Method and apparatus for manufacturing a composite panel
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Solution Overview
Problem
There is a need to optimize heat transfer to and from buildings due to increasing energy costs, which existing insulating technologies have not adequately addressed.
Innovation Solution
A method for manufacturing a composite insulating panel comprising a first sheet, a second sheet, and an insulating foam body between them, where liquid foam reactants are applied and allowed to expand to fill the space, defining longitudinally extending conduit means for heat exchange, with barriers used to prevent foam entry into specific areas and create voids for enhanced air circulation and heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If liquid foam reactants are applied to fill the space between sheets, then insulating performance is improved, but manufacturing complexity increases due to the need for formers and barriers
Solution Approach 1:
The former is positioned and barriers are installed before the foam reactants are applied. This preliminary arrangement of components ensures that when the foam expands, it automatically forms the desired conduit structure without requiring post-manufacturing intervention, thus improving insulation while managing complexity through sequential preparation
Solution Approach 2:
The former acts as an intermediary tool that temporarily occupies space to define the conduit geometry. The barriers serve as intermediaries that control foam flow and prevent it from entering areas where conduits should not form. These intermediary elements are removed or remain as part of the final structure, enabling complex foam shaping without requiring equally complex direct molding processes
2Temperature
If formers are used to define conduit spaces, then heat exchange efficiency is improved, but removal difficulty increases
Solution Approach 1:
The former material is selected to undergo phase transition or chemical degradation at specific conditions. For example, the former may be made of a material that dissolves in water, decomposes at elevated temperatures, or melts at controlled heat, allowing easy removal after the foam has cured. This enables the former to serve its shaping function during manufacturing while facilitating simple removal afterward
Solution Approach 2:
The former is designed as a temporary, disposable component that is discarded after serving its purpose of defining the conduit space. The barriers may be removed and reused or discarded. This approach accepts the cost of the former as a manufacturing expense rather than designing for permanent retention, simplifying the overall manufacturing process by eliminating the need for complex removal mechanisms
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 solution effectively enhances solar energy collection and heat transfer efficiency, providing a renewable heating source by circulating warmed air through the panels, which can significantly contribute to reducing energy costs in building insulation.
Implementation Method 1
laying liquid foam reactants down on top of the former and the first sheet; placing a top sheet on top of the foam reactants; allowing the foam to expand to substantially fill the space between the front sheet, the former and the second sheet
Implementation Method 2
a composite insulating panel comprising a first sheet, a second sheet, and an insulating foam body between them
Implementation Method 3
the foam defines a plurality of longitudinally extending conduit means through which a heat exchange medium is circulated
Data Source
Figure 1
Figure 2~2(b)
Figure 3~4
AI summary
An insulating panel (1) comprises a first sheet (2), a second sheet (4), and a body of insulating foam (5) between the sheets (2), (4). The foam (5) has a plurality of longitudinally extending conduits (7) through which a heat exchange medium such as air is circulated. A barrier (10) is used to create an enlarged void space for air circulation. The. barrier is located below profile crowns (3) to prevent foam from entering the crowns (3) and to create additional foam - free voids below the crown. Heat transfer efficiency is increased.