Polyester Backing Layer for Insulating Panels
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Solution Overview
Problem
Existing multi-layer insulating panels for building constructions face challenges with gas-tight coatings that are difficult to recycle, have high manufacturing costs, and pose safety hazards due to smooth surfaces, which affect adhesion and dimensional stability.
Innovation Solution
A backing layer composed of a plastic gas-barrier film and a fibrous reinforcing layer made of polyester, applied together to provide gas-tightness and mechanical resistance, allowing for improved surface roughness and recyclability, without metal layers, thus reducing manufacturing and recycling costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a heterogeneous multi-layer gas-tight coating is applied to both faces of the insulating panel, then gas-tight properties are improved, but recycling difficulty increases and manufacturing cost increases
Solution Approach 1:
The backing layer is divided into two functional segments: a plastic gas-barrier film layer for gas-tightness and a fibrous reinforcing layer for mechanical strength. This segmentation allows each layer to perform its specific function while enabling easier recycling compared to heterogeneous multi-layer coatings, as the fibrous layer can be separated or degraded more easily than multiple plastic layers
Solution Approach 2:
The invention extracts the metal layer from the gas-tight coating structure, replacing it with a fibrous reinforcing layer made of organic material. This extraction eliminates the need for complex mechanical separation processes required for metal-plastic composite recycling, while maintaining gas-tight properties through the plastic film layer
2Reliability
If a heterogeneous multi-layer gas-tight coating is applied to both faces of the insulating panel, then gas-tight properties are improved, but manufacturing cost increases
Solution Approach 1:
The invention replaces expensive metal layers with a more economical fibrous reinforcing layer made of organic materials. This substitution reduces manufacturing costs while maintaining the necessary mechanical strength and gas-tight properties through the combination of the plastic film and fibrous layer
Solution Approach 2:
The backing layer uses a composite structure combining plastic gas-barrier film and fibrous reinforcing material. This composite approach provides cost-effective gas-tightness and mechanical strength without requiring expensive metal layers, reducing overall manufacturing costs while maintaining performance
3Reliability
If a smooth gas-tight coating is applied to the insulating panel, then gas-tight properties are improved, but safety hazards increase due to slippery surface
Solution Approach 1:
The fibrous reinforcing layer provides a locally rough surface texture that improves safety and adhesion, while the underlying plastic gas-barrier film layer maintains the gas-tight properties. This local quality differentiation allows the surface to be rough for safety while the subsurface remains smooth and gas-tight
4Reliability
If a smooth gas-tight coating is applied to the insulating panel, then gas-tight properties are improved, but adhesion of glues or mortars deteriorates
Solution Approach 1:
The fibrous reinforcing layer creates a locally rough surface that enhances adhesion of glues and mortars, while the plastic gas-barrier film layer beneath maintains the gas-tight properties. This layered structure with differentiated local qualities resolves the conflict between smooth gas-tight surfaces and rough adhesive surfaces
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 maintains gas-tight properties over time, enhances surface roughness for safety, and facilitates recycling, while reducing costs and improving adhesion, making it suitable for industrial manufacturing and installation.
Implementation Method 1
a plastic gas-barrier film (1) configured to prevent the diffusion of the gaseous phase of the main layer (50) to the outside
Implementation Method 2
a fibrous reinforcing layer (2) made of a material selected from the group consisting of: non-woven fabric, fabric (weft warp), mesh/canvas
Data Source
Figure 1
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Figure 3
AI summary
The invention relates to a backing layer (10, 10a, 10b) for a multi-layer insulating panel (100; 100A; 100B; 100C) for building constructions. Such a backing layer consists of: - a plastic gas-barrier (gas-tight) film (1) comprising a first film surface (F1) and an opposing second film surface (F2); - a reinforcing layer (2) made of fibrous material comprising a first reinforcing surface (A1) and an opposing second reinforcing surface (A2). The fibrous reinforcing layer is applied to said first film surface of the plastic gas-barrier film by means of the first reinforcing surface. The backing layer is characterized in that the plastic gas-barrier film and the fibrous reinforcing layer comprise polyester.