Method of manufacturing a hybrid insulating frame and panel
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Solution Overview
Problem
Conventional freezer and refrigerated enclosure frames face a trade-off between structural reliability and thermal insulance, as materials with high insulative properties often lack structural integrity, and vice versa, leading to compromised performance in both aspects.
Innovation Solution
A method of manufacturing a hybrid insulating frame and panel that integrates a structurally reliable core member with a highly insulative foam jacket, where a beam is surrounded by foam material within a mold, forming a compressible mating joint for improved thermal and structural performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If high-density rail (HDR) is used for the frame to improve thermal resistivity, then insulative performance is improved, but structural integrity deteriorates
Solution Approach 1:
The patent applies composite materials by combining high-density rail (HDR) foam insulation with a structurally strong frame material such as wood, steel, or aluminum. The HDR foam provides high thermal resistivity (R-value) while the structural frame material provides the necessary strength and integrity. This composite construction allows the refrigerated enclosure to achieve both excellent insulative performance and structural reliability, resolving the contradiction between these two properties.
2Strength
If wood frame is used for the frame to improve structural reliability, then strength capacity is improved, but thermal resistivity deteriorates
Solution Approach 1:
The patent uses composite materials construction where the frame consists of a structural core (wood, steel, or aluminum) providing strength and integrity, combined with HDR foam insulation layers that provide high thermal resistivity. This composite approach allows the frame to achieve both structural reliability and excellent insulative performance, eliminating the need to choose between strength and thermal resistance.
3Temperature
If high-density rail (HDR) frame is used to optimize thermal resistivity, then insulative performance is improved, but structural performance deteriorates
Solution Approach 1:
The patent implements composite materials by creating a hybrid frame structure where HDR foam provides the thermal insulation function while a separate structural framework (made from wood, steel, or aluminum) provides the mechanical strength and reliability. This division of functions within a composite structure allows the enclosure to achieve both optimized thermal resistivity and superior structural performance, resolving the contradiction between these two critical properties.
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 hybrid insulating frame and panel achieve enhanced thermal performance, structural reliability, and energy efficiency by combining the benefits of foam insulation with the structural integrity of a core beam, resulting in improved life-cycle performance.
Implementation Method 1
dispensing a first foam material in a liquid phase in the mold... curing the first foam material to form an integrated frame
Data Source
AI summary
A method of manufacturing a hybrid insulating panel includes providing a mold of a frame, dispensing a first foam material in a liquid phase in the mold, and placing a beam in the mold. The method includes curing the first foam material to form an integrated frame, in which the integrated frame includes the beam at least partially surrounded by the first foam. Further, the method includes dispensing a second foam material into a panel cavity to form a panel body. The panel cavity is at least partially defined by a side of the integrated frame. The method includes curing the second foam material to form a panel body, wherein the panel body is secured to the integrated frame.