Layered Thermal Insulation With Dimpled Metal Foil Reflection

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Solution Overview

Problem

Existing thermal insulation systems for heat-producing equipment face issues such as increased fire risk due to absorption of combustible fluids by woven materials, restricted airflow leading to overheating, and poor coverage of critical areas, which are not adequately addressed by current solutions.

Innovation Solution

A layered thermal insulation system comprising an inner high-temperature resistant insulation layer, an outer high-temperature resistant insulation layer, and two reflection layers made of metal foil, with protrusions and dimples to enhance air circulation, designed to conform to three-dimensional surfaces and reduce surface temperature effectively.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If woven materials are used for thermal insulation, then flexibility and thermal insulation are improved, but fire risk increases due to absorption of combustible fluids

Engineering Contradiction:

Improvethermal insulation performanceVSAvoidfire risk

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The insulation system is divided into multiple layers with distinct functions: an inner woven layer for structural integrity and thermal insulation, and an outer non-woven layer for fluid resistance. This segmentation allows each layer to optimize its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses a composite structure combining woven and non-woven materials in a single insulation system. The woven inner layer provides thermal insulation and flexibility, while the non-woven outer layer provides fluid resistance, creating a material system that exhibits properties superior to either material alone.

Inventive Principle:

Principle #40Composite materials

2Temperature

If thermal insulation covers are applied, then temperature reduction is improved, but air flow is restricted leading to overheating

Engineering Contradiction:

Improvesurface temperature reductionVSAvoidair flow

Core Design Contradiction:

TemperatureVSProductivity

Solution Approach 1:

The outer non-woven layer is specifically designed with different local properties than the inner layer - it has higher porosity and air permeability in the regions where air flow is needed, while maintaining thermal insulation capabilities. This localized quality differentiation resolves the contradiction between temperature reduction and air flow.

Inventive Principle:

Principle #3Local quality

3Ease of manufacture

If conventional insulation materials are used, then ease of manufacture is improved, but coverage of critical areas is poor

Engineering Contradiction:

Improvefabrication simplicityVSAvoidcoverage area

Core Design Contradiction:

Ease of manufactureVSArea of stationary object

Solution Approach 1:

The use of flexible woven and non-woven fabric layers allows the insulation cover to conform to complex three-dimensional geometries of heat-producing equipment. The flexibility enables comprehensive coverage of critical areas including irregular surfaces, joints, and protrusions that rigid insulation materials cannot adequately cover.

Inventive Principle:

Principle #30Flexible shells and thin films

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 system effectively reduces the surface temperature of heat-producing equipment to below 150°C, minimizing the risk of fire ignition and improving airflow, while preventing fluid absorption and ensuring comprehensive coverage.

Implementation Method 1

a first reflection layer and a second reflection layer, each of said reflection layers being formed of a metal foil

Methodology Applied

Scientific EffectThermal radiation reflection: Reflection

Implementation Method 2

an inner high temperature resistant insulation layer; an outer high temperature resistant insulation layer adjacent the inner high temperature resistant insulation layer

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS12054861B2Layered thermal insulation system and thermal insulation products fabricated therefrom

Publication Date: 2024.08.06 MEI GRP PTY LTD

AI summary

A layered thermal insulation system generally conformable to three-dimensioned surfaces of heat-producing elements in need of insulation is described. The system comprises:i) an inner high temperature resistant insulation layer;ii) an outer high temperature resistant insulation layer adjacent the inner high temperature resistant insulation layer; and,iii) a first reflection layer and a second reflection layer. Each of said reflection layers is formed of a material selected from a group consisting of metal foils and are provided with a plurality of dimples and/or protrusions. The first reflection layer is adjacent the inner high temperature insulation layer such that, in use, an opposing surface thereof is in close proximity to said surfaces of said element to be insulated. The second reflection layer is adjacent to the outer high temperature insulation layer such that, in use, an opposing surface thereof comprises an exposed surface having a lower temperature than said surfaces of said element.