Thermoformed vacuum insulation container

Claim 2

A vacuum insulation panel containing a volume of microporous insulating material and having a useful life measured in years, comprising: a semi-rigid thermoformed container made of a material impervious to gases and moisture and having a central receptacle area with an open top for receiving said volume of said microporous insulating material and being bounded by a peripheral ledge area; a porous layer providing a boundary between ambient atmosphere and said volume of microporous insulating material in said receptacle, said porous layer permitting passage of gases and moisture, but preventing passage of said microporous insulating material; and an impermeable layer sealingly received along the entire peripheral ledge area to close said top after said receptacle area and volume of microporous insulating material has been evacuated of gases and moisture, to prevent entry of gases and moisture into said receptacle during the useful life of said panel; said container and impermeable layer both being formed of a material such that said panel, when sealed closed, is able to maintain an evacuation pressure level of approximately 20 mm Hg for several years.

Claim 3

A vacuum insulation panel containing a volume of microporous insulating material and having a useful life measured in years, comprising: a formed container made of a material impervious to gases and moisture and having a central receptacle area with an open top for receiving said volume of said microporous insulating material and being bounded by a peripheral ledge area; a porous layer sealed to said ledge area providing a boundary between ambient atmosphere and said volume of microporous insulating material in said receptacle, said porous layer permitting passage of gases and moisture, but preventing passage of said microporous insulating material; and an impermeable layer sealingly received along the entire peripheral ledge area to close said top after said receptacle area and volume of microporous insulating material has been evacuated of gases and moisture, to prevent entry of gases and moisture into said receptacle during the useful life of said panel.

Claim 4

A vacuum insulation panel containing a volume of microporous insulating material and having a useful life measured in years, comprising: a formed container made of a material impervious to gases and moisture and having a central receptacle area with an open top for receiving said volume of said microporous insulating material and being bounded by a peripheral ledge area; a porous layer sealed to said ledge area providing a boundary between ambient atmosphere and said volume of microporous insulating material in said receptacle, said porous layer permitting passage of gases and moisture, but preventing passage of said microporous insulating material; and an impermeable layer sealingly received along the entire peripheral ledge area to close said top after said receptacle area and volume of microporous insulating material has been evacuated of gases and moisture, to prevent entry of gases and moisture into said receptacle during the useful life of said panel.

Claim 5

A vacuum insulation panel according to claim 1, wherein said porous layer completely surrounds said microporous insulating material.

Claim 6

A vacuum insulation panel according to claim 3, wherein said porous layer forms a sealed bag.

Claim 7

A vacuum insulation panel according to claim 1, wherein said container is substantially rectangular in shape.

Claim 8

A vacuum insulation container according to claim 1, further comprising a sealed container made of material impervious to gases and moisture and containing a charge of microporous insulating material received within said central receptacle area along with said microporous insulating material.

Claim 9

A vacuum insulation container according to claim 6, wherein gettering materials are used within said containers, with different gettering materials used in the different chambers.

Claim 10

A vacuum insulation container according to claim 2, further comprising a sealed container made of material impervious to gases and moisture and containing a charge of microporous insulating material received within said central receptacle area along with said microporous insulating material.

Claim 11

A vacuum insulation container according to claim 8, wherein gettering materials are used within said containers, with different gettering materials used in the different chambers.

Claim 12

A vacuum insulation panel containing a volume of microporous insulating material and having a useful life measured in years, comprising: a formed containing made of a material impervious to gases and moisture and having a central receptacle area with an open top for receiving said volume of said microporous insulating material and being bounded by a peripheral ledge area; a porous layer providing a boundary between ambient atmosphere and said volume of microporous insulating material in said receptacle, said porous layer permitting passage of gases and moisture, but preventing passage of said microporous insulating material; an impermeable layer sealingly received along the entire peripheral ledge area to close said top after said receptacle area and volume of microporous insulating material has been evacuated of gases and moisture, to prevent entry of gases and moisture into said receptacle during the useful life of said panel; and at least one passage formed through said receptacle area, said passage formed by a hollow boss with a passage therethrough and having a flat surface area at a top end, substantially coplanar with said ledge area, for sealing engagement with said impermeable layer.

Claim 13

A vacuum insulation panel containing a volume of microporous insulating material and having a useful life measured in years, comprising: a formed containing made of a material impervious to gases and moisture and having a central receptacle area with an open top for receiving said volume of said microporous insulating material and being bounded by a peripheral ledge area; a porous layer providing a boundary between ambient atmosphere and said volume of microporous insulating material in said receptacle, said porous layer permitting passage of gases and moisture, but preventing passage of said microporous insulating material; an impermeable layer sealingly received along the entire peripheral ledge area to close said top after said receptacle area and volume of microporous insulating material has been evacuated of gases and moisture, to prevent entry of gases and moisture into said receptacle during the useful life of said panel; and at least one passage formed through said receptacle area, said passage formed by a hollow boss with a passage therethrough and having a flat surface area at a top end, substantially coplanar with said ledge area, for sealing engagement with said impermeable layer.

Claim 14

A vacuum insulation container according to claim 10, further comprising a sealed container made of material impervious to gases and moisture and containing a charge of microporous insulating material received within said central receptacle area along with said microporous insulating material.

Claim 15

A vacuum insulation container according to claim 11, wherein gettering materials are used within said containers, with different gettering materials used in the different chambers.

Claim 16

A vacuum insulation panel containing a volume of microporous insulating material and having a useful life measured in years, comprising: a formed container of a material impervious to gases and moisture and having a central receptacle area with an open top for receiving said volume of said microporous insulating material and being bounded by a peripheral ledge area; a plurality of receptacle areas formed in said container to provide a plurality of discrete insulation filled volumes; a porous layer providing a boundary between ambient atmosphere and said volume of microporous insulating material in said receptacle, said porous layer permitting passage of gases and moisture, but preventing passage of said microporous insulating material; and an impermeable layer sealingly received along the entire peripheral ledge area to close said top after said receptacle area and volume of microporous insulating material has been evacuated of gases and moisture, to prevent entry of gases and moisture into said receptacle during the useful life of said panel; said container being made of a material which at room temperature can be folded at least 90° along a line between adjacent receptacle areas such that said panel can be folded to form a multi-sided panel.

Claim 17

A vacuum insulation panel containing a volume of microporous insulating material and having a useful life measured in years, comprising: a formed container of a material impervious to gases and moisture and having a central receptacle area with an open top for receiving said volume of said microporous insulating material and being bounded by a peripheral ledge area; a plurality of receptacle areas formed in said container to provide a plurality of discrete insulation filled volumes; a porous layer providing a boundary between ambient atmosphere and said volume of microporous insulating material in said receptacle, said porous layer permitting passage of gases and moisture, but preventing passage of said microporous insulating material; and an impermeable layer sealingly received along the entire peripheral ledge area to close said top after said receptacle area and volume of microporous insulating material has been evacuated of gases and moisture, to prevent entry of gases and moisture into said receptacle during the useful life of said panel; said container being made of a material which at room temperature can be folded at least 90° along a line between adjacent receptacle areas such that said panel can be folded to form a multi-sided panel.

Claim 18

A vacuum insulation container according to claim 13, further comprising a sealed container made of material impervious to gases and moisture and containing a charge of microporous insulating material received within said central receptacle area along with said microporous insulating material.

Claim 19

A vacuum insulation container according to claim 14, wherein gettering materials are used within said containers, with different gettering materials used in the different chambers.

Claim 20

A vacuum insulation panel containing a volume of microporous insulating material and having a useful life measured in years, comprising: a formed container made of a material impervious to gases and moisture and having a central receptacle area with an open top for receiving said volume of said microporous insulating material and being bounded by a peripheral ledge area; a porous layer providing a boundary between ambient atmosphere and said volume of microporous insulating material in said receptacle, said porous layer permitting passage of gases and moisture, but preventing passage of said microporous insulating material; and an impermeable layer sealingly received along the entire peripheral ledge area to close said top after said receptacle area and volume of microporous insulating material has been evacuated of gases and moisture, to prevent entry of gases and moisture into said receptacle during the useful life of said panel; said container and impermeable layer both being formed of a multi-ply laminate material which is resistant to foam chemicals, yet allows foam adhesion.

Claim 21

A vacuum insulation panel containing a volume of microporous insulating material and having a useful life measured in years, comprising: a formed container made of a material impervious to gases and moisture and having a central receptacle area with an open top for receiving said volume of said microporous insulating material and being bounded by a peripheral ledge area; a porous layer providing a boundary between ambient atmosphere and said volume of microporous insulating material in said receptacle, said porous layer permitting passage of gases and moisture, but preventing passage of said microporous insulating material; and an impermeable layer sealingly received along the entire peripheral ledge area to close said top after said receptacle area and volume of microporous insulating material has been evacuated of gases and moisture, to prevent entry of gases and moisture into said receptacle during the useful life of said panel; said container and impermeable layer both being formed of a multi-ply laminate material which is resistant to foam chemicals, yet allows foam adhesion.

Claim 22

A vacuum insulation container according to claim 16, further comprising a sealed container made of material impervious to gases and moisture and containing a charge of microporous insulating material received within said central receptacle area along with said microporous insulating material.

Claim 23

A vacuum insulation container according to claim 17, wherein gettering materials are used within said containers, with different gettering materials used in the different chambers.

Claim 24

A vacuum insulation panel containing a volume of microporous insulating material and having a useful life measured in years, comprising: a semi-rigid thermoformed container made of a material impervious to gases and moisture and having a central receptacle area with an open top for receiving said volume of said microporous insulating material and being bounded by a peripheral ledge area; an impermeable layer sealingly received along the entire peripheral ledge area to close said top after said receptacle area and volume of microporous insulating material has been evacuated of gases and moisture, to prevent entry of gases and moisture into said receptacle during the useful life of said panel; said container and impermeable layer both being formed of a multi-ply laminate material which is resistant to foam chemicals, yet allows foam adhesion such that said panel, when sealed closed, is able to maintain an evacuation pressure level of approximately 20 mm Hg for several years.

Claim 25

A vacuum insulation panel containing a volume of microporous insulating material and having a useful life measured in years, comprising: a semi-rigid thermoformed container made of a material impervious to gases and moisture and having a central receptacle area with an open top for receiving said volume of said microporous insulating material and being bounded by a peripheral ledge area; an impermeable layer sealingly received along the entire peripheral ledge area to close said top after said receptacle area and volume of microporous insulating material has been evacuated of gases and moisture, to prevent entry of gases and moisture into said receptacle during the useful life of said panel; said container and impermeable layer both being formed of a multi-ply laminate material which is resistant to foam chemicals, yet allows foam adhesion such that said panel, when sealed closed, is able to maintain an evacuation pressure level of approximately 20 mm Hg for several years.

Claim 26

A vacuum insulation container according to claim 19, further comprising a sealed container made of material impervious to gases and moisture and containing a charge of microporous insulating material received within said central receptacle area along with said microporous insulating material.

Claim 27

A vacuum insulation container according to claim 20, wherein gettering materials are used within said containers, with different gettering materials used in the different chambers.