Polymer Multiwall Panels with Micro-Features for Greenhouses
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Solution Overview
Problem
Glass panel roofing systems for naturally lit structures like greenhouses are costly and have high maintenance expenses due to their weight and poor insulating ability, while polymeric multiwall panels offer improved impact resistance and insulation but lower light transmission, which can reduce crop yields.
Innovation Solution
Polymeric multiwall panels with micro-scale surface features, measuring 30 micrometers to 3 millimeters in width, are designed to enhance light transmission to greater than 70% across various incidence angles, achieved through manufacturing methods such as extrusion, injection molding, and surface feature formation processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If glass panel roofing systems are used, then light transmission is good, but cost and maintenance expenses are high
Solution Approach 1:
The patent replaces expensive glass panels with cheaper polymeric panels that can be easily replaced if damaged. The polymer panels are less costly and can be replaced without significant financial loss, addressing the high maintenance cost issue while maintaining adequate light transmission properties.
Solution Approach 2:
The patent uses multiwall polymer structures that combine multiple layers and air chambers to achieve both insulation and light transmission. This composite approach allows the material to provide thermal insulation like glass while being cheaper and more impact-resistant.
2Illumination intensity
If glass panels are used, then light transmission is good, but structural support cost is high
Solution Approach 1:
The patent employs thin-walled polymer structures that are sufficiently strong due to their multiwall design with air chambers. These thin film structures replace heavy glass panels, reducing the structural support requirements while maintaining light transmission properties.
Solution Approach 2:
The patent divides the panel into multiple walls separated by air chambers, creating a segmented structure. This segmentation provides structural strength without requiring thick, heavy materials, thereby reducing overall weight while maintaining the ability to transmit light.
3Strength
If polymeric multiwall panels are used, then impact resistance and insulation are improved, but light transmission is lower
Solution Approach 1:
The patent applies different properties to different parts of the panel structure. The polymer material is selected for its impact resistance and insulation properties, while the multiwall design with air chambers is optimized to minimize light blocking. Surface treatments or coatings may be applied to specific areas to enhance light transmission without compromising structural strength.
Solution Approach 2:
The patent optimizes parameters such as wall thickness, air chamber size, and polymer material selection to achieve the desired balance between impact resistance, insulation, and light transmission. By carefully controlling these parameters, the panel achieves high strength while maintaining adequate light transmission for agricultural applications.
4Reliability
If polymeric multiwall panels are used, then maintenance expenses are reduced, but light transmission is insufficient
Solution Approach 1:
The patent optimizes the optical parameters of the polymer panels, such as material selection and surface properties, to maximize light transmission. The multiwall structure is designed with optimized air chamber configurations that minimize light scattering while maintaining insulation properties, thereby achieving both low maintenance cost and adequate light transmission.
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 panels provide improved light transmission and reduced weight compared to previous designs, potentially increasing crop yields by up to 5% for every 1% increase in light transmission, while maintaining structural integrity and reducing maintenance costs.
Implementation Method 1
micro-scale surface features disposed on a surface of the multiwall panel... the micro-scale surface features comprise a width measured at a base of the micro-scale surface features that is about 30 micrometers to about 3 millimeters... the multiwall panel comprises an average light transmission of greater than or equal to about 70%
Data Source
AI summary
Disclosed herein are multiwall panels comprising micro-scale surface features and methods of making the same. In one embodiment, a multiwall panel is disclosed. The multiwall panel comprises, a top sheet, a bottom sheet, a rib disposed between and connected to the top sheet and the bottom sheet, and a micro-scale surface feature disposed on a surface of the multiwall panel, wherein the micro-scale surface feature comprises a width measured at a base of the surface feature, wherein the width is about 30 micrometers to about 3 millimeters. In another embodiment, a process of forming multiwall panels is disclosed. In yet another embodiment, a naturally lit structure is disclosed.