Monolithic Insulating Assemblies for Lower Thermal Conductivity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing insulated glass units (IGUs) with glass panes and air or gas between them do not achieve optimal thermal insulation and light transmission, necessitating improved materials and methods for better insulating properties.
Innovation Solution
Incorporating monolithic insulating layers with thermal conductivity lower than 26 mW/(K·m) between glass panes, which can be self-supporting or porous, and using airgaps or vacuum to reduce thermal conductivity and enhance light transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional glass panes with air or gas gaps are used, then structural simplicity and ease of manufacture are maintained, but thermal insulation performance is insufficient
Solution Approach 1:
The patent employs porous insulating materials (such as aerogels, foams, or porous ceramics) with controlled pore structures to achieve superior thermal insulation. These porous materials have low thermal conductivity due to the air trapped within their porous structure, providing effective thermal blocking while maintaining a compact form factor.
Solution Approach 2:
The patent utilizes composite material structures combining multiple materials with complementary properties (e.g., transparent polymers with insulating fillers, or layered composites of different thermal conductivities) to simultaneously achieve good thermal insulation and optical transparency. The composite structure allows optimization of both thermal and optical performance.
2Loss of energy
If thicker insulating layers are used to reduce thermal conductivity, then thermal insulation improves, but weight increases
Solution Approach 1:
The patent employs highly porous materials such as aerogels with porosity exceeding 99%, which provide exceptional thermal insulation with minimal density. The porous structure traps gas molecules that provide thermal resistance while contributing negligible mass, enabling thin insulating layers that are both effective and lightweight.
Solution Approach 2:
The patent changes the physical parameters of the insulating material by selecting materials with inherently low density and low thermal conductivity, or by modifying material properties through controlled porosity, bubble structures, or vacuum insulation techniques to achieve maximum insulation with minimum weight.
3Loss of energy
If monolithic insulating layers are introduced between glass panes, then thermal conductivity decreases, but manufacturing complexity increases
Solution Approach 1:
The patent incorporates the insulating layer during the glass manufacturing process itself, such as forming the insulating layer on the glass surface before assembly, or pre-assembling the insulating unit with the glass panes in a controlled environment. This preliminary action integrates the insulation function into the manufacturing process rather than requiring separate post-assembly steps.
Solution Approach 2:
The patent uses intermediary substances or bonding agents that facilitate the attachment of insulating layers to glass panes. These intermediaries can be transparent adhesives, vacuum bonding techniques, or mechanical interlocking structures that enable reliable bonding without complex assembly procedures.
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 insulated assemblies achieve lower thermal conductivity and higher light transmission compared to traditional IGUs, with the potential for thinner or thicker designs to suit various applications, while maintaining structural integrity and reducing weight.
Implementation Method 1
one or more monolithic insulating layers interposed between the first pane of material and the second pane of material, the insulating layer having a thermal conductivity less than 26 mW/(K·m)
Implementation Method 2
at least one of the one or more monolithic insulating layers comprises a porous material
Data Source
AI summary
Insulated assemblies, insulation units including an assembly, and methods of forming the assemblies and units are disclosed. Exemplary assemblies include a first pane of material, a second pane of material, and one or more monolithic insulating layers interposed between the first pane of material and the second pane of material. The insulating layer can exhibit a thermal conductivity less than 26 mW/(K·m).