Flexible Graphite Heat Insulation Sheet With Thin Adhesive Lamination
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Solution Overview
Problem
Conventional heat insulation sheets with carbon sheets face issues of reduced flexibility due to adhesive solidification and contraction, making them unsuitable for flexible applications like curtains or blinds, and are cumbersome to handle due to thickness and weight, with a risk of carbon powder scattering upon breakage.
Innovation Solution
A heat insulation sheet with a pressure-sensitive or hot-melt adhesive fixing layer between a flexible base material and a carbon sheet made from rolled expanded graphite, enhancing flexibility and handleability, and incorporating activated carbon for improved performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive is used for lamination of base material sheet and carbon sheet, then heat insulation effect is achieved, but flexibility deteriorates due to solidification and contraction of adhesive
Solution Approach 1:
The patent changes the physical and chemical parameters of the adhesive by specifying particular types (polyurethane-based, silicone-based, acrylic-based pressure-sensitive adhesives) and controlling their thickness (1-10 μm), composition, and curing characteristics to maintain flexibility while achieving heat insulation
Solution Approach 2:
The patent creates a composite structure combining base material sheet, adhesive layer, and carbon sheet, where each component is carefully selected and proportioned to achieve both heat insulation performance and flexibility. The adhesive acts as a flexible bonding matrix that preserves the overall flexibility of the composite
2Strength
If fixing layer is applied to whole surface of sheet, then bonding strength is improved, but flexibility is impaired significantly
Solution Approach 1:
The patent applies local quality by specifying that the adhesive layer should have non-uniform thickness distribution, with thinner regions (1-10 μm) in areas requiring flexibility and potentially thicker regions in areas requiring stronger bonding, optimizing both properties locally
Solution Approach 2:
The patent suggests that complete surface coverage with thick adhesive is excessive; instead, a thin partial coverage or strategic placement of adhesive in key bonding areas is sufficient to achieve adequate bonding while preserving flexibility
3Reliability
If overall thicknesses of base material sheet and carbon sheet are increased, then heat insulation performance is improved, but flexibility deteriorates naturally
Solution Approach 1:
The patent optimizes the thickness parameters of each layer (base material sheet, adhesive, carbon sheet) to achieve the minimum required heat insulation performance while keeping the total thickness as small as possible to maintain flexibility
Solution Approach 2:
The patent employs thin-film technology, using extremely thin adhesive layers (1-10 μm) and thin carbon sheets that provide adequate heat insulation while maintaining flexibility, avoiding the need for thick rigid structures
4Reliability
If heat insulation sheet is formed in roll-like shape with great thickness, then heat insulation effect is enhanced, but handle-ability becomes difficult
Solution Approach 1:
The patent changes the thickness parameter to an optimized range that provides sufficient heat insulation without excessive bulk, making the rolled product manageable and easy to handle, install, and store
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 provides a heat insulation sheet with high flexibility, improved handleability, and a wide range of applications, maintaining excellent heat insulation performance while being lightweight and easy to manage, even in rolled forms.
Implementation Method 1
a fixing layer being arranged between a base material and a carbon sheet, the fixing layer being made of a pressure-sensitive adhesive
Implementation Method 2
the carbon sheet being made by rolling expanded graphite and having a thickness from twenty-five micrometers to one hundred micrometers
Data Source
AI summary
The heat insulation sheet is provided with a fixing layer that is arranged between a base material and a carbon sheet. The fixing layer is made of a pressure-sensitive adhesive. The base material has flexibility. The carbon sheet is made by rolling expanded graphite and has a thickness from twenty-five micrometers to one hundred micrometers. In the sheet material, activated carbon is arranged opposite to the fixing layer side of the heat insulation sheet, and a surface material is arranged on a surface of the activated carbon. The fixing layer can be constituted in such a manner that a hot-melt adhesive is arranged in a reticulate manner.