Unitized Container Panel with Multilayer Insulation

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Solution Overview

Problem

Existing container systems face challenges in providing efficient insulation and structural integrity, especially when subjected to damage, and require complex assembly processes with loose parts, which can be time-consuming and prone to errors during deployment and relocation.

Innovation Solution

The development of unitized container panels fabricated using a multilayer insulated structure with opposing external layers and an intermediate layer comprising insulation material and buffer material, which are assembled using a process involving pressure application and release, creating a robust and efficient insulation system that can be easily assembled and disassembled, and integrated into expandable container designs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If existing container systems use traditional insulation structures, then manufacturing and assembly are simpler, but insulation performance and structural integrity deteriorate when subjected to damage

Engineering Contradiction:

Improvestructural integrityVSAvoidpanel structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies composite materials by creating a multilayer panel structure consisting of an external layer, intermediate layer with insulation material, and buffer material. This composite structure provides both insulation performance and structural integrity, resolving the contradiction between reliability and complexity by integrating multiple functions into a unified panel system.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent segments the container into modular unitized panels that can be independently manufactured and assembled. Each panel is a self-contained unit with integrated insulation and structural components, allowing for easier replacement and repair while maintaining overall structural integrity, thus addressing the reliability-complexity tradeoff.

Inventive Principle:

Principle #1Segmentation

2Productivity

If container systems use complex assembly processes with loose parts, then structural integrity may be improved, but assembly time and error probability increase

Engineering Contradiction:

Improveassembly speedVSAvoidassembly accuracy

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent merges multiple components (insulation material, buffer material, external layers) into a single unitized panel assembly. This integration eliminates the need for separate assembly steps involving loose parts, thereby increasing assembly speed while maintaining structural integrity and reducing error probability through pre-assembled modular units.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent applies preliminary action by pre-assembling and pre-inspecting the unitized panels before final container assembly. The panels are manufactured as complete, tested units with all insulation and structural components already in place, allowing for rapid deployment and relocation with minimal on-site assembly required, thus improving both productivity and reliability.

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If traditional container panels are used, then manufacturing process is simpler, but insulation performance and resistance to damage deteriorate

Engineering Contradiction:

Improvefabrication simplicityVSAvoidthermal loss and damage susceptibility

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent uses composite materials in the panel construction, combining external layers, insulation material, and buffer material into a unified structure. This composite approach enhances thermal insulation performance and damage resistance while maintaining ease of manufacture through standardized panel fabrication processes, effectively addressing the contradiction between manufacturing simplicity and performance requirements.

Inventive Principle:

Principle #40Composite materials

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 enhanced insulation performance, structural resilience against damage, and simplified assembly processes, reducing operational costs and man-hours required for deployment and relocation, while maintaining high thermal resistance and flexibility in container configurations.

Implementation Method 1

forming a multilayer insulated panel comprising opposing external layers encasing an intermediate layer therebetween

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS10865942B2Container panel and structures using container panels

Publication Date: 2020.12.15 NEXGEN COMPOSITES LLC

AI summary

According to aspects of the present disclosure, a process of fabricating a unitized container panel is disclosed. The unitized container panel is fabricated by forming a multilayer insulated panel, which has opposing external layers and an intermediate layer therebetween. The intermediate layer is a combination of an insulation material (e.g., vacuum insulated panel, aerogel, etc.), and a buffer material (e.g., a foam board, polystyrene, fiberglass, minerals, plastic, natural fibers, wood, plastic, etc.) that bounds the insulation material. Pressure is applied about the multilayer insulated panel for a predetermined process time, causing the external layers to encase the intermediate layer. After elapse of the predetermined process time, the pressure is released about the multilayer insulated panel, thereby resulting in a unitized container panel.