EP3889377A1

EP3889377A1 - Thermal lining and systems utilising same

Info

Publication number: EP3889377A1
Application number: EP21166685.4A
Authority: EP
Inventors: Adam ALLFREY
Original assignee: Direct Acoustics Ltd
Current assignee: Direct Acoustics Ltd
Priority date: 2020-04-01
Filing date: 2021-04-01
Publication date: 2021-10-06
Also published as: AU2021202068A1; GB202004818D0

Abstract

The present disclosure relates to a liner comprising a thermal insulation portion (1) connected to a bead (16), wherein the thermal insulation portion comprises multiple distinct layers (3) of insulation material. Systems, particularly temporary structures such as marquees and tents, are also provided which utilise the liners to improve their thermal insulation properties.

Description

The present invention relates to a liner comprising a thermal insulation portion connected to a bead, wherein the thermal insulation portion comprises multiple distinct layers of insulation material. Systems, particularly temporary structures such as marquees and tents, are also provided which utilise the liners to improve their thermal insulation properties.
Temporary structures, such as tents and marquees, are routinely used in situations where additional covered space is required in an area where there exists no permanent structure, and where it would be inappropriate to build a permanent structure. This is usually because the situation is only temporary, and does not therefore warrant the expense, additional administration, planning permissions and extra labour and materials required for erecting (and thereafter maintaining) a permanent structure. In order to provide increased protection from the elements for the internal space, these temporary structures will often have side walls as well as a roof. Enclosing the internal space in this manner also provides privacy for the events occurring inside the structure, as well as shielding the outside area from the events within.
Typically, a temporary structure will comprise a frame over which material is positioned in order to form the roof and walls of the structure. If the structure is large, then there may be poles within the internal space to help support the roof. There are certain types of structures, such as Clearspan and Multispan marquees, that although large have been developed to do away with the requirement of supporting poles within the internal space. This allows complete freedom of action within. Such systems are also modular, which means that the marquee can be as long as required and up to 60m in clear span width.
The clear span systems make use of wall and roof beams containing keder channels. Keder systems are well known and essentially comprise a channel into which fits a bead (e.g. rod) or a rope. Material attached to the rope or rod protrudes out of a slot in the channel, but the slot is too narrow for the rope or rod to be pulled through. There are many configurations of the basic product and a growing number of applications for its use. In the world of fabric structures, it is used in tents, clear span structures, temporary buildings, temporary roofs, agricultural environments, and scaffold covers. Keder is also used to attach awnings to buildings, camping vehicles, and boats.
In clear span marquees, the support beams are typically made from aluminium, and have keder channels running down the length of them. The diameter of the channel varies depending on the size of marquee profile. With multiple keder channels, typically set near the corners of the beams (where the beams have a substantially square or rectangular section, although other cross sections can be utilised using the same principles), the beams allow the attachment of materials to form the roof portions and side walls. The nature of temporary structures, such as tents and marquees, often means that the materials from which they are made are relatively thin and flexible so that they can be folded or otherwise suitably stored for transport to and from the site. Typically a material such as PVC coated fabric is used, but there are variations available depending on the requirement of the structure. For example, roofs and walls can be changed to clear panels, or even glass or hard sided acrylic.
Most marquees offer no or negligible thermal insulation, the roof or wall simply providing 650g PVC fabric weatherising roof and walls. The only thermal insulation that is currently achieved in marquees is by using what is known as a thermo roof (and this in only approx. 3% of marquees in operation). This uses two layers of PVC fabric fixed to a keder bead and a compressor continuously pumping air between each PVC fabric layer ensuring pressure is maintained at all times. Manufacturers have designed this thermal solution to go into the roof and gable triangles of a marquee. They are not installed into the walls of a marquee. Marquee walls typically are treated by using insulation/ISO panels which are effectively polyisocyanurate (PIR) insulation boards or ABS 4mm ridged plastic. These connect to the marquee using a 'U' aluminium section. The 'U' section has a small 'C' channel connected to it meaning it can be clipped it into the marquee keder channel. The insulation/ABS panel then slides into the 'U' section.
However, using two different products to control the roof, gable and walls independently can produce inconsistent results. Currently with what is available, the inflated roof is the largest surface area and a significant weak link.
There is therefore a need for a product which attempts to improve on the existing thermal insulation offerings to achieve one or more of: (i) maintaining a stable temperature; (ii) reduce energy consumption; and (iii) cut fuel bills and reduce harmful CO₂ emissions. It is also useful to be able to create a bespoke environment.
The present disclosure provides a structure comprising a plurality of supporting elements, each of said supporting elements containing at least one channel adapted to receive a bead connected to a liner, said liner comprising a thermal insulation portion connected to said bead, wherein said thermal insulation portion comprises multiple distinct layers of insulation material.
There is also provided a liner for use in the system, said liner comprising a thermal insulation portion comprising multiple distinct layers of insulation material and being connected to a bead.
The multiple layers of material of the thermal insulation portion preferably comprise at least one layer of a reflective material, optionally multiple layers of reflective material. Preferably the reflective material comprises foil.
The multiple layers of material of the thermal insulation portion preferably additionally comprise at least one layer of an insulative material alternative to the reflective material, optionally multiple layers of insulative material.
In various arrangements of the liner there may be at least one layer adapted to provide additional strength to the liner. Such a layer is typically comprised of mesh or gauze. Such open lattice arrangements have been found to provide additional mechanical strength to the liner which aids in the prevention of rips and tears. Such events are unwanted and may compromise the insulative properties of the liner.
Alternatively or in addition, various arrangements of the liner can optionally comprise a (preferably outer) protective layer that inhibits, prevents, or can help to prevent, fluid penetration into the liner and/or which can be easily cleaned. Where present, preferably the protective layer comprises a plastics material, such as PVC. Typically the protective layer when present will be situated at least on the outer layer of the liner that faces towards the internal space of the temporary structure when in situ.
The liner of the present disclosure has also been found to have beneficial properties in controlling vapour and condensation.
In some arrangements, the liner comprises at least one acoustic layer adapted to absorb sound and/or reduce noise penetration through the liner.
In some arrangements, the liner further comprises at least one attachment region on an outer face for attaching additional material to said liner.
The present invention will now be described in more detail in relation to the figures, in which:

Figure 1 is a representation of a thermal insulation portion of a liner comprising multiple distinct layers of material.
Figure 2 is a cross sectional view of a support beam incorporating keder channels.
Figure 3 is a cross section of the support beam of Figure 2 with a standard roof panel/wall panel installed along one keder channel, and a thermal liner of the present disclosure installed along another keder channel. In the arrangement shown, the thermal liner also comprises an attachment region to which a further lining portion is attached.

A number of temporary structures are in existence. Of widespread use are Clearspan marquee systems, which are modular systems that do not need supporting poles within the internal space. This provides for an internal space that is free from obstacles. These systems employ supporting beams with keder channels incorporated into them, to allow roofing and wall panels to be installed relatively quickly and easily between the supporting beams. The keder system provides a join that is tight enough to weatherise the roof and walls.
Keder systems are well known, and in their basic forms comprise a channel into which fits a bead. The bead is then connected to, or integrated within, the material that is desired to be connected to the support beam via the keder channel. The connection of the bead to the material can be carried out in a number of ways. Typically this involves wrapping the bead in an intermediate material and allowing the intermediate material to extend from the bead in one or two flaps. The flap(s) of the intermediate material are then connected (either directly or via a further intermediate material, which can be the same or different) to the material that is desired to be connected to the support beam via the keder channel. The person of skill in the art is aware of the various configurations that can be employed in connecting keder beads to panelling materials.
The present invention is based in part on the connection of a keder bead to a multi-layered thermal insulation liner, which is understood not to have been conducted before now. The present invention also relates to the use of such a liner within a structure employing beams with keder channels, to improve the thermal properties of that structure.
The liner of the present disclosure comprises a thermal insulation portion comprising multiple distinct layers of insulation material, which is also connected (directly or indirectly) to a bead that is adapted to be used in a keder system (e.g. adapted to fit into a keder channel). An example of such a multi-layered thermal insulation portion (1) is depicted in Figure 1. Note that the figure is merely a representation to highlight various layers of a multi-layered thermal insulation portion, but the thermal insulation portion can comprise a greater or lesser number of layers depending on requirements.
Figure 1 depicts two materials (2, 3) being used in multiple layers. As is generally preferred, at least one of the materials used in the thermal insulation portion is a reflective material (2). The reflective material can comprise foil. Reflective materials are useful for thermal insulation since they are better than non-reflective materials at reflecting radiant heat rather than absorbing it. Optionally there can be multiple layers of reflective material (which can be the same material or different) used throughout the thermal insulation portion, as is depicted in Figure 1. This provides more opportunity to reflect any heat that has managed to pass through surrounding layers.
By reflective material, we intend to mean "reflective" as used in common parlance as being a material that is specifically designed to reflect radiation (e.g. typically a "shiny" material).
As well as the one or more layers of reflective material depicted in Figure 1, there is also shown additional layers of an insulative material (3) alternative to the reflective material. Again, although Figure 1 shows multiple layers of insulative material, this can be adapted according to need. In some arrangements, therefore, there might only be a single layer of the alternative insulative material.
It is useful to have at least one layer of an insulative material alternative to the reflective material so as to improve the reduction of heat conduction which is generally not suitably achieved with a layer of reflective material alone.
The skilled person will be aware of a number of different materials that are suitable as insulative materials. For example, the alternative insulative material can comprise cotton fibres and/or synthetic material. Moreover, the layers of alternative insulative material do not need to be the same throughout in the thermal insulation portion. So there can be multiple layers of alternative insulative material, each one made from the same material as each other (e.g. cotton fibres), each one made from different material from each other (e.g. cotton fibre, synthetic material 1, synthetic material 2, synthetic material 3, etc.), or a variation of those two extremes where a number of alternative insulative materials are used throughout the thermal insulation portion but where different layers comprise the same alternative insulative material (e.g. cotton fibre, synthetic material 1, cotton fibre, synthetic material 1, etc.).
The liner of the present disclosure should also be relatively lightweight, as these temporary structures and marquee cannot take excessive weight in the roof. Therefore materials and numbers of layers for the liner can be chosen in order to combine suitable insulative properties with appropriates combined mass of the liner so as to prevent undesired sag/stress on the joins/stress on the supporting beams etc.
As depicted in Figure 1, preferably the thermal insulation portion will comprise a reflective material and the alternative insulative material in alternating layers, broadly speaking. This does not mean to say that the alternating layers need to follow a strict pattern of, for example, foil-cotton-foil-cotton-foil-cotton-etc. Instead, the thermal insulation portion can comprise different patterns of alternative layers, such as foil-cotton-foil-foil-cotton-[synthetic material-]foil-etc. The skilled person will be able to select appropriate arrangements of layers depending on requirements.
Moreover, the thickness of two or more of the layers making up the multi-layered liner may be the same or different, depending on need. So while the reflective material will typically be of relatively constant thickness in each of the layers where it is utilised (although again may be of different thicknesses), the alternative insulative layers might vary in thickness depending on material used and on requirement. In this regard, in some arrangements it might, for example, be desired to have a thin layer of insulative material in between two reflective layers followed by a thicker layer of the same or different insulative material between other layers of reflective material.
In various arrangements of the liner of the present disclosure, there is optionally at least one layer that is incorporated to provide additional mechanical strength to the liner. Having such a layer strengthens and improves the durability and integrity of the product. This is useful when the liner is intended for repeated operation of installation and dismantling, where it might be folded and unfolded repeatedly. In certain scenarios it may also be desired to have a liner which is robust to prevent undesired compromise of the liner. This might particularly be the case when the liner is intended to be used in rapid deployment temporary hospitals, or in temporary morgues where additional assurance of robustness may be desired.
The layer to provide mechanical strength, where present, can be made of any suitable material in suitable configuration. In the present disclosure it is preferred to be of a lattice structure, such as comprises open cells between crossing strips of material, such as gauze or mesh. This has been found to provide adequate strength while e.g. not unnecessarily increasing weight of the overall structure. The material is usefully a plastics material, such as PVC, but can be a natural material such as a cotton mesh or the like. This might be practicable if the mesh is subsequently covered by a protective layer, as will be discussed in more detail below.
In some arrangements there may also be one or more layers of mesh throughout the liner. These could, for example, be in an offset arrangement from each other to provide additional strength in multiple directions of force.
In arrangements where a strengthening layer is present, at least one layer of strengthening material (e.g. mesh) is preferably situated on or near at least one of the outer faces of the liner. Such a face could be one or both of the outward facing portion of the liner (i.e. the portion facing away from the inner space of the structure) or the inward facing portion of the liner (i.e. the portion facing towards the inner space of the structure). In some arrangements it has been found that mesh on the outward facing portion is less preferred as it can reduce the insulative effectiveness of the liner. Although in certain arrangements the mesh on the outer face can subsequently be covered with a protective layer, in which case the mesh would not be the outermost layer of the liner.
Alternatively or in addition, various arrangements of the liner may comprise an outer protective layer that prevents, or can help to prevent, fluid penetration into the liner and/or which can be easily cleaned and/or disinfected. Preferably the protective layer comprises a plastics material, such as one incorporating PVC (e.g. PVC or PVC fabric). Typically where present, the protective layer will be situated at least on the outer layer that faces towards the internal space of the temporary structure when in situ. This allows for easy cleaning of the liner should it become contaminated by events occurring within the internal space of the temporary structure. For example, by bodily fluids, foodstuffs, etc. In certain arrangements, it may be desired to have the protective layer substantially covering both inward-facing and outward-facing portions of the liner. In such arrangements, the protective layer would typically cover any strengthening layer (e.g. mesh) that was present on the outermost layer of the thermal insulating portion of the liner.
In some arrangements, the protective layer and the strengthening layer may be integrated as a single layer. For example a protective layer may be manufactured with an incorporated mesh to give strength and protective properties.
In some arrangements, the protective layer may not be present on one or both surfaces of the liner. For example, such a layer may not be required in every situation or on every liner panel of the structure even in a given situtation. For example roofing panels are less likely to become contaminated than wall panels, and thus it may not be desired to incorporate the extra protection (and therefore weight) provided by a protective layer for such panels.
In some arrangements, the liner comprises at least one acoustic layer adapted to absorb sound and/or reduce noise penetration through the liner. Although the thermal insulation portion is likely to have some sound absorbing properties in light of the various insulative materials used (these typically are 'padding' layers), it may be desired to include at least one layer in the liner that is specifically designed to absorb and attenuate sound. As such, the material and/or thickness of the acoustic layer(s) is typically different from the other materials and/or thickness used as the reflective material and as the alternative insulative material. Such an acoustic layer could be made from e.g. foam or other suitable materials. Foam is useful for sound absorption. Mass loaded vinyl and rubber can be used to attenuate sound. For example, good acoustic properties can be achieved using a layer of mass loaded vinyl and a layer of foam.
As mentioned above, the present invention is based in part on the thermal liner being connected to a keder bead such that it can be used in keder systems. A typical beam for a keder system is presented in Figure 2, where a supporting beam (10) with rectangular section is shown having four keder channels (12) at its corners.
Typically a keder bead comprises a flexibly resilient material, such as a plastic circular extrusion. The profile of the bead is such that it suitably fits into the keder channel of the support beam. For example, the diameter of the channel can vary depending on the size of marquee profile. Typically the keder channel can be approximately 4mm larger than the keder bead used within the linings, which allows the user to pull/slide each lining into its required position with relative ease.
In order to connect the keder bead to the liner, the bead is typically initially wrapped in a material that is resilient to being slid into and out of the keder channels during erection and dismantling. , such as canvas or other natural or synthetic material. In some arrangements the material wrapping the keder bead extends from the bead and can be attached directly to the thermal liner. However, for ease of manufacture it is often the case that the material wrapping the keder bead extends out and is connected to an auxiliary material which is then connected to the thermal liner. If the auxiliary material is suitably chosen to correspond to the outer layer of the thermal lining (such as a plastics (e.g. PVC) flap or strip, where the outer layers of the thermal lining comprise a PVC mesh and/or PVC protective layer), then the auxiliary material can advantageously be high frequency (HF) welded to both of the outer layers of the liner to provide a strong bond. Of course, the skilled person will be aware of other suitable connection methods, such a stitching, gluing, riveting, etc.
In effect, the bead is connected to a first intermediate material, and the first intermediate material is connected to the thermal liner optionally through at least a second intermediate material. The first and second intermediate material individually can be natural or synthetic, such as canvas or other material such as a plastics material (e.g. PVC).
Typically the bead is connected at at least one edge of the liner, usually on two opposite edges to allow the liner to be slid into keder channels on two different support beams. The keder bead need not be continuous down the entire edge of the liner, for example if a break is desired to make folding more easy. In some arrangements the bead could be offset from the edge of the liner and attached to one of the outer facing portions away from the edge to allow the edge of the liner to overhang the bead. In this manner, it is possible in use that once the liner has been installed into the supporting beam, then the edge of the liner overhangs the support beam itself and hence covers the keder join to provide improved insulation around the join.
In particular arrangements of the liner disclosed herein, the waterproof PVC membrane and PVC mesh/gauze is fixed to the keder bead via high frequency welding. This process takes approximately 10 seconds fusing each product together.
The thermal qualities come from the multi-layered reflective foil system, typically incorporated with cotton fibres. There may be approximately 40 layers within the thermal liner including the internal PVC and exterior PVC gauze.
In arrangements where a foil layer (i.e. reflective material) is an outer layer of the thermal insulation portion of the liner, the foil is preferably stitched, riveted, stuck, and bonded and/or welded into the protective (PVC) and/or strengthening (mesh) membrane.
The composite can typically comprise the following:

PVC Open Cell Gauze/Mesh ------------------ attached to Keder Bead (optional layer)
19 layer foil/cotton sheets
19 layer foil/cotton sheets
PVC Waterproof Membrane ------------------ attached to Keder Bead

However, as discussed the number of layers can be increased or decreased to achieve a desired thermal efficiency according to need.
The present disclosure also provides a structure comprising a plurality of supporting elements, each of said supporting elements containing at least one channel adapted to receive a thermal liner as described herein (i.e. with a multi-layered thermal insulating portion connected to a keder bead).
The structure is typically a temporary structure, such as tent or marquee. The utility of the structure can vary depending on requirements. However, the use of the thermal insulation liner of the present disclosure is particularly beneficial in situations where temperature regulation is of importance. These can be in the leisure sector where outdoor functions are prevalent, such as weddings, music events, dining, acts of worship, conferencing, etc. where the comfort of users of the structure is of importance. However, the use of the thermal insulation liner of the present disclosure is also important for other functions such as in rapid deployment hospital facilities, temporary morgues / mortuaries, quarantine facilities, isolation units, etc.
As depicted in figure 3, an additional advantage of utilising a thermal liner (1) with a keder system is that the thermal liner (1) can be slid into the keder channel (12) (for example of a clear span marquee having supporting beams (10) containing roofing / wall panels (14)), greatly improving the ease of installation. The nature of the system also means that there are significantly fewer gaps present between the liner (1) and the support beams (10) (since the liner is connected to the keder bead (16) which is slid into the support beam (10) itself, thereby forming a substantially continuous barrier between the inner space and the outer space) thus improving the thermal qualities of the temporary structure and greatly reducing areas where the thermal qualities are compromised or where drafts might occur.
However, since the liner (1) of the present disclosure typically attaches to support beams (10) of the structure along an edge of the beam, in structures comprising a number of support beams there can potentially be a not-insignificant area over which the bare beams are exposed and/or where there is a reduction of insulation (e.g. over the beam itself, or along the joins between the thermal liner and the keder bead). In some arrangements of the liner, therefore, the liner (1) further comprises at least one attachment region (18) on an outer face for attaching additional material (20) to said liner. Preferably the attachment region (18) comprises a hook and loop portion (e.g. Velcro ®) for attaching the liner to the additional material, although other attachment means will be apparent to the skilled person (e.g. poppers, zips, etc.). The additional material (20) can be a further lining portion comprising a layered structure as described in respect of the liner disclosed herein. Or it may be a much more simple arrangement of material, for example simply a plastics material such as PVC in order to protect the beam from unwanted contact with the inside space. The further lining portion will also have an attachment region (18') that is complimentary to that on the liner (1). With two liners situated either side of a beam each having an attachment portion, the lining portion can be attached to each of the liners across the beam so as to form a substantially continuous internal lining.

Claims

A structure comprising a plurality of supporting elements, each of said supporting elements containing at least one channel adapted to receive a bead connected to a liner, said liner comprising a thermal insulation portion connected to said bead, wherein said thermal insulation portion comprises multiple distinct layers of insulation material.
A liner for use in a keder system, said liner comprising a thermal insulation portion comprising multiple distinct layers of insulation material and being connected to a bead.
The structure of claim 1 or the liner of claim 2, wherein said multiple layers of insulation material comprise at least one layer of a reflective material, optionally multiple layers of reflective material.
The structure or liner of any of claims 1 to 3, wherein said multiple layers of material comprise at least one layer of an insulative material, optionally multiple layers of insulative material, wherein said insulative material is different from a reflective material.
The structure or liner of any of claims 1 to 4, wherein said liner comprises a strengthening layer, wherein said layer is different from the multiple distinct layers of insulation material.
The structure or liner of claim 5, wherein said strengthening layer comprises a lattice structure, preferably a mesh or gauze.
The structure or liner of any of claims 5 or 6, wherein strengthening layer is situated on at least one of the outer faces of the liner.
The structure or liner of any of claims 1 to 7, wherein said liner comprises a protective layer that prevents or inhibits fluid penetration into the liner, preferably wherein said protective layer comprises a plastics material.
The structure or liner of claim 8, wherein the protective layer is situated on one or both outer faces of the liner.
The structure or liner of any of claims 5 to 9, wherein a protective material and strengthening material are integrated into a single layer.
The structure or liner of any of claims 1 to 10, wherein said liner comprises at least one acoustic layer adapted to absorb sound and/or reduce noise penetration through the liner.
The structure or liner of any of claims 1 to 11, wherein said liner further comprises at least one attachment region on an outer face for attaching additional material to said liner.
The structure or liner of claim 12, wherein said liner and additional material are attached to one another.
The structure of claim 1, wherein the structure is a temporary hospital facility or morgue.
The use of the structure or liner of any of claims 1 to 13 in a medical facility, such as a morgue.