Foamed Polymeric Coating Seals Insulation Edges

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Solution Overview

Problem

Air infiltration through insulated frame constructions, particularly those with fiber wool or particulate insulation, is not adequately addressed by existing methods, leading to heat loss and the need for costly and invasive retrofitting in older buildings.

Innovation Solution

Applying a thin layer of foamed fluid polymeric composition onto the exposed surface of the insulation to seal edges and gaps, which cures to form a polymeric coating that acts as an effective air barrier without compressing the insulation or significantly affecting its thermal performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a thick layer of polymeric composition is applied to seal edges and gaps, then air leakage reduction is improved, but insulation compression increases and thermal performance deteriorates

Engineering Contradiction:

Improveair leakage reductionVSAvoidthermal performance

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent applies a thin film of polymeric composition (coating layer) that flexes and conforms to seal edges and gaps between insulation and framing members. This thin film approach provides effective air sealing without requiring thick material application, thereby avoiding insulation compression and maintaining thermal performance while reducing air leakage.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent changes the physical parameters of the polymeric composition by incorporating blowing agents that create foam structures with controlled cell sizes and densities. This parameter modification allows the coating to achieve effective sealing at minimal thickness, preventing both air leakage and insulation compression that would occur with thicker applications.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If sealing is performed during initial construction, then air infiltration is reduced, but retrofitting older buildings requires insulation removal and replacement

Engineering Contradiction:

Improveair infiltration reductionVSAvoidretrofitting complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent enables preliminary sealing action to be performed on existing structures without dismantling. The polymeric composition is applied directly over existing insulation surfaces, where it flows and seals gaps between insulation and framing members, providing air infiltration reduction in retrofit scenarios without requiring insulation removal and replacement.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The polymeric composition acts as an intermediary sealing layer between the existing insulation and the framing members. This intermediary material flows into and seals gaps and voids, providing air infiltration control in retrofit applications without disturbing the existing insulation installation.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If a thick coating layer is applied to ensure complete sealing, then air barrier effectiveness is improved, but material usage increases and cost rises

Engineering Contradiction:

Improveair barrier effectivenessVSAvoidpolymeric material usage

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent utilizes a thin film polymeric coating that flexes to conform to irregular surfaces and seal gaps effectively. This thin film approach provides complete sealing coverage with minimal material thickness, reducing polymeric material usage while maintaining air barrier effectiveness.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent incorporates blowing agents that create foam structures within the polymeric composition. This pneumatic approach allows the material to expand and fill gaps during application, achieving complete sealing with less actual polymeric material than would be required in a non-foaming coating of equivalent sealing capability.

Inventive Principle:

Principle #29Pneumatics and hydraulics

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 polymeric coating substantially reduces air flow through the insulated assembly, maintaining thermal insulation efficiency while minimizing material usage and avoiding the need for extensive retrofitting in existing structures.

Implementation Method 1

applying a layer of a foamed fluid polymeric composition onto the exposed surface of the insulation

Methodology Applied

Scientific EffectFoaming: Foam

Implementation Method 2

curing the applied layer of foamed fluid polymeric composition to form a polymeric coating

Methodology Applied

Scientific EffectCuring:

Data Source

PatentUS10202758B2Method to reduce air infiltration through an insulated frame structure

Publication Date: 2019.02.12 DOW GLOBAL TECHNOLOGIES LLC

AI summary

Air flow is reduced through a structure insulated with one more layers of fiber wool or particulate insulating material. A layer of a foamed fluid polymeric composition is applied onto the exposed surface of the insulation to cover the edges at which the exposed surface of the insulation meets an enclosing member of the structure. The layer is then cured to form a polymeric coating on the exposed surface of the insulation. The coating seals the edge or edges at which the exposed surface of the insulation meets the enclosing members of the structure.