Flexible Insulation Blanket With Cauterized Edges for Particle Retention

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Solution Overview

Problem

Insulation blankets face a challenge in maintaining their insulating performance due to the loss of small insulation particles, such as fumed silica, through cut edges, which reduces their thermal efficiency and creates dust issues during installation.

Innovation Solution

The insulation blanket features a cauterized edge formed by applying heat to the cut edge, creating a barrier that encases the fumed silica particles within the blanket, preventing shedding and maintaining flexibility for easier installation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the insulation blanket is cut to fit around objects, then the blanket can be applied to various shapes and sizes, but the cut edge exposes small insulation particles to the environment causing them to shed and be lost

Engineering Contradiction:

Improveability to fit around objectsVSAvoidloss of insulation particles

Core Design Contradiction:

Adaptability or versatilityVSLoss of substance

Solution Approach 1:

The edge of the insulation blanket is cauterized before the particles can shed. By applying heat treatment in advance to seal the cut edge, the blanket prevents particle loss that would otherwise occur during handling and installation, thus resolving the contradiction between adaptability and substance loss

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The harmful effect of exposed cut edges causing particle shedding is converted into a benefit by deliberately applying controlled heat to cauterize the edge. This transforms the potential harm (exposed particles) into a positive outcome (sealed edge that prevents shedding)

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Reliability

If small particles are used to increase insulation R-value, then the insulating performance is improved, but the particles may be shed or lost from the cut edge

Engineering Contradiction:

Improveinsulating performanceVSAvoidloss of insulation particles

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The edge is cauterized in advance before particle loss can occur. This preliminary heat treatment seals the small insulation particles within the blanket structure, ensuring that the high R-value performance is maintained without particle shedding compromising either performance or quantity

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The physical state of the edge material is changed through heat treatment. By altering the temperature parameter during cauterization, the edge material transitions to a sealed state that traps particles, thus maintaining both insulating performance and preventing substance loss

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If the cut edge is left exposed, then the blanket remains flexible and easy to handle, but the insulation particles are exposed to the environment and may be lost

Engineering Contradiction:

Improveease of handlingVSAvoiddust generation from shed particles

Core Design Contradiction:

Ease of operationVSObject-generated harmful factors

Solution Approach 1:

The potentially harmful exposed cut edge is transformed into a beneficial sealed edge through cauterization. This converts the harm (particle shedding and dust generation) into a benefit (particle containment), while the sealing process is designed to maintain the flexibility needed for easy handling and installation

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 cauterized edge effectively minimizes the loss of insulation particles, enhances thermal performance, and reduces dust, allowing for efficient and flexible application of the insulation blanket in industrial settings.

Implementation Method 1

The insulation blanket includes at least one exposed edge that includes a cauterized face that is roughly orthogonal to the first and second facer layers. The cauterized face forms a barrier on the exposed edge that encases the fumed silica insulating powder within the interior of the insulation blanket

Methodology Applied

Scientific EffectCauterization: Heat Treatment

Implementation Method 2

A fumed silica insulating powder is also disposed between the first and second facer layers and within the intermeshed non-woven glass fibers

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS11815217B2High temperature flexible blanket for industrial insulation applications

Publication Date: 2023.11.14 JOHNS MANVILLE CORP

AI summary

According to one embodiment, an insulation blanket for insulating a structure includes a first facer layer and a second facer layer. A plurality of intermeshed non-woven glass fibers are disposed between the first and second facer layers and a fumed silica insulating powder is also disposed between the first and second facer layers. The fumed silica insulating powder has an average particle size of between about 2 and 20 nanometers. The insulation blanket includes at least one exposed edge having a cauterized face that forms a barrier on the exposed edge to encase the fumed silica insulating powder within the interior of the insulation blanket, which minimizes degradation of the insulating value due to loss or shedding of the fumed silica insulating powder through the exposed edge. The cauterized edge has a depth of cauterized material of between about 0.05 mm and 3 mm.