Insulation Panel Seal
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Refrigerated enclosures experience air leakage and thermal conductivity issues through joints and mating surfaces due to inefficient assembly methods.
Innovation Solution
The use of a thermally insulated joint comprising a continuous layer of cured foam and non-foam sealant bonded to insulated panels, which are sandwiched between thermally conductive sheets, to form a seamless and thermally insulated connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional assembly methods are used to join insulated panels, then assembly is simpler, but air leakage and thermal conductivity increase through joints
Solution Approach 1:
The joint uses a composite structure combining foam material (for filling and initial sealing) with a non-foam sealant layer (for enhanced sealing and thermal barrier). This composite approach addresses air leakage and thermal conductivity issues by leveraging the complementary properties of both materials, achieving superior seal integrity compared to conventional single-material joints.
Solution Approach 2:
The joint structure applies different materials at different locations: foam fills the center portion for bulk sealing and structural support, while non-foam sealant is applied at the outer edges for enhanced sealing. This local differentiation optimizes both seal integrity and thermal performance without unnecessarily complicating the entire joint structure.
2Reliability
If conventional sealing methods are used at joints, then assembly is easier, but thermal conduction increases through mating surfaces
Solution Approach 1:
The dual-layer joint construction with foam and non-foam sealant creates an enhanced thermal barrier. The non-foam sealant layer specifically addresses thermal conduction at the mating surfaces while the foam provides bulk insulation, together achieving superior thermal insulation performance.
Solution Approach 2:
The joint structure acts as an intermediary element between insulated panels, providing both mechanical bonding and thermal blocking functions. The combination of foam and non-foam sealant creates an intermediate layer that reduces thermal conduction while maintaining assembly feasibility.
3Ease of manufacture
If simple joint structures are used between panels, then manufacturing is simpler, but air leakage occurs through joints
Solution Approach 1:
The foam-non-foam sealant composite structure provides effective air leakage prevention. The foam fills and seals the joint cavity while the non-foam sealant layer provides an additional sealing barrier at the interface, together eliminating air leakage paths without requiring overly complex manufacturing processes.
Solution Approach 2:
The foam material, being inherently porous yet expandable, fills irregularities and voids in the joint space, creating an effective air barrier. This porous structure adapts to the joint geometry while preventing air leakage, maintaining manufacturing simplicity.
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 method effectively prevents air leakage and minimizes thermal conduction, enhancing the insulation and structural integrity of refrigerated display cases.
Implementation Method 1
The thermally insulated joint includes a continuous layer of cured foam and a continuous layer of non-foam sealant. The continuous layer of cured foam is bonded to both the first end face and the second end face extending along a mated length between the first and second end faces.
Implementation Method 2
The continuous layer of non-foam sealant is bonded to both the first end face and the second end face and is adjacent to an outer edge of the layer of cured foam. The layer of non-foam sealant extends along an entire length of the layer of cured foam.
Implementation Method 3
The first insulated panel includes a first foam core sandwiched between a first pair of thermally conductive sheets. The second insulated panel includes a second foam core sandwiched between a second pair of thermally conductive sheets.
Data Source
AI summary
Implementations of the present disclosure include an insulated case that includes a first insulated panel and a second insulated panel. The first insulated panel includes a first foam core sandwiched between a first pair of thermally conductive sheets. The first insulated panel includes a first end face. The second insulated panel includes a second end face that is bonded to the first end face by a thermally insulated joint. The thermally insulated joint includes a continuous layer of cured foam and a continuous layer of non-foam sealant. The continuous layer of cured foam is bonded to both the first end face and the second end face extending along a mated length between the first and second end faces. The continuous layer of non-foam sealant is bonded to both the first end face and the second end face and is adjacent to an outer edge of the layer of cured foam.