Insulating Panel with Embedded Vacuum Panels
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Solution Overview
Problem
There is a need for insulating panels with improved thermal performance that can be achieved in a cost-efficient manner.
Innovation Solution
The solution involves an insulating panel comprising an external and internal facing with a body of expanded insulating foam, where a plurality of vacuum insulated panels are embedded, extending across the length and/or width, and interconnected for easier handling, and manufactured by laying down liquid foam reactants with pre-inserted vacuum panels, which can extend for at least 25% to 65% of the foam thickness, using metal sheets as facings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional insulating foam panels are used to achieve required thermal insulation, then insulation performance is maintained, but panel thickness and weight increase
Solution Approach 1:
The patent combines vacuum insulated panels (VIPs) with expanded insulating foam material to create a composite insulation structure. The VIPs provide high thermal resistance in thin profiles, while the foam material fills remaining spaces and provides structural support, achieving superior insulation performance with reduced overall thickness compared to conventional foam-only panels
Solution Approach 2:
The vacuum insulated panels are embedded within and nested in the expanded insulating foam material. This nesting arrangement allows the high-performance VIPs to be integrated into the foam matrix, maximizing thermal insulation effectiveness while minimizing the total panel thickness required to achieve target R-values
2Temperature
If traditional insulating foam panels are used to achieve required thermal insulation, then insulation performance is maintained, but panel weight increases
Solution Approach 1:
The composite structure replaces portions of heavy foam material with lighter vacuum insulated panels that provide equivalent or superior insulation performance per unit thickness, thereby reducing overall panel weight while maintaining required thermal performance
Solution Approach 2:
By nesting VIPs within the foam matrix, the design utilizes the weight efficiency of vacuum insulation technology while leveraging the foam material only where structurally necessary, optimizing the weight-performance ratio
3Temperature
If vacuum insulated panels are embedded in expanded insulating foam, then thermal performance improves and thickness reduces, but manufacturing complexity increases
Solution Approach 1:
The vacuum insulated panels are pre-manufactured and prepared before being integrated into the foam structure. This preliminary preparation allows for standardized VIP components to be embedded in the expanding foam, simplifying the overall manufacturing process compared to attempting to create vacuum insulation structures from scratch during panel fabrication
Solution Approach 2:
The manufacturing process merges two distinct technologies (VIP fabrication and foam panel production) into a single integrated process, where VIPs are embedded in foam during the foam expansion process, combining the benefits of both insulation methods while streamlining production
4Ease of operation
If vacuum insulated panels are used without interconnection, then individual panel flexibility is maintained, but handling and storage efficiency decreases
Solution Approach 1:
Multiple individual vacuum insulated panels are connected together using webbing or other interconnection means to form a unified assembly. This merging of separate panels into a single handled unit improves storage efficiency and handling ease while the interconnection elements are designed to be minimally intrusive to the overall panel structure
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 configuration enhances thermal performance, reduces panel thickness, weight, and costs by achieving similar insulation properties with thinner panels, allowing for reduced transport and support structure needs.
Implementation Method 1
a plurality of vacuum insulated panels embedded in the expanded insulating foam
Implementation Method 2
The vacuum insulated panels extend across the length and/or with of said insulating panel
Implementation Method 3
a body of expanded insulating foam extending between the facings
Implementation Method 4
a body of expanded insulating foam
Implementation Method 5
laying liquid foam reactants onto the first substrate; allowing the foam to expand to form an insulating body
Data Source
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AI summary
An insulating panel comprises sheets (1, 2) with a body (3) of insulating foam between the sheets. The insulating material has a vacuum insulated panel (4) embedded therein. The panel is substantially thinner than corresponding panels without a vacuum insulated panel (4).