Dual-Layer Closed-Cell Thermal Insulation with Polymer Films
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Solution Overview
Problem
Conventional insulating materials face challenges in minimizing heat transfer through conduction, convection, and radiation while being cost-effective, recyclable, and space-efficient, with existing solutions like polyurethane and vacuum panels having drawbacks such as high costs, poor workability, and limited recyclability.
Innovation Solution
The development of an insulating element with a dual-layer structure comprising two groups of closed cells formed by recesses in flat elements, where each group is independently produced and assembled to minimize empty volume, allowing for efficient gas filling and reduced thermal conductivity, using polymer films that can be recycled and coated with low-emissivity metallic layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If vacuum panels are used to achieve low thermal conductivity, then thermal insulation performance is improved, but costs increase and workability deteriorates
Solution Approach 1:
The patent uses flexible polymer films to create closed-cell structures that can be easily manufactured and installed. The films are formed into three-dimensional cells through processes like deep-drawing, creating a flexible yet effective insulation panel that maintains good workability while achieving low thermal conductivity through the gas-filled closed cells.
Solution Approach 2:
The patent employs a porous closed-cell structure where polymer films are formed into three-dimensional cells with gas filling. This porous architecture provides thermal insulation by trapping gas within closed cells, reducing thermal conductivity while maintaining a lightweight and manufacturable structure that doesn't require vacuum conditions.
2Ease of manufacture
If aerogels are used to improve workability compared to vacuum panels, then ease of manufacture is improved, but thermal conductivity coefficient increases (insulation value decreases)
Solution Approach 1:
The patent creates a composite structure combining polymer films with gas filling within closed cells. This composite approach achieves thermal conductivity values between conventional foams and aerogels, providing good workability like aerogels while improving insulation performance through the closed-cell gas-filled architecture that reduces both conduction and convection.
3Ease of manufacture
If honeycomb structure elements with deep-drawn recesses are used, then production cost is reduced, but volume utilization for gas filling decreases
Solution Approach 1:
The patent applies preliminary action by forming the closed-cell structures before final assembly and gas filling. The polymer films are pre-formed into three-dimensional cells with optimized geometry that maximizes gas filling volume, ensuring that the majority of the panel volume is utilized for insulation purposes while maintaining cost-effective deep-drawing production methods.
4Volume of stationary object
If insulating materials with thin structure are used to reduce space, then volume is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent segments the insulation into multiple thin layers, each consisting of polymer films formed into closed-cell structures. These segmented layers can be manufactured independently using standardized processes and then assembled into the final insulation panel, reducing overall thickness while maintaining manufacturing simplicity through modular construction.
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
This approach enhances thermal insulation by optimizing gas filling, reducing thermal conductivity, and lowering production costs, while being flexible and recyclable, thus addressing the limitations of existing insulating materials.
Implementation Method 1
Foams based on polystyrene or polyurethane are used as core materials having low thermal conductivity coefficients. These insulating materials achieve thermal conductivity coefficients of down to 22 mW/mK
Implementation Method 2
heat transfer can be reduced by applying a reflecting metal layer with a low thermal emissivity
Data Source
AI summary
An insulating element for thermally insulating spaces, including closed cells, in which a first and a second group of closed cells are formed by first or second recesses in a first or second flat element and the first and the second flat elements form first or second connection regions between recesses adjacent to the edges of the openings, to which respectively a flat covering element closing the openings of a plurality of first recesses is bonded on a front side of the flat element. The second recesses are arranged between the first recesses on a rear side of the first flat element and the first recesses are arranged between the second recesses on a rear side of the second flat element such that the space remaining of the first and second recesses between the first and the second flat elements amounts to less than 50% of the space enclosed by the first and second recesses.