Rigid Facing Panel with Multilayer Thermal Insulator
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Solution Overview
Problem
Traditional modular facing panels in building construction lack thermal insulation performance, are heavy and difficult to handle, and are not compatible with thin multilayer insulators due to their rigidity and installation requirements.
Innovation Solution
A modular rigid insulating facing panel with a multilayer thermal insulator composed of reflective films and undivided solid polymer separating layers, allowing for screw assembly and cutting like traditional panels, with a thickness and weight optimized for construction use, and featuring improved thermal insulation and mechanical reinforcement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional thermal insulation materials (glass wool, rock wool, expanded polystyrene) are combined with modular facing panels to achieve thermal insulation, then thermal insulation performance is improved, but the panel thickness must be increased to 30-120mm which makes the panel heavier and more difficult to handle
Solution Approach 1:
The patent changes the physical state of the separating layers from fibrous or granular materials to solid polymer material in a defined state, enabling the thermal insulation structure to achieve high insulation performance with reduced thickness and weight while maintaining structural integrity for screw assembly
Solution Approach 2:
The patent creates a composite structure combining reflective films with solid polymer separating layers to form a multilayer thermal insulator that integrates both thermal insulation functionality and mechanical strength, allowing the panel to be both insulating and structurally sound for traditional assembly methods
2Ease of operation
If thin multilayer insulators (5-50mm thickness) are used to reduce weight and improve handling, then ease of operation is improved, but they are flexible rather than rigid and must be installed by stapling or nailing which is incompatible with traditional facing panels
Solution Approach 1:
The patent changes the mechanical properties of the separating layers by using solid polymer material instead of fibrous materials, transforming the insulator from flexible to rigid while maintaining thin dimensions, enabling both easy handling and compatibility with screw assembly methods
Solution Approach 2:
The patent applies different properties to different parts of the panel structure: the facing plate provides rigidity and structural strength, while the thin multilayer insulator provides thermal insulation, with the solid polymer separating layers providing both thermal resistance and mechanical support for screw penetration
3Length of stationary object
If thin multilayer insulators are used to reduce thickness, then the thickness constraint is improved, but they require specific installation rules (peripheral edges closed, junctions by overlapping, air gap provided) that are incompatible with traditional facing panel assembly
Solution Approach 1:
The patent changes the material state of the separating layers to solid polymer, which allows the insulator to be cut with saws or cutters like traditional facing panels and assembled by screwing, eliminating the need for special installation procedures such as stapling, nailing, or providing air gaps
Solution Approach 2:
The solid polymer separating layers serve multiple functions: they provide thermal insulation, maintain the rigid structure of the panel, enable traditional cutting and screwing operations, and allow direct bonding to the facing plate, making the panel universally compatible with existing construction practices
4Strength
If traditional facing panels are used to provide mechanical support and protection, then strength is improved, but they are relatively heavy and have poor thermal insulation performance
Solution Approach 1:
The patent merges the mechanical support function of the facing plate with the thermal insulation function of the multilayer insulator into a single integrated panel assembly, eliminating the need for separate insulation layers and achieving both structural strength and energy efficiency in one component
Solution Approach 2:
The patent creates a composite panel system combining a rigid facing plate with a multilayer thermal insulator consisting of reflective films and solid polymer separating layers, where the composite structure provides both the mechanical strength needed for support and protection and the thermal insulation performance required for energy efficiency
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 provides superior thermal insulation performance, ease of handling and installation, and compatibility with existing panel assembly methods, while being lightweight and adaptable for various applications, with the added benefit of being mass-producible at low cost.
Implementation Method 1
a multilayer insulator consisting of a plurality of reflective films and a plurality of superposed separating layers
Implementation Method 2
each separating layer being formed of a plate or sheet of material undivided solid polymer
Data Source
Figure 1
Figure 2
AI summary
The facing has a plane rigid gypsum board (1) having two parallel plane main sides in which one is a facing side (2) and other is a backside (3). An insulating material (4) is fixed on the backside of the board. The material is a multilayer insulant having reflecting films (5) and a separation layer (6) in undivided solid polymer material. Each film is stuck on a side of a separation layer and the material is stuck on the side (3) of the board.