Vacuum Composite Insulated Truck Panels Without Thermal Shorts
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Solution Overview
Problem
Conventional insulated structural elements in refrigerated containers are heavy, prone to thermal shorts, and suffer from durability issues that degrade their insulating capacity over time due to foam breakdown during use and transport.
Innovation Solution
A vacuum-sealed composite panel assembly with desiccant material and foam core, using fiber-reinforced polymer composite panels and a gas-impermeable cover to maintain a vacuum and minimize insulation degradation, along with a bracket system for assembly, providing a lightweight and durable thermal insulation solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional insulated structures use metal frames with blown foam, then assembly is relatively simple and cost is low, but weight increases considerably and thermal shorts degrade R value
Solution Approach 1:
The patent removes the metal frame from the conventional insulated structure and replaces it with a composite panel system that integrates structural support and insulation functions. The composite panels use fiber-reinforced polymers and foam core materials to provide both structural integrity and thermal insulation without the weight penalty of metal frames.
Solution Approach 2:
The patent employs composite materials including fiber-reinforced polymer panels with foam core, vacuum-sealed insulation layers, and polyurethane coatings. These composite structures provide high strength-to-weight ratio while maintaining excellent thermal insulation properties, eliminating the need for separate metal framing.
2Ease of manufacture
If conventional insulated structures use metal frames with blown foam, then initial assembly is simple, but durability degrades over time due to foam breakdown
Solution Approach 1:
The patent applies polyurethane coating materials to the composite panels during manufacturing to create a protective barrier that seals the foam core and prevents moisture ingress. This preliminary protective action prevents foam degradation before the structure is put into service, ensuring long-term durability.
Solution Approach 2:
The patent replaces the mechanical blown foam insulation system with a vacuum-sealed insulation panel system. This substitution eliminates the foam breakdown issue by creating a vacuum environment that prevents foam degradation while maintaining structural integrity through the composite panel design.
3Quantity of substance
If conventional insulated structures use blown foam insulation, then insulation is provided, but thermal shorts through metal frames reduce overall R value
Solution Approach 1:
The patent removes the metal frame that creates thermal shorts and replaces it with composite panel construction. The composite panels use foam core materials with integrated structural layers that eliminate continuous thermal pathways while maintaining insulation capacity.
Solution Approach 2:
The patent uses composite panel construction with foam core materials surrounded by fiber-reinforced polymer skins and vacuum-sealed layers. This composite structure provides thermal break functionality inherent to the material composition, eliminating thermal shorts without requiring additional insulation layers.
4Weight of moving object
If vacuum-sealed insulating panels are used with desiccant material, then weight is reduced and thermal efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The patent combines multiple functions into integrated composite panel assemblies: structural support, vacuum sealing, insulation, and moisture protection are all incorporated into a single manufactured unit. The desiccant material is integrated within the vacuum-sealed panel construction, eliminating the need for separate components.
Solution Approach 2:
The vacuum-sealed insulating panels with desiccant material are pre-manufactured and pre-assembled before installation. This preliminary manufacturing of complete panel assemblies reduces on-site complexity while maintaining the advanced vacuum insulation technology benefits.
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 results in a durable, lightweight, and thermally efficient insulation system with minimal degradation of the R value over time, reducing heat transfer and maintaining insulation capacity during the life of the assembly.
Implementation Method 1
a vacuum-sealed insulating panel operably engaged between the first composite panel and the second composite panel
Implementation Method 2
The vacuum-sealed insulating panel comprises a desiccant material disposed within the vacuum-sealed insulating panel
Implementation Method 3
The foam core material may comprise insulating materials that may include, but are not limited to: open cell polyurethane foam; polystyrene foam
Data Source
AI summary
Various embodiments of the present invention provide an insulated structural panel including a superinsulating, desiccant-filled, vacuum-sealed insulating panel sandwiched between a pair of composite panels. The composite panels are configured to impart structural strength to the panel without introducing heat transfer pathways through the vacuum-sealed insulating panel. The desiccant material disposed within the vacuum-sealed insulating panel is capable of absorbing moisture within the vacuum established within the vacuum-sealed insulating panel and thereby reducing the degradation of the vacuum-sealed panel's insulating capacity.