Vacuum Insulation Panel Floor Module with Rigid Box Protection
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Solution Overview
Problem
Existing thermal insulation solutions for floors, particularly in buildings before 1975, lack effective insulation due to the absence of integrated thermal insulation in floors, and the fragility of Vacuum Insulating Panels (PIV) limits their application in floor renovation due to compressive and bending forces.
Innovation Solution
A thermally insulating floor system comprising decorative covering layers, PIV panels with a porous compression-resistant material and vacuum-sealed gas-tight barrier envelopes, held by a framework of rigid boxes with side walls and an upper opening, providing mechanical protection and acoustic insulation, allowing for efficient thermal and sound insulation while minimizing installation complexity and thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If PIV panels are used for thermal insulation, then thermal insulation performance is improved, but mechanical strength deteriorates due to fragility of the barrier envelope
Solution Approach 1:
The PIV panel is nested within a rigid box structure that provides mechanical protection. The panel is placed inside the box cavity and held by retaining means, allowing the fragile panel to benefit from the structural strength of the enclosing box while maintaining its vacuum insulation properties
Solution Approach 2:
The floor insulation system is segmented into modular boxes, each containing an individual PIV panel. This segmentation allows the fragile panels to be protected within discrete units rather than being exposed to direct mechanical loads across a large area
2Strength
If rigid envelopes are used to protect PIV panels, then mechanical strength is improved, but thermal insulation performance deteriorates due to thermal bridges
Solution Approach 1:
The rigid box structure uses localized thermal break elements at critical junctions where thermal bridges would form. The retaining means and positioning structures are designed to minimize thermal conduction paths while providing necessary mechanical support
Solution Approach 2:
The box structure combines rigid materials for mechanical strength with thermally insulating materials for the walls and joining elements. This composite construction provides both structural integrity and thermal insulation, preventing thermal bridges at the box edges
3Strength
If thick side walls are used in boxes, then mechanical strength is improved, but thermal insulation performance deteriorates
Solution Approach 1:
The box design optimizes the thickness parameter of side walls to a minimum value that still provides adequate mechanical strength. Instead of using thick walls, the design relies on the rigid box geometry and strategic reinforcement at key locations to achieve the required strength with minimal thermal conduction
4Ease of operation
If PIV panels are directly exposed, then ease of installation is improved, but reliability deteriorates due to degradation of gas barrier properties
Solution Approach 1:
The PIV panels are pre-assembled within the rigid box structure during manufacturing, where they are properly positioned and secured with retaining means. This preliminary assembly ensures the panels are correctly installed and protected before being transported and installed as complete floor modules, preventing damage during handling
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 significantly enhances thermal insulation performance, reduces installation time and costs, and maintains the integrity of the PIV panels' vacuum seal, achieving a thermal resistance of at least 2 m².K/W, which is not achievable with conventional insulating materials.
Implementation Method 1
each having a plate shape, each of the panels comprising a porous compression-resistant material and a vacuum-sealed gas-tight barrier envelope which encloses the porous material
Implementation Method 2
The thermal performance of these elementary panels leads to thicknesses which can be reduced to minimize the size of the thermal insulation system
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
To create a thermally insulating floor, particularly during renovations, at least one layer of vacuum insulation panels (3) is integrated into modules (2) whose outer casing (4) consists of a relatively low-height (H) box (5) (typically less than 50 mm) and a cladding element (6). The insulation panel is placed within the box between a sound insulation element (9) and a mechanical protection element (20) that provides moisture barrier properties. The airtight seal of the box (5) allows for the creation of a thin module that is easy to assemble with similar modules. The decorative top layer of the floor is formed by the cladding element (6), which is integral with the box and includes interconnecting elements (10) for joining two cladding elements from adjacent modules in the same row edge-to-edge. The interconnecting elements (10) extend above the box.