Insulated panel assembly
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Solution Overview
Problem
The existing manufacturing and assembly processes for thermally insulated enclosures are cumbersome and time-consuming due to the difficulty in connecting inner and outer metal panel members, which hinders rapid construction and efficiency.
Innovation Solution
A thermally insulated panel assembly design featuring a housing with an interior cavity and an elongate slot in its edge surfaces, allowing for the insertion of thermally insulating slats to connect adjacent panels without conventional fasteners, using a gasket for spacing and caulk for sealing, thereby simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fasteners and gaskets are used to connect inner and outer panel members, then the enclosure provides thermal insulation, but the assembly process becomes time-consuming and complex
Solution Approach 1:
The patent removes conventional fasteners and gaskets from the assembly process. Instead, pre-formed insulation panels with integrated recesses and protrusions are used, allowing panels to interlock directly without additional connecting components, thereby eliminating assembly time while maintaining thermal insulation integrity
Solution Approach 2:
The insulation panels are designed with self-aligning features where recesses in one panel automatically receive protrusions from adjacent panels. This self-service mechanism eliminates the need for manual fastening operations, reducing assembly time from minutes to seconds while ensuring proper thermal insulation installation
2Strength
If conventional fasteners and gaskets are used to connect panel members, then the enclosure structure is secured, but the manufacturing and assembly process becomes difficult and time-consuming
Solution Approach 1:
The enclosure is divided into modular insulation panels that can be manufactured independently and then assembled by simply interlocking them. Each panel is a complete, self-contained unit with integrated fastening features, making both manufacturing and assembly straightforward while maintaining structural integrity through the interlocking design
Solution Approach 2:
The patent combines the insulation material, structural panel, and fastening mechanism into a single integrated component. This merging eliminates the need for separate manufacturing and assembly steps for different components, significantly improving ease of manufacture and assembly while maintaining the required structural strength
3Reliability
If inner and outer metal panel members are joined together to form a volume, then thermal insulation is achieved, but the panel members become difficult to manufacture and attach
Solution Approach 1:
The patent extracts the separate inner and outer metal panel members and replaces them with a single pre-formed insulation panel that provides both structural and insulating functions. This eliminates the complexity of joining multiple metal components while maintaining thermal insulation performance
Solution Approach 2:
The invention uses composite insulation panels that integrate multiple materials and functions into a single component. These panels combine structural support, thermal insulation, and interlocking fastening features in one element, reducing assembly complexity while maintaining the required thermal performance
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 design significantly reduces assembly time by up to 85% (from 35 minutes to 5 minutes) and provides a rapid, efficient method for constructing thermally insulated enclosures like walk-in coolers and freezers with improved thermal insulation and a smooth outer surface for easy cleaning and aesthetics.
Implementation Method 1
an insulating core is located within the interior cavity of the housing
Data Source
AI summary
Insulated panel assemblies can be used to construct an insulating enclosure and the like. The insulated panel assemblies can have the same configuration and fit together to form a substantially sealed, insulated enclosure. The insulated panel assemblies themselves are particularly constructed for ease of formation and construction of the panel assemblies. Methods of forming an insulated panel assembly and using the panel assemblies to construct an insulated disclosure are also disclosed.