Sandwich Laminate Insulation for 350°C Climate Chambers
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Solution Overview
Problem
Conventional thermally insulating sandwich-structured laminates using two-component PUR foam have low thermal stability, limiting their application to temperatures below 120°C, making them unsuitable for high-temperature climate chambers that require simulation up to 350°C.
Innovation Solution
A method involving a sandwich-structured laminate with an internal and external wall, where high-temperature stable insulation panels are adhered to the internal wall and connected with a second rigid foam layer of PUR foam, forming a robust and thermally insulating structure with low thermal conductivity, using a 2K adhesive and preferably rigid polyisocyanurate foam for enhanced temperature stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional two-component PUR foam is used to fill the hollow volume between internal and external walls, then the sandwich-structured laminate achieves good thermal insulation properties and structural stability, but the thermal stability is limited to maximum 120°C making it unsuitable for high-temperature climate chambers
Solution Approach 1:
The insulation system is segmented into two distinct parts: a first foam layer made of high-temperature stable insulation material (such as polyisocyanurate foam) that directly contacts the internal wall and withstands high temperatures, and a second foam layer made of conventional PUR foam that provides additional thermal insulation but is protected from direct high-temperature exposure. This segmentation allows each layer to perform its function within its optimal temperature range, enabling the overall structure to withstand temperatures up to 350°C while maintaining reliability.
2Strength
If the hollow volume is completely filled with PUR foam to connect internal and external walls, then structural stability is achieved, but the PUR foam undergoes thermal decomposition at temperatures above 120°C
Solution Approach 1:
The first foam layer acts as an intermediary barrier between the high-temperature environment and the second PUR foam layer. This intermediary layer protects the PUR foam from direct thermal exposure, preventing its decomposition while still allowing the PUR foam to provide structural stability and thermal insulation. The intermediary layer absorbs the thermal stress, enabling the PUR foam to function within its safe temperature range.
3Ease of manufacture
If a single-layer PUR foam structure is used, then the manufacturing process is simple and cost-effective, but the laminate cannot withstand high temperatures above 120°C
Solution Approach 1:
The patent employs composite material construction by combining two different foam materials with complementary properties: the first foam layer uses high-temperature stable insulation material (such as polyisocyanurate) that can withstand temperatures up to 350°C, while the second foam layer uses conventional PUR foam that provides excellent thermal insulation and structural properties at lower temperatures. This composite approach maintains manufacturing simplicity through a sequential filling process while achieving superior temperature resistance that neither material could provide alone.
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 a structurally stable and thermally insulating laminate suitable for high-temperature ranges, maintaining thermal integrity and preventing thermal decomposition of the PUR foam, enabling effective thermal decoupling and extended temperature resistance up to 350°C.
Implementation Method 1
conventional two-component PUR foams are introduced into a hollow volume developed between the internal wall and the external wall, which, at adequate dosing, completely fills the available hollow volume
Implementation Method 2
based on the physical properties, in particular of the cured PUR foam, has good thermally insulating properties and hence very low thermal conductivity
Data Source
AI summary
A method for the development of a thermally insulating sandwich-structured laminate, such as a sandwich-structured laminate of a housing of a climate chamber for the high temperature range, with an internal wall and an external wall, can include the method steps: providing the internal wall, adhering at least one high temperature stable insulation panel onto the internal wall, positioning the external wall with respect to the internal wall such that between the internal wall and the external wall the at least one high temperature stable insulation panel and a hollow volume are developed. The method can further include filling the hollow volume with a PUR foam for the formation of a second rigid foam layer connecting the at least one high temperature stable insulation panel and the external wall.