Anisotropic PUR Foam Insulation for Adhesive Strength
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Solution Overview
Problem
Existing polyurethane (PUR) and polyisocyanurate (PIR) rigid foams used in thermal insulation composite systems face issues with adhesive strength loss due to moisture, increased edge dynamic stiffness leading to crack formation, and potential air or gas accumulation causing bubble formation and detachment under extreme loads.
Innovation Solution
A molded foam element is developed, comprising at least 50% PUR or PIR foam produced in a continuous process with a homogeneous bulk density of 28-40 kg/m³, featuring an anisotropic cell structure with distinct geometric properties and compressive strengths in different spatial directions, and a film-free design, allowing for versatile applications including thermal insulation and fire protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If facing layers are added to PUR/PIR rigid foams to improve surface protection, then thermal insulation performance is improved, but adhesive strength is lost when exposed to moisture and edge stiffness increases causing cracking
Solution Approach 1:
The patent removes the facing layers from the foam structure, extracting the problematic component that caused adhesive strength loss and edge cracking. The solution uses bare PUR/PIR rigid foam without any metallic or flexible facing sheets, thereby eliminating the moisture-related adhesive degradation while maintaining thermal insulation performance through the foam's inherent properties.
Solution Approach 2:
The patent employs composite material strategy by combining PUR and PIR foam materials in a specific ratio (30-70% PUR and 70-30% PIR) to create a homogeneous mixture that achieves both thermal insulation and structural stability without requiring facing layers. This composite approach allows optimization of both insulation performance and mechanical properties.
2Reliability
If facing layers are incorporated to improve thermal insulation, then insulation performance is improved, but air or gas accumulations occur causing blistering and detachment under stress
Solution Approach 1:
The patent extracts and removes the facing layers that trapped air and gas accumulations, eliminating the root cause of blistering and detachment. By using bare foam without facing sheets, the structure allows for better gas escape during manufacturing and prevents the formation of voids that would compromise structural stability under external thermal insulation composite system stress.
Solution Approach 2:
The patent changes the manufacturing parameters by adjusting the homogeneous bulk density to 28-40 kg/m³ and controlling the mixing ratio of PUR and PIR components. These parameter changes ensure proper foam expansion and consolidation, preventing air or gas accumulations that would lead to blistering while maintaining the required thermal insulation performance.
3Reliability
If facing layers are added to improve insulation, then thermal performance is improved, but production complexity and cost increase
Solution Approach 1:
The patent removes the facing layers and associated lamination processes, dramatically simplifying the production system. The manufacturing process becomes a straightforward continuous foaming operation without the need for separate facing sheet attachment steps, reducing both production complexity and manufacturing costs while maintaining effective thermal insulation through the optimized foam composition.
Solution Approach 2:
The patent makes the foam material itself perform multiple functions that were previously requiring separate components: the PUR/PIR foam provides both thermal insulation and structural stability without needing facing layers for protection or reinforcement. This multi-functionality simplifies the overall product design and production process.
4Reliability
If facing layers are incorporated to improve insulation, then thermal performance is improved, but the molded element becomes more expensive
Solution Approach 1:
The patent removes expensive facing layers and lamination materials, reducing the quantity of substance and associated costs. The solution relies on optimizing the foam material itself to provide both insulation and structural functions, eliminating the need for additional costly components and simplifying the bill of materials.
Solution Approach 2:
The patent optimizes the homogeneous bulk density parameter to 28-40 kg/m³ and controls the PUR/PIR mixing ratio to achieve the desired performance at minimum cost. By carefully controlling these parameters, the foam provides adequate thermal insulation without requiring expensive facing layers, thereby reducing overall production costs.
Data Source
Figure 1~2
Figure 3
AI summary
The molded foam element partially made of polyurethane foam and/or polyisocyanurate for heat insulating-composite system on buildings, comprises a cell structure (13) that comprises different geometry structures (14, 15, 16) in two spatial directions (10, 11) vertically oriented to each other. The cell structure comprises different compressive stresses and compressive strength associated to individual spatial direction. The cell structure comprises a geometry structure, which is oriented in a third spatial direction (12) and is distinguishable from the both other geometry structures. The molded foam element partially made of polyurethane foam and/or polyisocyanurate for heat insulating-composite system on buildings, comprises a cell structure (13) that comprises different geometry structures (14, 15, 16) in two spatial directions (10, 11) vertically oriented to each other. The cell structure comprises different compressive stresses and compressive strength associated to individual spatial direction. The cell structure comprises a geometry structure, which is oriented in a third spatial direction (12) and is distinguishable from the both other geometry structures. One of the geometry structures is oriented along a foam direction (17). A gross density of the foam element is 28-40 kg/m 3>. A thermal conductivity of the foam element is 0.028 W/(mk). A coating is applied on a partial surface area of the foam element. The coating is provided for the protection against UV radiation and dust formation. Independent claims are included for (1) a process for producing a thermal insulation element; and (2) a method for producing a fire protection latching element.