Insulated panel structure
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Solution Overview
Problem
Existing methods for constructing cold storage rooms using custom molded insulated panels are time-consuming, expensive, and labor-intensive, with suboptimal insulation and weak connections between panels.
Innovation Solution
A method for manufacturing a kit for constructing a cold storage room using continuously manufactured insulation panels, which are cut to specific dimensions and equipped with alignment structures, connection structures, and connection hardware to facilitate quick and robust assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If custom molded insulated panels are used, then the insulation panels can be assembled into a cold storage room within a specified structure, but the manufacturing process is time-consuming, expensive, and labor-intensive
Solution Approach 1:
The panel is divided into a panel body and a separate connection element. The connection element is inserted into a recess in the panel body after molding, allowing the panel to be assembled in modules rather than requiring complex integrated molding for each panel.
Solution Approach 2:
The connection elements are pre-inserted into the recesses of the panels during manufacturing. This preliminary action allows for faster on-site assembly since the connection mechanism is already in place, eliminating the need for complex field installation procedures.
2Adaptability or versatility
If custom molded insulated panels are used, then the panels can be customized to desired sizes, but the insulation provided is less even than that provided by continuously manufactured insulation panels
Solution Approach 1:
The panel consists of a panel body and a separate connection element with a stem. This segmentation allows the panel body to be continuously manufactured with uniform insulation, while the connection element provides the necessary customization and connection functionality without compromising insulation uniformity.
Solution Approach 2:
The connection element acts as an intermediary between the panel body and the joining mechanism. It allows for size customization and connection adaptability while the panel body maintains continuous manufacturing insulation uniformity, effectively decoupling the customization requirement from the insulation quality.
3Ease of operation
If connection elements are embedded in the foam of the panels, then the panels can be connected together, but the foam holding the connection element may be damaged when the connection element is used to form a connection or when a load is applied
Solution Approach 1:
The connection element is extracted from the foam matrix and placed in a separate recess. The stem of the connection element extends from the recess rather than being fully embedded in the foam, so when connections are formed or loads applied, the foam is not subjected to damaging stresses.
Solution Approach 2:
The recess provides a predetermined path and support structure for the connection element stem. This beforehand cushioning ensures that when loads are applied during connection formation, the stress is distributed along the recess walls and stem structure rather than concentrating in the foam, preventing foam damage.
4Ease of manufacture
If connection elements are added to panels during the manufacturing process, then the panels are ready for assembly, but there is little flexibility for later modifications
Solution Approach 1:
The connection element is designed with a stem that can be inserted into and removed from the recess, creating a dynamic rather than fixed connection. This allows panels to be easily assembled during manufacturing but also easily modified or reconfigured later by simply removing and repositioning the connection elements.
Data Source
AI summary
A method of manufacturing a kit for a cold storage room includes the following steps: determining one or more dimensions of the cold storage room; providing continuously manufactured insulation panels, cut to have a length based on the dimensions of the cold storage room, and having alignment structures formed thereon; cutting one or more of the continuously manufactured insulation panels to have a width based on the dimensions of the cold storage room and to form one or more joints; forming connecting structures on one or more of the continuously manufactured insulation panels, the connecting structures configured to form one or more joints; and providing connection hardware configured to mate with the connecting structures and to form one or more joints.