Embossed Insulating Panel Structure for Secure Heating Wire Fixing
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Solution Overview
Problem
Existing insulating panels for building heating systems, particularly those with embossed sheets, suffer from ineffective adhesion and mechanical instability, leading to potential detachment issues, especially in wall installations, and have complex, time-consuming manufacturing processes.
Innovation Solution
A multilayer insulating panel featuring a polymeric embossed sheet with bosses and recesses, combined with a connection layer, provides enhanced adhesion and mechanical resistance, using polyurethane foam as the main insulating material and employing a continuous manufacturing process for improved efficiency and reduced thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an embossed sheet is glued to a polystyrene sheet to create an insulating panel, then the panel provides thermal insulation and mechanical support, but the adhesion is ineffective and the sheet may detach involuntarily
Solution Approach 1:
The embossed sheet is divided into multiple bosses that project from one surface, creating multiple localized bonding points. Each boss acts as a separate anchoring element that penetrates or bonds to the insulating layer, distributing the adhesion force across multiple points rather than relying on a single continuous bond surface.
Solution Approach 2:
The embossed sheet introduces a third dimension by creating bosses that project outward from the sheet surface. This vertical dimension allows the bosses to penetrate or bond with the insulating layer in a perpendicular direction, creating mechanical interlocking rather than relying solely on surface-area-based adhesion.
2Ease of manufacture
If the embossed sheet is molded together with the polystyrene sheet to create a preformed panel, then the manufacturing process becomes integrated, but the process is batch-based, complex and slower
Solution Approach 1:
The manufacturing process is segmented into separate operations: first producing the embossed sheet independently, then separately producing or preparing the insulating layer, and finally assembling them together. This segmentation allows each component to be manufactured using optimized processes and enables continuous production rather than batch processing.
Solution Approach 2:
The embossed sheet is pre-formed with its boss structures before assembly with the insulating layer. This preliminary action allows the embossed sheet to be prepared in advance using efficient extrusion or forming processes, and then quickly assembled with the insulating layer, avoiding the need for complex simultaneous molding operations.
3Ease of operation
If a sheet with bosses is used to fix electric heating wires, then the wires can be reversibly fixed to the panel, but the gluing process becomes less effective due to reduced adhesion surface
Solution Approach 1:
The adhesion surface is segmented into multiple discrete boss structures rather than a continuous surface. Each boss provides a localized bonding zone that concentrates adhesive force, while the spaces between bosses allow for wire placement and reversible fixing without requiring adhesion across the entire sheet surface.
Solution Approach 2:
The fixing mechanism transitions from a two-dimensional surface adhesion problem to a three-dimensional mechanical interlocking solution. The bosses project vertically from the sheet, creating anchoring points that secure wires through mechanical engagement rather than relying solely on surface-area-based adhesive bonding.
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 ensures effective adhesion of the embossed sheet to the insulating layer, enhances mechanical resistance, and allows for faster, less costly manufacturing with superior heat insulation properties, reducing the risk of detachment and simplifying the production process.
Implementation Method 1
a sheet (2) made of a polymeric material adhering to a main insulating layer (1)
Implementation Method 2
They reduce the propagation of heat towards the slab
Implementation Method 3
electric cables operating as electrical resistance or electric heating wires which, if crossed by electric current, heat up due to the Joule effect
Data Source
Figure 1~2
AI summary
The invention relates to a multilayer insulating panel (100) for the installation of an electric heating system comprising electric heating wires (50) in a subfloor or in a wall of a building. The panel comprises: - a main insulating layer (1) including a first surface (10) and a second opposite surface (11); - a sheet (2) made of polymeric material operatively associated with one of such first (10) or second (11) surfaces; such a sheet (2) has a first face (20) and a second opposite face (21) and comprises a plurality of reliefs (22) equally spaced apart on the first face to fix the electric heating wires (50) on the first face (20) in a reversible manner. The panel further comprises a connection layer (3) fixed to the second face (21) of the sheet (2). Such a connection layer (3) is interposed between the second face of the sheet and one of the first (10) or the second (11) surface of the main layer (1) following the association of the main insulating layer (1) with the polymeric sheet (2).