Prefabricated Modular Freezer Panels to Reduce On-Site Assembly Time
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Solution Overview
Problem
Existing freezer constructions require labor-intensive on-site assembly, leading to prolonged downtime, potential damage to insulation, and compromised quality due to the need for skilled craftsmanship and specialized shielding and cleaning processes, which can result in uneven surfaces and reduced insulation efficiency.
Innovation Solution
A modular thermally insulated construction system comprising prefabricated elements with an inner and outer cladding and an insulating layer, where the insulating layer is maintained intact during assembly, allowing for efficient connection of modular elements along substantial edges without interfering with the insulation, facilitating quick and high-quality assembly with reduced labor and site-specific challenges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If on-site assembly of freezer constructions is performed using traditional methods, then the construction can be completed with standard materials and processes, but the assembly time is prolonged and labor requirements increase
Solution Approach 1:
The patent applies preliminary action by pre-assembling and pre-insulating wall panels in a controlled factory environment before delivery to the construction site. The insulating layers are applied and cured, and panels are pre-positioned with precise alignment features before final installation, eliminating time-consuming on-site insulation application and alignment work.
Solution Approach 2:
The freezer construction is divided into modular wall panels that can be independently manufactured, transported, and assembled. Each panel is a self-contained unit with integrated insulation and cladding, allowing parallel manufacturing and simplified on-site assembly through standardized connection mechanisms.
2Adaptability or versatility
If traditional on-site assembly methods are used, then the construction can be adapted to site conditions, but the quality of assembly decreases due to lack of skilled craftsmanship and specialized processes
Solution Approach 1:
Critical quality-sensitive operations such as insulation application, panel alignment, and joint preparation are performed in advance in a controlled factory setting where skilled workers can ensure consistent high quality. The panels arrive at the site ready for final assembly, transferring quality control from the construction site to the manufacturing environment.
Solution Approach 2:
Different parts of the construction process are performed in different locations with different quality characteristics. Factory-based panel manufacturing achieves high precision through controlled conditions and specialized equipment, while on-site assembly focuses on straightforward mechanical connection of pre-prepared components, optimizing quality for each stage.
3Reliability
If traditional assembly methods with shielding and cleaning processes are used, then food product safety can be maintained, but the assembly process becomes more complex and requires specialized procedures
Solution Approach 1:
Cleanroom-grade insulation application and panel preparation are performed in controlled factory environments where hygiene conditions can be strictly maintained. Panels are pre-assembled with clean surfaces and proper sealing before delivery, eliminating the need for complex on-site shielding and cleaning procedures while maintaining food safety standards.
Solution Approach 2:
The complex hygiene-critical processes are extracted from the on-site assembly operation and relocated to the factory manufacturing environment. This separates the food safety-critical insulation application from the mechanical assembly process, allowing each to be optimized independently for its specific requirements.
4Ease of manufacture
If traditional on-site assembly is performed, then the construction can be built with standard materials, but the insulation layer may be damaged and insulation efficiency reduced
Solution Approach 1:
The insulating layers are applied and fully cured in the controlled factory environment before the panels are disassembled for transport. This preliminary curing ensures the insulation achieves its full structural integrity and thermal performance properties before handling and installation, preventing damage that would occur if insulation were applied after panel assembly at the site.
Data Source
AI summary
A modular element for a thermally insulated construction such as a freezer construction or a heated construction, wherein the modular element is a thermally insulated structural element comprising an inner cladding, an outer cladding and an insulating layer located between the inner cladding and the outer cladding. The modular element is configured with the insulating layer placed adjacent to the inner cladding prior to assembly of said modular element in a modular construction. Further, the inner cladding of the modular element is adapted to be joined to an inner cladding of the modular construction along at least a substantial part of at least one edge with the insulating layer of the modular element maintained intact.