Coextruded Thermoplastic with Infrared-Reflective Intermediate Layer

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Solution Overview

Problem

Thermoplastic construction products are prone to heat distortion due to excessive solar energy absorption, leading to warping, curling, or melting, especially in dark-colored products which also suffer from unappealing shiny or metallic appearances when modified to reflect more light.

Innovation Solution

A coextruded layered structure comprising a base layer, an outer layer, and an infrared-reflective intermediate layer with a thickness of at least 30 micrometers, where the intermediate layer is coextruded with the base and outer layers and includes infrared-reflective pigments dispersed in a thermoplastic matrix, enhancing solar reflectance and reducing heat buildup.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If a thermoplastic construction product is made in dark colors, then aesthetic appeal is improved, but heat absorption increases leading to heat distortion

Engineering Contradiction:

Improveaesthetic appealVSAvoidheat buildup

Core Design Contradiction:

Illumination intensityVSTemperature

Solution Approach 1:

The construction product is divided into multiple functional layers: an outer layer providing aesthetic appearance (dark colors) and an intermediate infrared-reflective layer preventing heat absorption. This segmentation allows each layer to perform its specific function independently, resolving the contradiction between aesthetic appeal and heat resistance

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

An intermediate infrared-reflective layer is introduced between the outer dark-colored layer and the base layer. This intermediary layer reflects infrared radiation back outward while allowing visible light to pass through, thereby maintaining the dark aesthetic appearance while preventing heat buildup that would cause distortion

Inventive Principle:

Principle #24Intermediary (Mediator)

2Temperature

If the surface of dark-colored thermoplastic products is modified to reflect more light, then heat buildup is reduced, but the products appear shiny or metallic which is unappealing

Engineering Contradiction:

Improveheat buildupVSAvoidaesthetic appearance

Core Design Contradiction:

TemperatureVSIllumination intensity

Solution Approach 1:

The product structure is segmented into distinct layers with the outer layer maintaining the desired dark aesthetic appearance and the intermediate layer providing infrared reflection. This allows the surface to remain matte and visually appealing while the internal structure handles heat reflection

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different layers are assigned different optical properties: the outer layer has properties optimized for visible light absorption (dark color, matte finish) while the intermediate layer has properties optimized for infrared reflection. Each layer's local quality is tailored to its specific function, resolving the contradiction between heat reflection and aesthetic appearance

Inventive Principle:

Principle #3Local quality

3Temperature

If an infrared-reflective intermediate layer is added to reduce heat buildup, then heat distortion is prevented, but the structural complexity increases

Engineering Contradiction:

Improveheat distortion resistanceVSAvoidlayered structure complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The construction product uses a composite layered structure combining different materials with specific properties: an outer thermoplastic layer for aesthetics and an intermediate infrared-reflective layer for thermal management. This composite approach integrates heat protection into the material structure itself rather than adding separate protective systems, managing complexity through material science

Inventive Principle:

Principle #40Composite materials

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 significantly reduces heat buildup and the risk of heat distortion while maintaining aesthetic appeal by increasing total solar reflectance and limiting infrared transmission, thereby preventing warping and melting, even in dark-colored products.

Implementation Method 1

an infrared-reflective intermediate layer that is coextruded with the base layer and the outer layer and is disposed between the base layer and the outer layer

Methodology Applied

Scientific EffectInfrared reflection: Reflection

Implementation Method 2

the infrared-reflective intermediate layer including an infrared-reflective pigment dispersed in a matrix of one of the first thermoplastic material or the second thermoplastic material

Methodology Applied

Scientific EffectInfrared absorption: Absorption (EM radiation)

Data Source

PatentUS11702845B2Layered thermoplastic structure with reflective intermediate layer and method of manufacture

Publication Date: 2023.07.18 CERTAINTEED LLC

AI summary

The present disclosure relates generally to polymer structures, for example, suitable for construction products. The present disclosure relates more particularly to a thermoplastic construction product including a coextruded layer structure having a base layer including a first thermoplastic material, an outer layer including a second thermoplastic material, and an infrared-reflective intermediate layer that is coextruded with the base layer and the outer layer and is disposed between the base layer and the outer layer. In some embodiments the intermediate layer has a thickness of at least 30 micrometers. In some embodiments the infrared-reflective intermediate layer includes a reflective pigment dispersed in a matrix of one of the first thermoplastic material or the second thermoplastic material.