Compressible Polyester Wadding Insulation for Thin Under-Roof Spaces
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Solution Overview
Problem
Conventional mineral insulation is too dense to be compressed to a very thin thickness, making it unsuitable for under-roof applications where space is limited or rafters are visible, necessitating a more thermally efficient insulation solution.
Innovation Solution
A multilayer insulation comprising a highly compressible wadding layer with a density of less than 15 kg/m³, covered with aluminum foil and a bonding membrane, allowing for up to 90% compression, achieved through extrusion and thermal lamination of air bubble films with aluminum foil and insertion of polyester fiber wadding, with a bonding membrane ensuring adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional mineral insulation is used, then thermal insulation performance is provided, but the insulation cannot be compressed to a very thin thickness due to high density
Solution Approach 1:
The patent changes the density parameter of the insulation material from conventional high-density mineral wool to low-density polyester wadding (less than 15 kg/m³), enabling the material to be compressed to very thin thickness while maintaining thermal insulation performance
Solution Approach 2:
The patent creates a composite structure combining polyester wadding with bubble film and aluminum foil layers, where each component contributes to both insulation performance and compressibility, resolving the contradiction between thermal performance and thinness
2Temperature
If conventional mineral insulation is used, then insulation function is provided, but it is not suitable for under-roof applications where space is limited
Solution Approach 1:
By changing the density parameter to less than 15 kg/m³ and enabling up to 90% compression, the insulation becomes adaptable to confined under-roof spaces where conventional insulation cannot be installed
Solution Approach 2:
The patent creates a multi-functional insulation system that serves both thermal insulation and vapor barrier functions (through aluminum foil), while being adaptable to various installation scenarios including visible rafter applications
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 insulation can be efficiently compressed to a thin thickness, enhancing thermal performance and adaptability in confined spaces, as demonstrated by compressive strength tests showing significant reduction in thickness with minimal load, suitable for under-roof, wall, and vapor barrier applications.
Implementation Method 1
The insulation typically has a reflective aluminum film on its outer surfaces, known for protecting the building against heat transfer from infrared radiation
Implementation Method 2
Insertion and bonding of the polyester fiber-based wadding between two laminates
Implementation Method 3
the bonding is carried out by spraying an ethylene-vinyl acetate based adhesive
Implementation Method 4
The middle layer 4 consists of non-woven polyester fibers... which has a density of less than 25 kg/m3, preferably less than 20 kg/m3, and very preferably less than 15 or even 13 kg/m3
Data Source
Figure 1~2
Figure 3~4
AI summary
Multilayer insulation (1) comprising a layer of wadding based on polyester fibres (4) sandwiched between two films containing air bubbles (2).