Open-Cell Foam Panel with Sealed Internal Voids
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing thermal insulation materials, particularly solid open-cell foams, are less effective due to airflow and moisture passage, limiting their insulating performance compared to closed-cell foams, and evacuated insulation panels have limitations in scalability and material compatibility.
Innovation Solution
A composite material panel with a solid open-cell foam layer featuring internal voids sealed by an airtight coating, creating a partial vacuum to enhance thermal insulation, and optionally combined with sheet-form polymeric materials and additional layers for structural support and fire retardancy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If solid open-cell foam is used as insulating material, then the material is easier to manufacture and more flexible, but thermal insulation performance deteriorates due to airflow and moisture passage
Solution Approach 1:
The foam panel is divided into multiple closed cells, with internal voids created within specific cell regions. These internal voids are then sealed with airtight coating to create vacuum chambers, while the rest of the foam structure remains open-cell for ease of manufacture and flexibility.
Solution Approach 2:
The invention combines open-cell foam material with airtight coating material to create a composite structure. The open-cell foam provides structural flexibility and ease of manufacture, while the airtight coating creates sealed vacuum chambers that provide superior thermal insulation.
2Reliability
If closed-cell foam is used to restrict airflow, then thermal insulation performance improves, but manufacturing complexity and cost increase
Solution Approach 1:
Instead of making the entire foam structure closed-cell, the invention applies airtight coating only to specific internal void surfaces within selected cell regions. This localized application of sealing creates vacuum chambers where needed for insulation, while the rest of the foam remains open-cell for manufacturing simplicity.
3Reliability
If evacuated insulation panels are used, then thermal insulation performance improves, but scalability and material compatibility are limited
Solution Approach 1:
The invention changes the physical state of air within specific regions by creating vacuum conditions in internal voids, while maintaining the foam panel at atmospheric pressure externally. This parameter change enables superior insulation without requiring complete evacuation of the entire panel structure, improving scalability.
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 significantly improves thermal insulation by restricting airflow and moisture, while maintaining structural integrity and flexibility, offering a scalable and versatile insulation solution for various applications.
Implementation Method 1
the internal voids are hermetically sealed to form a partial vacuum within the coating
Implementation Method 2
These materials reduce heat transfer by restricting air-flow, thereby limiting convective heat transfer
Implementation Method 3
Conductive heat transfer is also limited by the low thermal conductivity and low density of the materials commonly employed
Data Source
AI summary
The invention is directed to composite material panels, comprising insulating layers comprising a solid open-cell foam panel, which may comprise at least one internal void therein, and wherein one or more surfaces of the panel are provided with an air-tight sealing coating.