FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
COMPLETE SPECIFICATION
(See Section 10)
Thermal insulation system for energy conservation, safety and comfortable working environment and the process for manufacturing the same
PRS Solutions Private Limited, a Company incorporated under the Companies Act, 1956 and having its office at 63, Bombay Samachar Marg, Mumbai - 400 001 Maharashtra State, India.
The following specification particularly describes the nature of this invention and the manner in which it is to be performed

FIELD OF THE INVENTION :
This invention relates to thermal insulation system for energy conservation, safety and comfortable working environment and the process for manufacturing the same. The said thermal insulation system consisting of three separate components (a) provide required insulation of heat loss through conduction, convection & radiation, (b) it is easily installed, capable of easily fitting a variety of surface geometries and (c) it is waterproof, flame retardant, space-saving, lightweight and durable. The said system comprises of an innermost layer of insulation mat, an outer layer of reflective reinforced foil and an end sealing tape made from reinforced foil. The said insulation system finds applications in variety of hot, heat radiating systems, giving benefits of energy saving, providing safety and comfortable working environment.
DESCRIPTION OF THE PRIOR-ART :
In industry, energy has to be expended to raise, lower, or maintain the temperature of objects or process fluids. If these are not insulated, this increases the heat energy requirements of a process, and therefore the cost and environmental impact. With increasing environmental awareness, more emphasis is now being placed on ways to save energy in any building, domestic or commercial.
Thermal insulation is the most preferred method of preventing heat energy from escaping a hot object to another surface or its surrounding which is at a lower temperature. In other words, a suitable thermal insulation system is used to keep an enclosed area
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such as a heating elements or its surface warm. Heat is transferred by from one material to another by conduction, convection and/or radiation. Insulators are used to minimize that transfer of heat energy.
The term thermal insulation can refer to materials used to reduce the rate of heat transfer, or the methods and processes used to reduce heat transfer. The major types of insulation are associated with the major types of heat transfer. While reflectors are used to reduce radiative heat transfer, foams, fibrous materials or air spaces are used to reduce conductive and convective heat transfer by reducing physical contact between objects and by reducing movement of gases around the insulated object respectively. Combinations of some of these methods are often used to increase the efficiency of thermal insulation.
Many different materials can be used as insulators. Many organic insulators are made from petrochemicals and recycled plastic. Many inorganic insulators are made from recycled materials such as glass (e.g. glass wool). Most insulators in common use rely on the principle of trapping air to reduce convective heat transfer. These insulators can be fibrous (e.g. asbestous), cellular (e.g. cork or plastic foam), or granular (e.g. sintered refractory materials). Standard types of insulation, such as fiberglass, asbestos, plastic foam, and cellulose primarily reduce heat transfer by trapping air or some type of a gas. Thus, these products or technologies reduce convection as a primary method of reducing heat transfer.
For practical and economic reasons, it is undesirable to use too much insulation. Specifications of industrial insulation are usually done following a heat-transfer analysis. It is often sufficient to choose the
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thickness of the insulative layer , based on materials that account for cost and desired results.
Conventionally, glass wool is used as an insulating material to prevent heat loss. However, glass wool primarily reduce heat transfer by trapping air or some type of a gas thus reducing convection as a primary method of reducing heat transfer. Further use.of glass wool is further complicated due to its large volume requirement to achieve effective control over heat loss and its adverse effect on health such as its irritating effect on skin, eyes and throat.
SUMMARY OF INVENTION
In the present invention an attempt has been made to prepare a thermal insulation system for energy conservation, safety and comfortable working environment especially for hot systems operating at a temperature of up to 450°C. The said composite when applied on such hot system otherwise radiating heat to the environment facilitates retention of heat inside and substantially reduces heat loss to the surrounding work place by all three modes of heat transfer viz. Conduction, Convection and Radiation. Energy savings to the tune of 10 to 30% can be achieved over conventional insulation systems presentiy used by the industry.
The manufacturing of the thermal insulation system for energy conservation, safety and comfortable working environment comprises of (a) coating of pressure sensitive silicone adhesive with a dry adhesive deposition of 5 to 25 g/m2 on glossy side of 10 to 75 micron thick soft Aluminium foil. The coating is carried out by use of
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conventional methods followed by drying operation which is also carried out by known conventional methods. The adhesive coated side of the Aluminium foil is then laminated to 25 to 125 micron thick woven glass fabric by pressing the two under laminating rollers with a pressure of 20 to 60 psi thereby obtaining a reflective reinforced foil (b) slitting of reflective reinforced foil thus obtained to desired width using conventional methods of slitting (c) manually cutting insulation mat of density ranging from 48 to 196 kg/m3 and having thickness ranging from 10 to 75 mm to desired shape and size, (d) manually wrapping the insulation mat on all sides with reflective reinforced foil obtained in (b) above and (e) sealing the junction point of the laminate with highly flexible and conformable end sealing tape comprising of super soft Aluminium foil- and woven glass fabric pressure sensitive adhesive tape having silicone adhesive on the glass fabric side to seal the joints completely.
The thermal insulation system for energy conservation, safety and comfortable working environment thus obtained has the following features:
1] It is highly flexible, and conformable hence can be applied on highly contoured surfaces.
2] It is fire retardant and is classified as "non-ignitablew as per UL -94 at V-0 level.
3] Insulation mat provides insulation against conduction and convection.
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4] Aluminium foil is having very low emissivity as compared to the value for most insulation, which significantly reduces radiative heat loss from surface and reduces work place temperature.
5] The change in thermal performance due to compaction or moisture absorption, a common concern with mass insulation, is not an issue with this invention as Aluminium foil used is moisture resistant and is waterproof.
6] It is free of any harmful substance like Asbestos and does not irritate the skin, eyes or throat and contain no substances which will emit a harmful gas.
7] It does not contain any leachable chlorides hence does not cause any corrosion on metal.
8] It is easy to apply and is re-usable.
When thermal insulation system for energy conservation, safety and comfortable working environment is applied on the outer surface of the hot system it provides following benefits:
1] Electrical energy conservation to the tune of 10 to 30% per hour.
2] Reduction in ambient temperature around the machine resulting in better working condition.
3] Lesser time required in reaching working temperature of the hot system start up thereby increasing productivity.
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4] Retention of uniform heat inside the hot system during processing thereby providing consistency in product output.
5] Maintenance friendly.
6] As the surface temperature is reduced drastically post installation, it offers safety to personnel working in the vicinity from burn injuries arising out of accidental touch.
DESCRIPTION OF THE PREFERRED EMBODIMENTS:

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Aluminium foil
Silicone pressure sensitive Adhesive
Woven glass fabric
Insulation mat
Woven glass fabric
Silicone pressure sensitive Adhesive
Aluminium foil

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WE CLAIM :
1. Thermal insulation system for energy conservation, safety and
comfortable working environment and the process for manufacturing
the same comprises of the following steps:-
(a) (i) coating glossy side of soft Aluminium foil with a formulated pressure sensitive silicone adhesive by depositing 5 to 25 gm/m2 on dry basis by conventional coating methods followed by drying with conventional methods;
(a) (ii) laminating coated side of the soft Aluminium foil
with woven glass fabric under pressure to obtain reflective
reinforced foil;
(b) the reflective reinforced foil so obtained is slit to
desired width by using conventional method of slitting;
(c) cutting insulation mat to desired shape and size;
(d) wrapping cut insulation mat so obtained from all sides with reflective reinforced foil ; and
(e) sealing the junction point of reflective reinforced foil with highly flexible and conformable super soft Aluminium foil- and woven glass fabric pressure sensitive adhesive tape having silicone adhesive on the glass fabric side to seal the joints completely.
2. Thermal insulation system for energy conservation, safety and
comfortable working environment and the process for manufacturing
the same as claimed in claim 1 wherein Aluminium foils used is soft
foil having thickness ranging from 10 to 75 micron.

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3. Thermal insulation system for energy conservation, safety and comfortable working environment and the process for manufacturing the same as claimed in claim 1 wherein the said formulated pressure sensitive silicone adhesive is prepared by using organic peroxide catalysts such as Benzoyl Peroxide, 2-4 dichloro benzoyl peroxide etc.
4. Thermal insulation system for energy conservation, safety and comfortable working environment and the process for manufacturing the same as claimed in claim 1 wherein the Glass Fabric used is a woven glass fabric having thickness of about 25 to 125 micron.
5. Thermal insulation system for energy conservation, safety and comfortable working environment and the process for manufacturing the same as claimed in claim 1 wherein the woven glass fabric is laminated to the adhesive coated side of aluminium foil by use of pressure of about 20 to 60 psi to obtain reflective reinforced foil by use of conventional coating cum laminating machines.
6. Thermal insulation system for energy conservation, safety and
comfortable working environment and the process for manufacturing
the same as claimed in claim 1 wherein the said insulation mat is
made of glass fibers, ceramic fibers, or quartz wool with thickness
varying between 10 to 75 mm and with density ranging from 48 to
196.
7. Thermal insulation system for energy conservation, safety and
comfortable working environment and the process for manufacturing
the same as claimed in claim 1 wherein the said insulation mat can
be cut to desired shape and size manually or by mechanical means.
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8. Thermal insulation system for energy conservation, safety and comfortable working environment and the process for manufacturing the same as claimed in claim 1 wherein the reflective reinforced foil is wrapped around precut insulation mat manually in such a fashion that Aluminium side of the laminate remains outside.
9. Thermal insulation system for energy conservation, safety and comfortable working environment and the process for manufacturing the same as claimed in claim 1 where the junction point of reflective reinforced foil in the final assembly is sealed by highly conformable and flexible super soft Aluminium foil - and woven glass fabric pressure sensitive adhesive tape having silicone adhesive on the glass fabric side.
10. Thermal insulation system for energy conservation, safety and comfortable working environment and the process for manufacturing the same as claimed in claim 1 to 9 by which Thermal insulation system for energy conservation, safety and comfortable working environment is obtained.
Dated this 29th day of March, 2007
(Shah Bharat S.)
Duly Constituted Attorney
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ABSTRACT
Thermal insulation system for energy conservation, safety and
comfortable working environment and the process for
manufacturing the same comprises of (a) (i) coating glossy side of soft Aluminium foil with a formulated pressure sensitive silicone adhesive followed by drying; (a) (ii) laminating coated side of the soft Aluminium foil with woven glass fabric under pressure to obtain reflective reinforced foil and the same is slit to desired width; (d) cutting insulation mat to desired shape and size; (e) wrapping cut insulation mat so obtained from all sides with reflective reinforced foil ; and (f) sealing the junction point of said foil with highly flexible and conformable super soft Aluminium foil-and woven glass fabric pressure sensitive adhesive tape having silicone adhesive on the glass fabric side to seal the joints completely.
Dated this 29th day of March, 2007
(Shah Bharat S.)
Duly Constituted Attorney