Insulation Board for Sandwich Panel Using Segmented Foil Elements
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Solution Overview
Problem
Existing sandwich panels with mineral wool fibre cores lack effective thermal insulation and structural reinforcement, as the gas-impermeable sealing foil can be punctured, compromising the thermal insulation properties, and the structural strengths are not adequately enhanced.
Innovation Solution
A method involving elongated insulation elements of porous material wrapped in gas-impermeable foil, arranged between mineral wool fibre boards, which are then cut into lamellae, rotated, and reassembled with additional mineral wool fibre boards to form a sandwich panel core, providing enhanced thermal insulation and structural strengths without adhesive attachment to maintain insulation integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If gas-impermeable sealing foil is used to wrap porous insulation material, then thermal insulation properties are improved, but the insulation properties are lost when the foil is punctured
Solution Approach 1:
The insulation board is segmented into multiple elongated insulation elements arranged in rows with spaces between them. This segmentation allows the insulation structure to maintain thermal performance even if individual elements are compromised, as the gas-impermeable foil wrapping is localized to each element rather than requiring continuous coverage across the entire board.
Solution Approach 2:
The gas-impermeable foil wrapping is applied locally to individual elongated insulation elements rather than uniformly across the entire insulation board. This localized application allows each element to maintain its insulation properties independently, and the overall board maintains thermal performance even if some elements are punctured.
2Strength
If mineral wool fibre boards are used to provide structural reinforcement, then compression and shear strength are increased, but thermal insulation properties are reduced due to higher density material
Solution Approach 1:
The insulation board combines porous insulation material wrapped in gas-impermeable foil with mineral wool fibre boards to create a composite structure. The porous insulation material provides superior thermal insulation, while the mineral wool fibre boards provide structural reinforcement for compression and shear strength, achieving both thermal and mechanical performance requirements.
Solution Approach 2:
The structural reinforcement is achieved through discrete mineral wool fibre boards positioned at specific locations (top and bottom surfaces) rather than using a uniformly dense material throughout. This allows the core insulation material to remain low-density for optimal thermal performance while still providing necessary structural strength at critical locations.
3Strength
If adhesive attachment is used to secure insulation elements, then structural integrity is improved, but insulation properties are compromised due to thermal bridging through adhesive
Solution Approach 1:
The adhesive attachment method is extracted and replaced with mechanical attachment using clips or fasteners. This removes the thermal bridging effect of adhesive while maintaining structural integrity through the mechanical fastening system, preserving the thermal insulation properties of the insulation elements.
Solution Approach 2:
Clips or fasteners are introduced as intermediary elements to secure the insulation elements to the mineral wool fibre boards. These mechanical fasteners provide structural attachment without creating thermal bridges, as they minimize thermal conduction paths compared to adhesive materials.
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 method results in a sandwich panel with improved thermal insulation and structural reinforcement, maintaining insulation properties while reducing material usage and weight, and enhancing compression, shear, bending, and delamination strengths.
Implementation Method 1
a board of porous insulation material wrapped in a gas-impermeable foil
Implementation Method 2
The enhanced thermal insulation properties of a board of porous insulation material, such as stone wool, wrapped in a gas-impermeable foil
Data Source
Figure 1~5
Figure 6~10
AI summary
The present invention concerns a method of producing an insulation board for use in a sandwich panel production process, said method comprising: - providing a plurality of elongated insulation elements, each comprising a board of porous insulation material wrapped in a gas-impermeable foil and having a top surface and a bottom surface and a generally rectangular cross-sectional shape; - arranging said elongated insulation elements adjacent each other on a first mineral wool fibre board at a predetermined distance from each other, the bottom surfaces of said elongated insulation elements being fixed to the first mineral wool fibre board; and - arranging and fixing a second mineral wool fibre board on the top surfaces of said elongated insulation elements. The invention also concerns an insulation board and a method of producing a sandwich panel.