A method of producing an insulation product
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Solution Overview
Problem
Current methods for producing insulation products with porous materials wrapped in gas-impermeable foils and insulating gases face challenges in thermal performance and production costs, limiting their widespread adoption in building construction.
Innovation Solution
A method involving a flow-wrapping process to substitute air in porous insulation material boards with insulating gases like CO2, using a gas-impermeable foil and sealing the ends, which reduces thermal conductivity and enables efficient large-scale production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If vacuum is applied to porous insulation material wrapped in gas-impermeable foil, then thermal insulating performance is improved, but production complexity and handling damage risk increase
Solution Approach 1:
The patent replaces vacuum with an inert or less reactive gas atmosphere (such as nitrogen or carbon dioxide) within the gas-impermeable foil envelope. This inert gas environment maintains the insulating performance by preventing thermal conduction while avoiding the complexities of vacuum maintenance, handling, and sealing required by vacuum insulation panels. The inert atmosphere is introduced during the wrapping process and trapped within the foil envelope.
Solution Approach 2:
The patent employs a disposable or single-use gas-impermeable foil envelope that is wrapped around the porous insulation material and sealed to trap the insulating gas. This approach eliminates the need for complex vacuum sealing and maintenance systems, allowing for simpler, more affordable production processes while maintaining effective thermal insulation performance.
2Temperature
If microporous materials are used to replace mineral fibres, then thermal performance is improved, but production cost increases
Solution Approach 1:
The patent creates a composite insulation system combining porous insulation material (such as expanded polystyrene beads or other lightweight porous materials) with a gas-impermeable foil envelope. This composite structure allows the use of cost-effective porous materials while the foil envelope provides the gas barrier necessary to maintain insulating performance, achieving both thermal efficiency and cost-effectiveness.
Solution Approach 2:
The patent utilizes porous insulation materials such as expanded polystyrene beads, perlite, or other lightweight porous substances that provide effective thermal insulation through their air-trapping structure. These materials are enclosed within gas-impermeable foil to prevent gas exchange and maintain insulating performance, offering a cost-effective alternative to expensive microporous materials while achieving comparable or superior thermal performance.
3Device complexity
If hermetically sealed bags with insulating gas are used instead of vacuum, then production is simplified, but thermal conductivity reduction is limited
Solution Approach 1:
The patent employs inert or low thermal conductivity gases (such as nitrogen, carbon dioxide, or argon) within the hermetically sealed gas-impermeable foil envelope. These gases have lower thermal conductivity than air, providing enhanced insulating performance while maintaining the production simplicity of gas filling rather than vacuum sealing. The inert atmosphere prevents thermal conduction and maintains stable insulating properties.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method significantly reduces thermal conductivity by replacing air with insulating gases, enhancing thermal performance and lowering production costs, making the insulation products more viable for building applications.
Implementation Method 1
gas having a low coefficient of thermal conductivity is used in combination with glass fibers or the like
Data Source
Figure 1~2
AI summary
The present invention concerns a method of producing an insulation product comprising a board of porous insulation material wrapped in a gas-impermeable foil, said method comprising the steps of providing a succession of porous insulation material boards on a first conveyor apparatus and feeding the boards on a second conveyor apparatus; providing wrapping foil and wrapping said foil to form a tube around the boards on said second conveyor apparatus, flushing the boards with an insulating gas, and sealing the wrapping foil at the ends of each board transverse to the direction of travel of the second conveyor apparatus.