Insulated Cargo Container Panels With PCM for Thermal Retention
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Solution Overview
Problem
Current climate-controlled cargo containers face challenges in maintaining thermal energy retention due to inadequate insulation in their walls, ceiling, and floor, which affects the efficiency of refrigeration units and energy consumption.
Innovation Solution
The development of insulated wall panels comprising an outer and inner sheet metal layer with a sandwiched structure of closed-cell and open-cell foams, where fiber tubes embedded within the open-cell foam enhance heat evacuation and structural stability, and the incorporation of phase change materials to store thermal energy, thereby improving the R-value and reducing heat flux.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional insulation materials are used in cargo container walls, then manufacturing is simpler, but thermal energy retention is insufficient
Solution Approach 1:
The patent applies composite materials by combining multiple insulation layers (rigid foam insulation board, flexible foam insulation board) with different thermal properties and structural characteristics. This composite structure achieves superior thermal energy retention compared to traditional single-material insulation, directly addressing the energy loss problem while managing the increased complexity through systematic material integration.
Solution Approach 2:
The patent implements local quality by using different types of foam insulation boards in different locations within the wall structure. Rigid foam insulation boards are positioned in specific areas requiring higher structural stability and thermal performance, while flexible foam insulation boards are used in areas requiring adaptability. This localized material differentiation optimizes thermal energy retention throughout the container walls.
2Loss of energy
If insulation thickness is increased to improve thermal retention, then energy loss reduces, but container volume for cargo decreases
Solution Approach 1:
The composite insulation structure achieves high thermal performance with optimized thickness by combining rigid and flexible foam boards with complementary thermal conductivities. This allows the wall assembly to attain superior heat flux reduction without requiring excessive total thickness, thereby preserving maximum cargo volume while effectively reducing energy loss.
Solution Approach 2:
The patent utilizes parameter changes by selecting foam insulation materials with specific thermal conductivity values and density characteristics. By carefully choosing materials with optimal thermal parameters, the design achieves effective heat flux reduction at reduced thickness compared to traditional insulation materials, thus maintaining larger cargo space.
3Loss of energy
If advanced insulation panels with multiple layers are used, then R-value improves, but manufacturing complexity increases
Solution Approach 1:
The insulation system is segmented into distinct rigid and flexible foam insulation board layers, each manufactured and positioned as separate components. This segmentation allows for standardized production of individual board types with consistent quality, while the modular nature facilitates assembly. The pre-fabricated panel structure with defined attachment points simplifies the overall manufacturing process despite the multi-layer composition.
Solution Approach 2:
The composite panel structure integrates rigid and flexible foam insulation boards into a unified assembly with standardized connection methods. This composite construction approach, while improving R-value, manages manufacturing complexity through systematic layering and standardized fastening procedures, making the enhanced insulation panels practical for production and installation.
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 proposed solution significantly enhances insulation performance, reducing energy consumption by maintaining thermal energy retention and minimizing the load on refrigeration units, while providing structural integrity for the cargo containers.
Implementation Method 1
insulated wall panels comprising an outer and inner sheet metal layer with a sandwiched structure of closed-cell and open-cell foams
Implementation Method 2
fiber tubes embedded within the open-cell foam enhance heat evacuation
Implementation Method 3
incorporation of phase change materials to store thermal energy
Implementation Method 4
phase change materials to store thermal energy, thereby improving the R-value and reducing heat flux
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A climate controlled cargo container includes at least one panel (50) including: an outer layer (52); an inner layer (54); a foam (58) positioned in between the inner layer (54) and the outer layer (52); and a plurality of fiber tubes (60) embedded within the foam. Another climate controlled cargo container includes at least one panel including: an outer layer; an inner layer; a foam positioned in between the inner layer and the outer layer; and a phase change material positioned between the inner layer and the outer layer.