Vacuum-Controlled Polyurethane Foam Insulation for Water Tanks
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Solution Overview
Problem
Existing methods for forming thermal insulation layers in thermo-accumulation containers for hot or cold water heaters are inefficient in terms of speed, precision, and material usage, and are not adaptable to different tank shapes and sizes without significant modifications to the production process.
Innovation Solution
A system using a vacuum generator, pressure transducers, and control valves to create a pressure lower than atmospheric pressure within a hollow layer, enhancing the flow and expansion of polyurethane resin to efficiently fill and adhere to the tank surfaces, with adjustable molds for various tank shapes and sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional atmospheric pressure foaming is used, then the process is simple, but the expansion speed is slow and filling is incomplete
Solution Approach 1:
The patent applies parameter changes by modifying the pressure condition from atmospheric pressure to vacuum (depression) to accelerate foam expansion. The command and control unit regulates the depression level, optimizing expansion speed while maintaining process control. This resolves the contradiction by improving expansion speed through parameter modification without excessive complexity.
Solution Approach 2:
The patent uses pneumatic principles by implementing a vacuum system with a depression generator connected to the mold through a suction duct. The depression generator creates negative pressure to enhance foam expansion, directly addressing the slow expansion issue while using established pneumatic technology to limit complexity increase.
2Reliability
If insulation thickness is increased to meet energy efficiency requirements, then thermal insulation performance improves, but material usage and production time increase
Solution Approach 1:
The patent changes the pressure parameter to vacuum conditions, which accelerates foam expansion and improves filling completeness. This allows achieving required insulation thickness with better material distribution and fewer defects, thereby improving both insulation performance and production efficiency simultaneously.
Solution Approach 2:
The command and control unit with pressure transducer implements feedback control to monitor and regulate depression levels during foaming. This ensures optimal expansion conditions are maintained, preventing over-expansion and material waste while ensuring complete filling, thus improving both insulation quality and productivity.
3Reliability
If complex insulation geometry is applied to meet energy efficiency standards, then thermal insulation effectiveness improves, but manufacturing precision requirements increase
Solution Approach 1:
The vacuum system enables the expanding foam to better conform to complex geometries by removing air resistance and creating uniform pressure distribution. This improves coating precision on intricate tank shapes and accessories while maintaining the required insulation effectiveness.
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 system ensures homogeneous density distribution, reduces material usage, and improves insulation efficiency by promoting faster expansion and adherence to tank surfaces, while being adaptable to different tank geometries with minimal production impact.
Implementation Method 1
adapted to generate, control and maintain a pressure lower than atmospheric pressure in the mould
Implementation Method 2
The depression control within the hollow layer may be carried out in feedback with the measurement of the internal pressure in the cavity
Implementation Method 3
increasing the flow scrolling, expansion speed and reducing the total density of a polyurethane resin foam injected via a pluggable injection inlet into the hollow layer
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
It is herein described an equipment (1) for making thermal insulation in expanded foam for a thermo-accumulation tank (3) for hot or cold water or water heater comprising - a sealing mould (2, 2') adapted to house the tank (3), a hollow layer (6) being comprised between inner walls (2C) of the mould (2) and the tank (3) to be housed; - a vacuum generator system comprising at least one vacuum accumulator tank (32) connected to a vacuum pump, said vacuum generator system being connected to the mould (2) by at least one suction duct (18); - at least one plugging system of said suction duct; - at least one pressure transducer for depression control connected to a command and control unit (36) adapted to apply said depression; - at least one activation and depression control valve (19) comprising a control valve of the on-off type or a control valve of the proportional type controlled by the command and control unit (36) adapted to allow a controlled flow of external air for the vacuum accumulator tank (32); - said vacuum generator system, said at least one plugging system, said at least one activation and depression control valve (19), said at least one pressure transducer connected to the command and control unit (36), being adapted to generate, control and maintain a pressure lower than the atmospheric pressure in said mould (2, 2'), thus increasing a flow scrolling and expansion speed of a polyurethane resin injected via a pluggable injection inlet (11) into the hollow layer (6) between the mould (2, 2') and the tank (3) to be housed.