Method of producing an insulation product and a product obtained by said method
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Solution Overview
Problem
Current methods for producing thermally insulating materials, such as vacuum insulation panels, face challenges with handling damage and high production costs, limiting their widespread adoption in building construction, and existing gas-filled insulation products have not been industrially viable due to production difficulties.
Innovation Solution
A method involving wrapping porous insulation material, such as bound fibrous or mineral materials, in a gas-impermeable foil and flushing with an insulating gas like CO2 to reduce thermal conductivity, utilizing a flow-wrapping process for efficient and cost-effective large-scale production of insulation boards with enhanced thermal performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If vacuum insulation panels are used to achieve high thermal insulation performance, then thermal conductivity is reduced, but handling damage and production costs increase
Solution Approach 1:
The patent changes the pressure parameter from vacuum (extreme low pressure) to partial vacuum (moderate low pressure), and replaces the gas composition from air to insulating gases like argon or CO2. This parameter optimization maintains thermal insulation performance while significantly improving the mechanical reliability and damage resistance of the insulation panels during handling and installation.
Solution Approach 2:
The patent uses composite construction by combining porous insulation material (mineral wool, glass wool, or foam) with a gas-tight envelope and insulating gases. This composite structure achieves high thermal insulation performance through multiple mechanisms: solid matrix insulation, gas phase insulation, and vacuum effects, while the robust composite construction improves handling reliability compared to pure vacuum panels.
2Temperature
If vacuum insulation panels are used to achieve high thermal insulation performance, then thermal conductivity is reduced, but production costs increase
Solution Approach 1:
The patent optimizes pressure and gas composition parameters to achieve effective thermal insulation without requiring complete vacuum conditions. The partial vacuum with insulating gases provides comparable thermal performance at significantly lower production costs, as the manufacturing process is simpler and does not require expensive high-vacuum equipment and procedures.
Solution Approach 2:
The patent employs cost-effective porous materials like mineral wool, glass wool, or standard foams as the insulation core, replacing expensive specialized vacuum panel materials. The gas-tight envelope uses conventional laminated foils rather than specialized vacuum-barrier materials, significantly reducing overall production costs while maintaining effective thermal insulation.
3Reliability
If insulating gas is used instead of vacuum to maintain thermal performance, then thermal conductivity increases slightly, but handling damage decreases
Solution Approach 1:
The patent optimizes the gas pressure and composition parameters to minimize thermal conductivity while ensuring sufficient mechanical pressure for structural integrity. By using insulating gases like argon or CO2 at partial vacuum pressures, the patent achieves the best compromise between thermal performance and handling reliability, with the gas pressure providing structural support that prevents envelope collapse during handling.
4Productivity
If continuous production method is implemented to increase productivity, then production capacity increases, but manufacturing complexity increases
Solution Approach 1:
The patent combines multiple production operations into a single continuous flow-wrapping process: the insulation boards are wrapped in gas-tight foil, evacuated to partial vacuum, flushed with insulating gas, and sealed all in one continuous operation. This merging of operations increases production capacity while the modular flow-wrapping equipment design keeps manufacturing complexity manageable through standardized, integrated machinery.
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 method significantly reduces thermal conductivity by replacing air with insulating gases, improving thermal performance and making the production process more efficient and cost-effective, while maintaining a lower pressure inside the insulation boards to prevent overpressure issues.
Implementation Method 1
gas having a low coefficient of thermal conductivity is used in combination with glass fibers or the like
Data Source
AI summary
The present invention concerns a method of producing an insulation product comprising a board of porous insulation material wrapped in a gas-impermeable foil, said method comprising the steps of providing a succession of porous insulation material boards on a first conveyor apparatus and feeding the boards on a second conveyor apparatus; providing wrapping foil and wrapping said foil to form a tube around the boards on said second conveyor apparatus, flushing the boards with an insulating gas, and sealing the wrapping foil at the ends of each board transverse to the direction of travel of the second conveyor apparatus.