Closed-Cell Foam Composition for Low-Impact Thermal Insulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing insulation materials, particularly closed cell foam products, face challenges in achieving high thermal insulation performance while minimizing environmental impact and maintaining commercial viability, with many renewable alternatives having suboptimal thermal conductivity and price-to-performance ratios.
Innovation Solution
A foam product comprising at least 5% by weight of components from renewable sources, such as lignin and bio-based formaldehyde, combined with blowing agents and other additives, to achieve thermal conductivities of 0.025 W/m·K or less over a 25-year life span, with a total Global Warming Potential (GWP) below 1.0 kg CO2 eq/kg and a closed cell content of at least 90%, while maintaining fire performance and mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional closed cell foam insulation materials (PIR, PUR, XPS, PF) are used, then thermal insulation performance is improved, but environmental impact increases
Solution Approach 1:
The patent changes the chemical composition parameters of the foam by incorporating at least 5% by weight of components from renewable sources (such as bio-based polyols, lignin, or other renewable polymers) into the foam formulation. This parameter change enables the foam to maintain low thermal conductivity (λ≤0.025 W/m·K) while reducing environmental impact through sustainable material usage
Solution Approach 2:
The patent creates a composite foam material combining traditional foam-forming components with renewable source components. The foam comprises a polyol component (at least 5% from renewable sources), isocyanate, and blowing agent, forming a composite structure that achieves both low thermal conductivity and reduced environmental footprint through the synergistic combination of materials
2Object-affected harmful factors
If renewable source components are used in foam production, then environmental impact is reduced, but thermal insulation performance may deteriorate
Solution Approach 1:
The patent optimizes the concentration parameter of renewable components, specifying at least 5% by weight but not exceeding 50% of the total polyol content. This parameter optimization ensures that sufficient renewable materials are used to reduce environmental impact while maintaining enough traditional high-performance components to guarantee low thermal conductivity (λ≤0.025 W/m·K)
3Temperature
If high performance insulation materials (vacuum insulation panels, nano particle, aerogel) are used, then thermal insulation performance is improved, but price-to-performance ratio deteriorates
Solution Approach 1:
The patent employs conventional foam technology with readily available renewable components rather than expensive specialized materials like vacuum panels or aerogel. This approach uses cost-effective bio-based polyols and standard foam-forming chemicals to achieve acceptable thermal performance (λ≤0.025 W/m·K) at a much better price-to-performance ratio
Solution Approach 2:
The patent changes the compositional parameters of conventional foam by incorporating renewable components at optimized levels (5-50% by weight), which improves environmental performance while maintaining cost-effectiveness. This parameter change avoids the need for expensive specialized insulation materials while achieving low thermal conductivity through formulation optimization
4Object-affected harmful factors
If renewable components are used to reduce environmental impact, then sustainability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent specifies clear compositional parameters (at least 5% but not more than 50% renewable polyol content) that guide the manufacturing process. These parameter specifications, while requiring some adjustment to raw material sourcing, maintain relatively simple foam formulation and processing compared to complex alternative materials, thus limiting the increase in manufacturing complexity
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 solution provides insulation materials with enhanced thermal insulation, reduced environmental footprint, and sustainable production, addressing the need for low-impact, high-performance insulation suitable for building renovation and new construction.
Implementation Method 1
a foamable composition comprising: a polyol component, in particular a polyether polyol or a polyester polyol, wherein at least 5% by weight of the polyol component is formed from at least one component from a renewable source
Implementation Method 2
the average thermal conductivity of the foam product over a 25 year life span of the product is 0.025 W/m·K or less
Data Source
AI summary
A foam product comprising an expanded foam body having cells defined therein and blowing agent held within the cells, wherein at least 5% by weight of the foam body is formed from at least one component from a renewable source.