Polymeric Vacuum Insulation Board with Evacuated Closed-Cell Pores
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Solution Overview
Problem
Traditional vacuum insulation panels are fragile, cannot be easily cut to size, and have limited maximum sizes, leading to reduced thermal performance and increased installation complexity due to the need for lower R-value infills and numerous panel joints.
Innovation Solution
A method for manufacturing a polymeric vacuum insulation board with a closed-cell structure using zeolite or expandable graphite particles, which creates evacuated pores within a polymer matrix, reducing gas permeance and enhancing thermal performance while allowing for easier installation and reduced susceptibility to punctures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional vacuum insulation panels are used, then thermal performance is achieved, but the panels are fragile and easily punctured
Solution Approach 1:
The patent uses a composite structure combining a polymer matrix (provides structural strength and puncture resistance) with evacuated closed-cell voids (provide vacuum insulation). This composite approach allows the panel to maintain both mechanical strength and thermal performance, resolving the contradiction between reliability and structural integrity.
Solution Approach 2:
The patent employs a porous closed-cell foam structure where gas is evacuated from the cells. The porous structure provides insulation while the closed-cell configuration maintains structural integrity and prevents punctures, as the cellular architecture distributes mechanical stress throughout the matrix.
2Ease of operation
If traditional vacuum insulation panels are used, then thermal performance is achieved, but the panels cannot be cut to size at construction sites
Solution Approach 1:
The patent creates a flexible polymer matrix that can be easily cut, bent, and shaped on-site. The flexible nature of the polymer allows the panels to be adapted to different sizes and configurations, providing both ease of operation and adaptability without compromising the vacuum insulation performance.
3Area of stationary object
If traditional vacuum insulation panels are used, then thermal performance is achieved, but maximum panel sizes are limited
Solution Approach 1:
The patent enables large panels to be manufactured and installed while maintaining thermal performance consistency. The closed-cell foam structure with uniform cell size ensures consistent insulation properties across large areas, eliminating the need for segmentation that would compromise thermal performance.
4Reliability
If traditional vacuum insulation panels are used, then thermal performance is achieved, but numerous panel joints are required
Solution Approach 1:
The patent creates a seamless panel structure that eliminates the need for multiple joints. The continuous polymer matrix with closed-cell voids provides uninterrupted vacuum insulation, merging the function of insulation and structural integrity into a single panel that requires minimal or no joints, thereby maintaining thermal performance while reducing complexity.
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 method results in improved thermal performance with higher R-values per inch, reduced susceptibility to punctures, and simplified installation, as the polymeric vacuum insulation board functions as a heat, air, and moisture barrier, decreasing material and labor costs.
Implementation Method 1
During extrusion, water in the zeolite particles evaporates due to reduced pressure right after passing a spinneret and creates a porous, closed-cell microstructure within a polymer matrix
Implementation Method 2
As the polymer matrix cools and solidifies, water vapor is reabsorbed by the zeolite, which at least partially evacuates the closed-cell pores
Implementation Method 3
The graphite particles expand to a second diameter greater than the first diameter. During expansion, voids are developed within the graphite particles that in turn lead to evacuated closed cells within the polymer
Data Source
AI summary
A method of forming a polymeric vacuum insulation board is provided, the polymeric vacuum insulation board including a plurality of evacuated, closed-cell pores therein. In one embodiment, the method includes intermixing a polymer with zeolite particles that contain water and extruding the resulting composition under high pressure. During extrusion, water in the zeolite particles evaporates and creates a porous, closed-cell microstructure within a polymer matrix. As the polymer matrix cools and solidifies, water vapor is reabsorbed by the zeolite, which at least partially evacuates the closed-cell pores. In another embodiment, the method includes intermixing a polymer with expandable graphite particles and extruding the resulting composition under high pressure. During extrusion, the expandable graphite particles define evacuated voids. The polymer binder can be selected to include low gas permeance, for example ethylene vinyl alcohol (EvOH) or polyvinylidene chloride (PVDC). In some applications, the polymer can be blended with nano-clays or other additives to further decrease the gas permeance of the vacuum insulation board.