Encapsulating Fragile Insulation in Polyisocyanurate Foam
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Solution Overview
Problem
Fragile insulation materials, such as vacuum insulation panels, are susceptible to mechanical damage and loss of insulating capabilities due to compromised gas-tight enclosures, and existing methods struggle to completely encapsulate these materials within foam layers during manufacturing.
Innovation Solution
A process involving the deposition of polyurethane or polyisocyanurate foam over fragile insulation materials to completely encapsulate them, using conventional equipment and techniques, ensuring accurate positioning and minimal gaps between the insulation materials and the foam layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If fragile insulation materials are used to provide advantageous insulating properties, then thermal insulation performance is improved, but mechanical strength deteriorates making them susceptible to mechanical damage
Solution Approach 1:
The patent combines fragile insulation materials (aerogel, vacuum insulation panels) with a foam matrix material to create a composite structure. The foam provides mechanical strength while the fragile insulation material provides thermal insulation, resolving the contradiction between insulation performance and mechanical strength.
2Manufacturing precision
If adhesive securing of VIPs to facer is used to enable accurate positioning, then positioning precision is improved, but complete encapsulation deteriorates leaving VIPs not fully protected by foam layer
Solution Approach 1:
The patent applies adhesive to the facer material before positioning the VIPs, securing them in place before the foam is applied. This preliminary action ensures accurate positioning while the subsequent foam application provides complete encapsulation, resolving the contradiction between positioning precision and complete encapsulation.
3Ease of manufacture
If conventional equipment and techniques are used for foam deposition, then ease of manufacture is improved, but complete encapsulation deteriorates making it difficult to fully protect insulation materials
Solution Approach 1:
The patent employs a continuous foam application process where foam is deposited over the VIPs as they move through the manufacturing line. This dynamic approach using conventional equipment achieves complete encapsulation while maintaining ease of manufacture, resolving the contradiction between ease of manufacture and complete encapsulation.
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 process effectively protects fragile insulation materials from mechanical damage while maintaining their insulating properties, enabling the production of durable and efficient construction boards with improved mechanical durability and thermal insulation.
Implementation Method 1
depositing a developing foam over the fragile insulation materials to at least partially cover the fragile insulation materials
Implementation Method 2
polyurethane or polyisocyanurate foam... providing advantageous insulating properties
Data Source
AI summary
Embodiments of the present invention are based, at least in part, on the discovery of methods for encapsulating fragile insulation materials within polyisocyanurate foam to thereby provide a construction board having an advantageous balance of insulating properties and mechanical durability.