Recyclable Multi-Layer Insulation With Impermeable Protective Layer
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Solution Overview
Problem
Current thermal insulation materials, such as mineral wool and polyurethane foams, pose environmental concerns due to energy consumption, non-recyclability, and resource availability, and lack protection against physical and chemical attacks, while existing recyclable options like polyethylene foam sleeves are not impermeable to fluids and lack durability.
Innovation Solution
A multi-layer insulating complex comprising a thermoplastic polymer-based insulating foam layer and a protective, impermeable layer, both formed from recyclable materials, assembled without additional adhesives, providing effective insulation and protection while being environmentally friendly and aesthetically pleasing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If mineral wool is used for thermal insulation, then insulation performance is achieved, but environmental impact increases due to high energy consumption and non-recyclability
Solution Approach 1:
The patent changes the material parameters from traditional mineral wool to thermoplastic polymer foams with specific cellular structures. The foam density, cell size, and polymer composition are optimized to achieve required thermal insulation performance while enabling recyclability and reducing manufacturing energy consumption.
Solution Approach 2:
The patent employs composite material structures including multi-layer foam configurations and polymer blends that combine different thermoplastic materials. These composites achieve superior insulation performance while maintaining recyclability, as the layered structure allows for selective material optimization and end-of-life recovery.
2Reliability
If polyethylene foam sleeves are used for insulation, then recyclability is improved, but protection against physical and chemical attacks deteriorates
Solution Approach 1:
The patent uses composite material systems where multiple thermoplastic polymer layers with different properties are combined. The outer layers provide mechanical strength and chemical resistance, while inner layers provide insulation. All layers are designed to be recyclable together, resolving the contradiction between protection and recyclability.
Solution Approach 2:
Different regions of the insulating complex are assigned different material qualities. The outer protective layers use high-strength, chemically resistant thermoplastics, while inner insulation layers use lower-density foams. This local differentiation provides targeted protection where needed while maintaining overall recyclability.
3Ease of operation
If polyethylene foam sleeves are used, then installation simplicity is improved, but fluid impermeability deteriorates
Solution Approach 1:
The patent employs multi-layer composite structures where specific layers are designed for fluid barrier performance. Impermeable thermoplastic layers are positioned strategically to prevent fluid penetration, while maintaining the overall simplicity of installation through the integrated sleeve design.
Solution Approach 2:
The patent uses flexible thermoplastic polymer films and foams that can be easily installed as sleeves while providing fluid impermeability. The flexible nature allows for simple installation around irregular surfaces, while the material composition ensures resistance to fluid penetration.
4Reliability
If non-recyclable materials like polyurethane foams are used, then insulation performance is improved, but environmental sustainability deteriorates
Solution Approach 1:
The patent transforms the material composition from non-recyclable polyurethane to recyclable thermoplastic polymers. The foam structure parameters are optimized to match or exceed the insulation performance of traditional materials, while the thermoplastic nature enables recycling and resource recovery at end of life.
Solution Approach 2:
The patent designs the insulating complex with recyclable thermoplastic materials that can be recovered and reprocessed. The material composition and structure are optimized to facilitate disassembly and recycling processes, enabling resource recovery and reducing environmental impact.
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 reduces environmental impact, conserves natural resources, and offers effective insulation and protection against physical and chemical attacks, while being recyclable and easy to install, thus aligning with sustainable development goals.
Implementation Method 1
at least one layer, called insulating layer, of an insulating foam formed from a gaseous phase dispersed in a solid phase made of at least one thermoplastic polymer material
Implementation Method 2
a layer, called protective layer, homogeneous in at least one thermoplastic polymer material, said protective layer being impermeable to fluids
Implementation Method 3
the insulating complex having an interface for assembling said insulating layer and said protective layer one on the other, devoid of material other than the thermoplastic polymer material forming the solid phase of the insulating foam and than the thermoplastic polymer material forming said protective layer
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to an insulating complex (1,11,13,14,17,18) formed of at least two distinct superimposed layers, of which: - at least one layer, said insulating layer (4), of an insulating foam formed of at least one thermoplastic polymer material and forming a face, said contact face (3), principal of the insulating complex (1,11,13,14,17,18), intended to be in contact with an object to be insulated, and; - a layer, said protective layer (6), of at least one solid thermoplastic polymer material, said protective layer (6) being impermeable to fluids and forming a face, said apparent face (2), principal of the insulating complex (1,11,13,14,17,18), opposite said contact face (3);the insulating complex (1,11,13,14,17,18) having an interface (7) for assembly by heat bonding of said insulating layer (4) and said protective layer (6) to each other, free from material other than the thermoplastic polymer material of the insulating foam and the thermoplastic polymer material forming said protective layer (6).