to 8, further comprising the step of using the positioning means to releasably align adjacent cells relative to one another.
20. The method of insulating a planar surface window, according to either one of claims 18 and 19, when dependent directly or indirectly on any one of claims 9 to 11, further comprising the step of using the attachment means to releasably attach the cells to the window.