Method and apparatus for insulating a lumber kiln

A lumber predrying/drying kiln comprises a multiplicity of panels, a multiplicity of mats, and resin. Each panel comprises a multiplicity of plates and a block of insulation. The plates comprise fibrous glass strands embedded in a resin. The plates surround and encapsulate each block of insulation. Panels are placed next to each other, and above and/or below each other, end-to-end, to form walls and a roof of the kiln. They are connected with several alternating layers of fiberglass mats and resin wide enough to cover the joint between, and rigidly and structurally connect, the panels.

BACKGROUND OF THE INVENTION 
I. Field of the Invention 
This invention relates generally to a method and apparatus for insulating a 
kiln, and more particularly for insulating a kiln for drying lumber and 
for insulating a lumber predrying building, with walls that are virtually 
impervious to caustic moisture. 
II. Prior Art and other Considerations 
Kiln drying lumber is done in a high temperature atmosphere of nearly 100% 
relative humidity. The kiln drying building must be well insulated to hold 
the appropriate heat in the building. In the past, if moisture reached the 
insulation material, the insulation material lost most of its 
effectiveness rendering the building substantially unusable without 
repair. 
It is expedient, therefore, that all moisture be kept from the insulation. 
In the kiln drying process the high temperatures and the acid released by 
the drying process are highly corrosive. The combination of high 
temperature, high humidity and high acidity, with pH frequently ranging to 
nearly as low as 3.0, defeat most attempts to keep moisture from the 
insulation in the building walls. The insulation technology used in lower 
temperature, lower humidity situations has not proven to be useful for 
kiln drying lumber. 
Prior kiln drying buildings have been constructed using panels made of 
insulation encapsulated by aluminum cladding. The panels were 
prefabricated. The panels were joined to construct a building by aluminum 
extrusions and bolts or by lap joints with mechanical bolts. These kiln 
panels deteriorate very rapidly from a combination of thermal cycling, 
high relative humidity, and acid from the wood drying process. The 
insulation in the panels quickly become moist reducing its insulation 
value, and requiring replacement of the panel. The panels have also proven 
difficult and expensive to install as well as unattractive once installed. 
Prior refrigeration insulation technology has not been concerned with the 
problems inherent in a high temperature, high relative humidity, high 
acidity environment. These conditions lead to corrosive conditions not 
faced in refrigeration type situations. 
SUMMARY 
In view of the foregoing, it is an object of the present invention to 
provide a durable method and a durable apparatus for effectively 
insulating kiln drying and predrying buildings for drying lumber. 
An advantage of the present invention is the provision of a method and 
apparatus wherein the insulation is protected from exposure to almost all 
moisture. 
An advantage of the present invention is the provision of a method and 
apparatus for prefabricating panels facilitating speedy, low cost 
fabrication, construction, implementaion and installation. 
Another advantage of the present invention is the provision of a method and 
apparatus for facilitating a desired kiln structural strength and 
integrity and durability. 
A further advantage of the present invention is the provision of a method 
and apparatus for facilitating a neat appearance of the kiln drying 
building all through its lifetime. 
Yet another advantage of the present invention is the provision of a method 
and apparatus for a durable building that can withstand high temperature, 
withstand high relative humidity and particularly withstand concentrated 
acidity. 
Still another advantage of the present invention is the provision of a 
method and apparatus for a predrying and drying lumber that has elements 
which strong enough to support elements in a building structure including 
itself and other elements. 
An effectively insulated, durable lumber drying kiln, including an 
effectively insulated, durable lumber predrying kiln, comprises a building 
comprising a paneling means and a connecting means. The paneling means 
comprises an insulating means surrounded by an encapsulating means which 
is virtually waterproof so that virtually no moisture can reach the 
insulating means. The encapsulating means can withstand environments which 
are high in temperature and high in relative humidity and can withstand 
environments, most importantly, which are strongly acidic. The insulating 
means is also highly resistant to degradation by moisture and is nearly 
impervious to moisture. The connecting means STRUCTURALLY joins a number 
of paneling means together to form the building that is durable in a 
manner whereby the abilities to withstand harsh inside environments, such 
as high in temperature, high in relative humidity, and strongly acidic, 
are not significantly, if at all, diminished.

DETAILED DESCRIPTION OF THE DRAWINGS 
A first preferred embodiment of lumber drying kiln of a FIG. 1 comprises a 
building 100 having a multiplicity of panels 120 and a multiplicity of 
connecting means 130. As shown in FIG. 2, each panel 120 comprises a 
number of plates 210 and an insulating block 220. Each panel 120 has a 
front surface plate 211, a back surface plate 212, two (2) side end plates 
215, a bottom end plate 217 and a top end plate 218. Consequently, every 
surface of each block 220 is covered by, and rigidly attached to, a plate 
210. Each plate 210 comprises fibrous glass strands embedded in a resin 
which completely encapsulate the insulating block 220. The plates 210 are 
virtually impervious to moisture. These plates 210 are connected to each 
other at all points where they intersect using the fibrous glass strands 
embedded in a resin so that the plates 210 completely seal the block 220 
into the interior of the volume defined by said plates 210 so that 
virtually no moisture can reach the insulation 220. Blocks 220 are 
typically composed of polyisosianurate. 
As shown in FIG. 3, panels 120 are placed side by side, side end plate 215 
of one panel 120 to side end plate 215 of the next panel 120, next to each 
other Then they are placed above and/or below each other, generally top 
end plate 218 of one panel 120 to bottom end plate 217 of an adjacent 
panel 120. Panels 120 positioned thusly are rigidly joined together with 
connecting means 130 to form the building 100. 
Connecting means 130 comprises multiple alternating layers of fiberglass 
mats 133 and resin 137 covering the joint between the panels 120. As shown 
in FIGS. 4 and 5, the mats 133 and the resin 137 thus serve to rigidly 
join two or more panels 120 together. The mat 133 and the resin 137 form a 
barrier in between each panel that is virtually impervious to moisture. 
In operation, a set of panels 120 are joined as set forth above to form the 
building 100. Some of the panels 120 are joined to form doors 101. 
Equipment is installed to provide for heating and ventilating and for the 
control thereof. Curing of uncured lumber commences in a typical manner.