Modular Lignocellulose Insulation for Uneven Substrates
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Solution Overview
Problem
Existing insulation systems using lignocellulose-based wood fiber boards face challenges with high bulk density leading to increased weight and complex processing, while foamed plastics emit chemicals and pose fire hazards, and existing solutions require extensive labor and struggle with uneven substrates.
Innovation Solution
A modular insulation system comprising a rigid module carrier panel with a bulk density of 180-280 kg/m³ and a flexible module compensation panel with 30-80 kg/m³, allowing for leveling uneven substrates and featuring an adjustable insulation anchor for secure attachment and airtight sealing, with optional hydrophobic or flame-retardant treatments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If lignocellulose-based wood fiber boards are used for insulation, then thermal insulation performance is improved, but bulk density increases leading to higher weight
Solution Approach 1:
The insulation board is divided into multiple layers with different bulk densities. The first layer (contact layer) has higher bulk density (150-250 kg/m³) for stability and substrate contact, while the second layer (insulation layer) has lower bulk density (50-150 kg/m³) for reduced weight and improved insulation. This segmentation allows each layer to optimize for its specific function.
Solution Approach 2:
Different regions of the insulation board have different bulk densities tailored to their specific requirements. The contact layer near the substrate has higher density for mechanical stability and firm contact, while the outer insulation layer has lower density for weight reduction and enhanced thermal insulation performance.
2Ease of operation
If lattice framework is attached to substructure for installing insulation panels, then insulation panels can be attached, but work complexity increases
Solution Approach 1:
The complex lattice framework intermediate structure is removed from the system. Instead, the insulation board is directly attached to the substrate using simple fixing elements that penetrate through the board, simplifying the installation process while maintaining structural integrity.
Solution Approach 2:
Instead of attaching insulation panels to a lattice framework and then securing the framework to the substrate, the approach is inverted: the insulation board is directly fixed to the substrate, eliminating the need for the intermediate lattice structure and simplifying the overall attachment system.
3Stability of the object's composition
If insulation layer with high bulk density is used, then structural stability is improved, but weight of insulation board increases
Solution Approach 1:
The insulation board is segmented into layers with different bulk densities. The first layer has higher density (150-250 kg/m³) to provide structural stability and firm contact with the substrate, while the second layer has lower density (50-150 kg/m³) to reduce overall weight and enhance insulation properties.
Solution Approach 2:
High bulk density is localized to the contact layer where structural stability is most needed for substrate attachment, while lower bulk density is used in the outer insulation layer where weight reduction and thermal insulation are prioritized, creating optimal local properties for each region.
4Weight of moving object
If foamed plastics are used for insulation, then weight is reduced, but chemical emissions and fire hazards increase
Solution Approach 1:
The material composition is changed from synthetic foamed plastics to natural lignocellulose-based wood fiber materials. This parameter change eliminates chemical emissions and fire hazards associated with plastics while achieving comparable weight and insulation properties through optimized layered structure.
Solution Approach 2:
The insulation board uses composite lignocellulose-based materials with different bulk densities in layered structure, combining the benefits of natural materials (low emissions, good fire resistance) with optimized physical properties (weight, insulation performance) through composite construction.
Data Source
Figure 1~2
Figure 3~4
AI summary
The insulating system has two modular insulating boards combined with each other, and an insulation plug (3) with socket. The insulating system has a rigid insulating board as carrier plate module (1) and another flexible insulation board as corrective plate module (2). The former insulating board has a density between 180 to 280 kilograms per cubic meters. The latter insulating board has a density between 30 to 80 kilograms per cubic meters. The raw material bases for the insulating system are lignocellulose and non-plant raw materials, e.g. mineral fibers, rock wool or glass wool. An independent claim is included for a two-layered, modular, combined insulating board on bases of lignocellulose or non-plant raw materials.