Foamed Insulation Material Expansion in Architectural Frames
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Solution Overview
Problem
Current methods for filling frames with thermal insulation materials often result in gaps, leading to suboptimal thermal insulation and soundproofing due to difficulties in sizing, insertion, and expansion, with existing foamed materials either being too large, too small, or causing damage during the process.
Innovation Solution
A method involving preparing a foamed molded product smaller than the frame's hollow part, adding moisture with a water-based adhesive for lubrication, and then expanding the material within the frame through additional foaming to ensure a tight fit without gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a foamed molded product is used to fill the frame, then thermal insulation performance is improved, but it is difficult to mold and cut to fit the exact size of the empty space
Solution Approach 1:
The foamed molded product is prepared in advance with a size slightly smaller than the frame's empty space, allowing easy handling and insertion. The actual size adjustment is then achieved through in-situ foaming expansion after insertion, eliminating the need for precise pre-cutting and molding.
Solution Approach 2:
The volume and density parameters of the insulation material are changed dynamically. The material starts with a smaller, more manageable density and volume for easy insertion, then undergoes parameter transformation through foaming expansion to achieve the final desired volume that completely fills the frame space.
2Manufacturing precision
If the foamed molded product is made too large, then it can fill the frame, but it is difficult to insert and may damage the surface due to friction
Solution Approach 1:
The insulation material is prepared in a compressed or smaller-expanded state before insertion, making it easy to handle and insert into the frame without excessive friction. After successful insertion, the material is then allowed to expand to its final volume, ensuring complete filling without insertion difficulties.
3Ease of operation
If the foamed molded product is made too small, then it is easy to insert, but gaps are formed between the product and frame during insertion
Solution Approach 1:
The material is inserted in a controlled smaller state to ensure easy placement, then a subsequent foaming expansion process is initiated to increase its volume. This expansion fills any gaps between the material and the frame, ensuring complete coverage and maintaining thermal insulation performance.
Solution Approach 2:
The insulation material transitions from a static smaller size at insertion to a dynamic expanded state after insertion. The material's volume is not fixed but changes over time through controlled foaming, adapting to completely fill the available space and eliminate gaps.
4Quantity of substance
If foamable material is used in excess amount, then the frame is overfilled, but a convex portion is formed requiring frame removal and reconstruction
Solution Approach 1:
The foaming expansion process is controlled with feedback mechanisms to monitor the expansion progress. When the material reaches the appropriate volume that completely fills the frame space, the foaming is stopped or controlled, preventing over-expansion and the formation of convex portions that would require costly reconstruction.
5Ease of manufacture
If foamable material is used in insufficient amount, then the frame is not sufficiently filled, but gaps remain causing cracks and condensation
Solution Approach 1:
Rather than attempting to precisely calculate and apply the exact amount of foamable material needed (which risks insufficiency), the method uses a two-stage approach: insert a smaller amount of material first, then initiate controlled foaming expansion to ensure complete filling. This eliminates the risk of insufficient filling and associated problems like cracks and condensation.
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 allows for easy handling and complete filling of the frame with minimal friction, achieving excellent thermal insulation and soundproofing by ensuring the material expands to match the frame's dimensions, eliminating gaps and enhancing performance.
Implementation Method 1
additional foaming of the thermal insulation material formed as a foamed molded product inside the frame by heating the frame into which the thermal insulation material is inserted
Implementation Method 2
expand the thermal insulation material via additional foaming of the thermal insulation material formed as a foamed molded product inside the frame by heating the frame
Data Source
Figure 1a
Figure 1b
Figure 2a
AI summary
The present invention relates to a method for filling an insulation material using additional foaming, and an architectural frame filled with an insulation material produced by the method. The method for filling an insulation material using additional foaming provided in the present invention, which is a method for filling an insulation material inside a frame, comprises: an insulation material preparation step for preparing the insulation material made of a foam molded product smaller than a hollow portion of the frame to be filled with the insulation material; a moisture adding step for adding moisture to the surface of the insulation material; an insulation material insertion step for inserting the moisture-added insulation material into the hollow portion of the frame; and an additional foaming expansion step for heating the frame into which the insulation material is inserted so as to perform additional foaming, inside the frame, of the insulation material made of the foam molded product, and expand the insulation material.