Double-Density Foam Panel With Through-Holes for Condensate Drainage
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Solution Overview
Problem
Existing insulating panels for buildings lack effective methods to prevent condensation and maintain thermal insulation efficiency, particularly in varying environmental conditions and building materials.
Innovation Solution
A thermally insulating panel made from double-density foam polystyrene with a lighter, more reflective outer layer and a darker, thicker inner layer, featuring small through holes for condensate discharge, and designed with grooves and de-tensioning lines for enhanced durability and adaptability, manufactured using a molding process with specific mold configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional insulating panel is used, then thermal insulation is provided, but condensation forms inside the building and insulation efficiency decreases
Solution Approach 1:
The patent applies porous materials by creating a foam substrate with controlled porosity and incorporating small through-holes (0.5-5 mm diameter) that allow condensate to pass through while maintaining thermal insulation. The porous structure enables the panel to manage moisture without compromising insulating performance.
Solution Approach 2:
The patent extracts the condensate discharge function from the insulating panel structure by incorporating separate drainage channels and through-holes that specifically remove condensate while leaving the insulation layers intact. This separation allows the insulation to maintain its thermal properties while the drainage system handles moisture removal.
2Ease of manufacture
If the insulating panel structure is simplified, then manufacturing is easier, but the panel lacks durability under mechanical and thermal stresses
Solution Approach 1:
The patent segments the insulating panel into multiple functional layers: an outer protective layer, an insulating foam substrate, and an inner layer with drainage channels. This segmentation allows each layer to be optimized for its specific function while maintaining overall structural integrity and durability under stresses.
Solution Approach 2:
The patent uses composite materials by combining different foam densities (lighter outer layer with 20-50 kg/m³ density, darker inner layer with 10-30 kg/m³ density) and integrating drainage channels within the foam structure. This composite approach provides both ease of manufacture and durability under mechanical and thermal conditions.
3Object-affected harmful factors
If small through holes are added for condensate discharge, then condensate can be drained, but thermal insulation efficiency may be reduced
Solution Approach 1:
The patent applies local quality by concentrating the through-holes in specific regions rather than uniformly distributing them throughout the entire panel. The holes are strategically positioned in the inner layer where they effectively drain condensate while minimizing their impact on overall thermal insulation, as insulation is maintained in the outer and intermediate regions.
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 panel effectively reduces heat loss, increases insulating capacity, and extends lifespan by managing condensate discharge while maintaining consistent insulation performance under mechanical and thermal stresses.
Implementation Method 1
a first overlying layer 6... made with a smaller thickness and a light colour, so as to reflect partially the incident solar radiation
Implementation Method 2
an insulating panel 5 for inhabited buildings of various kind... made of a single insulating material, of the kind formed by foamable plastic materials, preferably foam polystyrene
Implementation Method 3
small through holes 14... adapted to let to pass the condensate which is formed in the walls of the housings from the inside toward the outside of the same housings
Data Source
Figure 1~2
Figure 3~4
Figure 5~8
AI summary
Insulating panel for inhabited buildings of various kind, in order to insulate thermally the housings into which it is mounted, preferably on to the outer surfaces of their peripheral walls, in a manner to provide for a covering enclosure of the inhabited buildings, which is subsequently covered with finishing materials and parging. Panel constituted by a single insulating material, of the kind formed by foamable plastic materials, preferably foam polystyrene, provided with a first overlying layer (6) and a second underlying layer (7), of which the first overlying layer (6) is turned outward the building and is realized with light colour, and with a greater density of material, and therefore with a stiffness and a sturdiness which are greater than that of said second layer (7), and the second underlying layer (7) is turned inward the building and is realized with a greater thickness with respect to said first layer (6) and with smaller density of material, and moreover is coloured dark, or black, so as to increase the insulating capacity of this zone of panel (5). The first and second layer (6, 7) of insulating material are crossed for the entire thickness thereof by a plurality of small through holes (14), adapted to let to pass from the inner side outward the housings the condensate which is formed in the walls of the same housings. Furthermore, the process for obtaining the small through holes of such panel is described.