Due to their material properties and structural characteristics, corrugated container houses require multi-dimensional design to optimize their thermal insulation performance. The core design logic revolves around improving material properties, structural innovation, and the application of auxiliary technologies to address the inherent drawbacks of corrugated paper, such as its high thermal conductivity and susceptibility to moisture absorption and deformation.
Material composites are a fundamental method for improving the thermal insulation performance of corrugated container houses. Traditional corrugated cardboard consists of a face paper, a corrugated core paper, and a liner paper. A composite structure can be formed by filling the interlayer with high-efficiency thermal insulation materials. For example, low-thermal-conductivity materials such as polystyrene foam particles, rock wool fibers, or aerogel felt can be embedded in the corrugated core layer, utilizing their porous structure to block heat conduction paths. Some designs use vacuum insulation panels (VIPs) combined with corrugated cardboard, eliminating gas convection through a vacuum environment and significantly reducing heat transfer efficiency. Furthermore, surface coatings with reflective coatings can reduce heat radiation absorption; for example, aluminum foil coatings or ceramic microsphere coatings can increase solar radiation reflectivity to over 80%, forming a thermal barrier.
Structural optimization is a key path to improving thermal insulation performance. The double-layer corrugated cardboard box wall design utilizes an air layer for thermal buffering, with a 10-15 cm gap between the two layers forming a static air insulation layer. Some designs incorporate a honeycomb structure instead of traditional corrugated cardboard, using hexagonal units with enclosed air cavities to enhance thermal resistance, improving insulation performance by over 30% compared to conventional corrugated cardboard. The roof features a sloping design with ventilation layers, utilizing thermal pressure to create natural convection and accelerate heat dissipation. The ground uses an elevated design to isolate soil moisture, and is covered with XPS extruded polystyrene board or EPS foam board to block ground-based heat conduction.
Sealing is essential to prevent heat loss. Hot melt adhesive or silicone sealant is used to fill the seams of the corrugated cardboard boxes, eliminating air penetration channels. The door and window system uses double-glazed windows or PC endurance boards, combined with EPDM rubber sealing strips to reduce the heat transfer coefficient. Some designs embed magnetic sealing strips in the door and window frames, achieving seamless closure through magnetic attraction. Metal strips are used to secure the waterproof membrane at the junction of the roof and walls, simultaneously forming a continuous insulation layer to prevent thermal bridging.
Auxiliary technologies further enhance thermal performance. The introduction of phase change materials (PCMs) regulates indoor temperature fluctuations through latent heat storage. For example, paraffin-based PCMs are encapsulated in microcapsules and incorporated into wall coatings, absorbing heat and melting during the day and releasing heat and solidifying at night, thus buffering the temperature. Intelligent ventilation systems, combined with temperature and humidity sensors, automatically control the opening and closing of roof vents to maintain a stable indoor thermal environment. Cool air is introduced at night by opening vents, and closed during the day to reduce heat intrusion, forming a passive energy-saving cycle.
Environmentally adaptable design must consider climate differences. In cold regions, wall thickness is increased to over 20 cm, filled internally with glass wool or down fibers, and covered with a waterproof and breathable membrane to prevent condensation buildup. The roof uses a dark-colored heat-absorbing coating in conjunction with solar collectors to convert solar energy into heat for auxiliary heating. In hot regions, light-colored reflective coatings are used on the walls, combined with shading louvers or climbing plants to form an external shading system, reducing heat gain from solar radiation. The ground is paved with permeable bricks or a layer of gravel to enhance thermal inertia and slow heat transfer.
Moisture-proofing is a long-term measure to ensure insulation performance. The inner walls of the corrugated cardboard boxes are coated with water-based polyurethane waterproofing paint, forming a continuous moisture barrier to prevent moisture penetration and an increase in the material's thermal conductivity. A concrete water-retaining sill, at least 20 cm high, is installed at the base of the walls to block the upward path of ground moisture. The roof uses an "inverted" insulation design, placing the waterproofing layer below the insulation layer to prevent UV aging and waterproofing failure, while the insulation layer protects the waterproofing layer from temperature stress damage.
Modular design provides a flexible solution for the insulation of corrugated container houses. Prefabricated wall units integrate insulation, waterproofing, and decorative finishes, using snap-fit connections for rapid assembly and reducing thermal bridges caused by on-site construction errors. The roof and walls are detachably connected, facilitating future maintenance and replacement of insulation materials. Some designs incorporate an expandable structure, allowing for the addition or removal of insulation modules according to seasonal changes. For example, external insulation panels can be added in winter and removed in summer to enhance ventilation.
