Insulation Composite With Drainage Layer for Moisture and Abrasion
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Solution Overview
Problem
Existing composite materials for thermal and acoustic insulation in vehicles and buildings face challenges in maintaining insulation properties under humid conditions and risk damaging adjacent components due to protruding drainage structures.
Innovation Solution
A composite material with a soft foam or volume fleece insulation and a reticulated foam drainage structure, where the drainage structure has protruding points for attachment and a smoothed or protected side to prevent abrasion, ensuring long-term insulation and protection against moisture and surface damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a wire mesh or plastic structure with interconnected filaments is used as a drainage structure, then moisture drainage function is improved, but damage to adjacent surfaces and coatings occurs due to protruding points
Solution Approach 1:
A protective layer is introduced as an intermediary between the drainage structure and the insulation material. This protective layer has a smooth outer surface that prevents direct contact between the protruding drainage structure points and the insulation material surface, thereby preventing damage while maintaining the drainage function.
Solution Approach 2:
The protective layer is implemented as a thin film or sheet material that covers the drainage structure. This film provides a smooth protective surface that eliminates the harmful protruding points while allowing the underlying drainage structure to maintain its moisture drainage functionality.
2Stability of the object's composition
If the drainage structure is firmly bonded to the insulation material at multiple points, then attachment stability is improved, but the insulation material's surface integrity and protective coatings are compromised
Solution Approach 1:
The bonding interface is segmented into two distinct surfaces: an inner surface that provides stable attachment between the drainage structure and insulation material, and an outer surface that remains smooth and intact to protect adjacent surfaces. The protective layer creates this segmentation, allowing stable bonding without compromising surface integrity.
3Device complexity
If conventional insulation materials are used without additional protective layers, then simplicity and cost-effectiveness are improved, but insulation properties deteriorate under humid conditions and external liquid penetration
Solution Approach 1:
The insulation system is constructed as a composite material combining the drainage structure, protective layer, and insulation material into a single integrated unit. This composite structure provides both the necessary insulation properties and protection against humid conditions and liquid penetration, while maintaining relative simplicity through integration.
Data Source
Figure 1a~2b
AI summary
Composite material (10) and manufacturing process of a composite material (10) for realizing thermal and/or acoustic insulation in vehicles, buildings or systems with an overall planar, plate-like basic shape, comprising at least one insulation material (2) and at least one functional layer connected to the insulation material (2) in the form of a drainage structure (1), wherein the drainage structure (1) forms an air- and liquid-permeable layer of the composite material (10), wherein the insulation material (2) comprises a soft foam or a volume fleece based in particular on PET, PP, PANox, cotton or a mixture thereof, wherein the drainage structure (1) is uneven on the side facing the insulation material (2), in particular with protruding points or parts for attachment to the insulation material (2), and on the opposite side a means (3,4) for abrasion protection on the outside of the composite material (10).