One-step-formed vacuum insulation panel with holes in edge and manufacturing process of one-step-formed vacuum insulation panel

Abstract

The invention relates to the technical field of heat insulation plate manufacturing, in particular to a one-time-formed edge-perforated vacuum heat insulation plate and a manufacturing process thereof. The one-time-formed edge-perforated vacuum heat insulation plate comprises a plate body, the outer wall of the plate body is slidably connected with a mold, and the mold is used for bearing the plate body to conduct vacuumizing operation inside; the plate comprises a barrier film, a waterproof film, a non-woven fabric and a core material which are arranged in an overlapped mode from outside to inside, holes are formed in the edges, so that in the production process of the vacuum insulation plate, the core material is wrapped with the non-woven fabric, the waterproof film and the barrier film after being perforated, and direct forming of the perforated positions can be achieved by directly vacuumizing in a mold; and secondary processing is not needed, so that the production procedures are reduced, the production cost is reduced, the production period is shortened, the production efficiency is improved, the product can be put on the market more quickly, and the market demand is met.

Description

Technical Field

[0001] The invention relates to the technical field of heat insulation board manufacturing, and in particular to a one-time formed edge-opening vacuum heat insulation board and a manufacturing process thereof. Background Art

[0002] In modern industry and daily life, the demand for thermal insulation materials is growing, especially in terms of energy conservation, temperature control and environmental protection, efficient thermal insulation technology is particularly important. As a high-performance thermal insulation material, vacuum insulation panels have broad application prospects in many fields.

[0003] The emergence of vacuum insulation panels provides an effective way to solve these problems. By forming a vacuum environment inside, it greatly reduces the path of heat transfer, thereby significantly improving the insulation performance. However, the existing vacuum insulation panel technology still has some shortcomings. In terms of the hole opening process, the conventional hole opening method requires a heating and pressurizing process after vacuuming to allow the film material at the hole opening position to bond, and then cut out the required hole specifications. This process is not only complicated, increasing production costs and production cycles, but also easily leads to product deformation, air leakage and other problems during the heating and pressurizing process, resulting in a high defective rate of the product. In addition, after the conventional hole opening is completed, in order to prevent air leakage, a certain width of bonded barrier film needs to be retained at the edge of the hole, which causes the core material hole specifications to be larger than the hole specifications required for the actual use of the product, which affects the performance and use effect of the product to a certain extent. At the same time, in the structural design of the insulation board, although the barrier film can prevent gas penetration, the existing barrier film structure may cause slow gas penetration during long-term use, affecting the insulation effect and service life of the vacuum insulation board. Moreover, there is still room for further improvement in the optimization of core material structure and the synergy between the various layers of materials to enhance the stability and reliability of insulation panels under different environmental conditions.

[0004] Based on the above-mentioned deficiencies of the prior art, there is an urgent need for a new vacuum insulation panel technology that can simplify the production process, improve product quality, enhance insulation performance, and expand the application range of the product to meet the growing market demand and higher performance requirements. The present invention proposes a one-time formed edge-opening vacuum insulation panel and its manufacturing process in response to these problems. Summary of the invention

[0005] In view of the shortcomings of the prior art, the technical solution adopted by the present invention to solve the technical problems is: a one-time formed edge perforated vacuum insulation panel, comprising: a plate, the outer wall of the plate is slidably connected to a mold, the mold is used to carry the plate to perform vacuum operation inside; the plate comprises a barrier film, a waterproof film, a non-woven fabric and a core material, and is stacked from outside to inside in order, the barrier film is wrapped around the surface of the core material after the opening, the waterproof film is located at the bottom of the barrier film, the non-woven fabric is located between the core material and the waterproof film, and the barrier film, the waterproof film, the non-woven fabric and the core material are bonded together by an adhesive; the core material comprises a core plate, the upper and lower outer walls of the core plate are fixedly connected with tenon strips, and holes are opened in the wall of the core plate. A raised tenon strip is designed on the edge of the core material, and a tight connection is achieved through tenon and mortise and tenon fit. This connection method can increase the connection area, improve the connection strength, and better disperse the stress when subjected to external force, preventing the connection part from loosening or separation. At the same time, the tenon and tenon structure can prevent gas from penetrating along the connection interface to a certain extent, thereby improving the sealing performance of the insulation panel.

[0006] The present invention is further configured such that the core plate is made of silicon dioxide, the number of the holes is one, and the hole structure is semicircular. One to five hole structures are provided on the core material, and the hole structure is one of semicircular, square or irregular shapes.

[0007] The present invention is further configured such that the non-woven fabric comprises a top layer fabric and a bottom layer fabric, wherein the top layer fabric is made of polyester fiber and the bottom layer fabric is made of polypropylene fiber. Polyester fiber has the advantages of high strength, wear resistance, chemical corrosion resistance, etc., while polypropylene fiber has the characteristics of light weight, low cost, and good chemical stability.

[0008] The present invention is further configured such that the fiber diameter of the bottom layer cloth is smaller than that of the top layer cloth, the weaving gap of the bottom layer cloth is smaller than that of the top layer cloth, the top layer cloth and the bottom layer cloth are formed by hot pressing, the top layer cloth is bonded to the waterproof membrane, and the bottom layer cloth is bonded to the core material. Larger pores can ensure a certain air permeability to avoid damage to the insulation board structure due to the internal and external pressure difference during the vacuuming process; smaller pores can effectively prevent the overflow of tiny particles in the core material, play a role in filtering and preventing dust pollution, and the bottom layer cloth close to the core material is selected from materials with smaller pores and finer fibers to better prevent the leakage of core material powder; the top layer cloth has higher strength and wear resistance, and is used to protect the inner layer structure and resist external friction and damage during the transportation and installation of the insulation board.

[0009] The present invention is further configured such that the material of the waterproof film is silicone and the waterproof film is applied to the outside of the top layer of fabric, so that the non-woven fabric has certain waterproof and moisture-proof properties, and prevents the performance of the insulation board from being affected by moisture absorption during use.

[0010] The present invention is further configured such that the barrier film comprises a thin film layer, a dense coating is arranged on the outside of the thin film layer, a barrier layer is arranged on the outside of the dense coating, and the thin film layer, dense coating and barrier layer are stacked in order from outside to inside and bonded together by an adhesive.

[0011] The present invention is further configured such that the material of the film layer is polyethylene, the material of the dense coating is silicon dioxide, and the material of the barrier layer is aluminum foil. These film layers have good flexibility, mechanical strength and processing performance, and can provide basic physical support for the barrier film. The aluminum foil has extremely low gas permeability and can effectively block the penetration of gas molecules such as oxygen, nitrogen, and water vapor. The inorganic oxide coating can form a nano-scale dense coating on the surface of the film layer through physical vapor deposition or chemical vapor deposition, which can greatly improve the barrier ability to gas and moisture without significantly increasing the thickness of the film. The present invention is further configured such that the pore size of the core plate is distributed in a gradient manner, and the pore size gradually increases from the surface of the core plate to the inside of the core plate, and the pore size of the core plate is distributed in a gradient manner, and the density gradually decreases from the surface of the core plate to the inside of the core plate. The high-density area close to the barrier film can provide better support for the barrier film, reduce the depression or deformation of the barrier film during the vacuuming process, and the central low-density area is conducive to reducing heat conduction. The area close to the barrier film forms a finer pore structure, which enhances the blocking effect on gas molecules. At the same time, the larger pore size inside helps to reduce the propagation of thermal radiation, because the larger pores can scatter and absorb more thermal radiation rays.

[0012] A one-step forming process for manufacturing an edge-perforated vacuum insulation panel comprises the following steps: Step 1: Opening a hole in the core material: cutting a semicircular hole in the core material according to the required position; Step 2: Wrapping with non-woven fabric: Wrap the surface of the core material with holes opened in step 1 with non-woven fabric, and wrap the outside of the wrapped non-woven fabric with a waterproof film; Step 3: Wrapping with barrier film: Wrapping the core material wrapped with the non-woven fabric in step 2 with a barrier film; Step 4: Vacuum forming: Place the product wrapped with barrier film in a mold for vacuuming. The shape of the mold is designed according to the hole size of the core material. The hole position will be filled in the mold outside the corresponding barrier film, so that the inner layer is the core material, the middle is the barrier film, and the outside of the barrier film is the mold. After vacuuming, the corresponding opening position is directly formed without secondary processing.

[0013] The beneficial effects of the present invention are as follows: 1. The present invention effectively reduces the heat transfer by setting the core material structure and the synergistic effect of each layer of material. The multi-layer composite structure of the barrier film greatly reduces the gas permeability and prevents heat convection; the special structure and material properties of the core material limit heat conduction; the waterproof film prevents moisture from entering and affecting the insulation performance, so that the insulation board has an excellent insulation effect and can be widely used in fields with strict temperature control requirements, such as cold chain transportation, refrigerators and freezers, etc., to reduce energy consumption and maintain the stability of low or high temperature environments.

[0014] 2. The present invention enhances the stability of the core material structure by setting the tenon in the core material, which can better maintain the shape and performance during processing and use. The layers of material are tightly bonded by adhesives to form an integral structure that is not easy to delaminate or damage. During the vacuum forming process, the supporting role of the mold further ensures the stability of the structure when it is subjected to the internal and external pressure difference, so that it can adapt to different use environments and working conditions, and extend the service life of the product.

[0015] 3. The present invention makes holes at the edges, so that during the production process of the vacuum insulation board, after the core material is opened, it is wrapped with non-woven fabric, waterproof film and barrier film, and vacuum is directly drawn in the mold to achieve direct molding at the opening position without the need for secondary processing. This not only reduces the production process and reduces the production cost, but also shortens the production cycle and improves the production efficiency, so that the product can be put on the market more quickly to meet market demand.

[0016] 4. The present invention sets the design of edge openings and a one-time forming process. Due to the hole position of the film material after vacuum, the product can be completely fitted with the edge of the core material opening, and the size of the core material opening is critical to the opening size required when the product is used, thereby avoiding the leakage problem caused by improper treatment of the opening edge, greatly reducing the defective rate, improving the stability and consistency of product quality, reducing the waste of raw materials, and improving production efficiency. The design of the edge openings and the one-time forming process enable the opening position to accurately meet the needs of the product in a specific application scenario, and on the premise of ensuring thermal insulation performance, it realizes functional diversification and expands the application range of the product. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 It is a front view of the present invention; Figure 2 It is a structural exploded diagram of the present invention; Figure 3 It is a structural schematic diagram of the plate of the present invention; Figure 4 It is a schematic diagram of the structure of the core material of the present invention; Figure 5 It is a schematic structural diagram of the nonwoven fabric of the present invention; Figure 6is a schematic structural diagram of the barrier film of the present invention; In the figure: 1. plate; 11. barrier film; 111. barrier layer; 112. dense coating; 113. film layer; 12. waterproof membrane; 13. non-woven fabric; 131. bottom fabric; 132. top fabric; 14. core material; 141. core board; 142. tenon; 143. opening; 2. mold. DETAILED DESCRIPTION

[0018] The present invention is further described in detail below in conjunction with the accompanying drawings and specific embodiments. The embodiments of the present invention are provided for the purpose of illustration and description, and are not intended to be exhaustive or to limit the present invention to the disclosed forms. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiments are selected and described in order to better illustrate the principles and practical applications of the present invention, and to enable those of ordinary skill in the art to understand the present invention and thereby design various embodiments with various modifications suitable for specific uses. Example

[0019] See also Figure 1 - Figure 6 The present invention provides a technical solution: a one-time formed edge-perforated vacuum insulation panel, comprising: a plate 1, the outer wall of the plate 1 is slidably connected to a mold 2, the mold 2 is used to support the plate 1 to perform a vacuum operation inside; the plate 1 comprises a barrier film 11, a waterproof film 12, a non-woven fabric 13 and a core material 14, and is stacked in order from outside to inside, the barrier film 11 is wrapped around the surface of the core material 14 after the holes are opened, the waterproof film 12 is located at the bottom end of the barrier film 11, the non-woven fabric 13 is located between the core material 14 and the waterproof film 12, the barrier film 11, the waterproof film 12, the non-woven fabric 13 and the core material 14 are bonded together by an adhesive; the core material 14 comprises a core board 141, the upper and lower outer walls of the core board 141 are fixedly connected with tenons 142, and a hole 143 is opened in the wall of the core board 141.

[0020] The core plate 141 is made of silicon dioxide, the number of the hole 143 is one, and the structure of the hole 143 is semicircular.

[0021] The nonwoven fabric 13 includes a top fabric 132 and a bottom fabric 131 . The top fabric 132 is made of polyester fiber, and the bottom fabric 131 is made of polypropylene fiber.

[0022] The fiber diameter of the bottom cloth 131 is smaller than that of the top cloth 132 , and the weaving gap of the bottom cloth 131 is smaller than that of the top cloth 132 . The top cloth 132 and the bottom cloth 131 are compositely formed by hot pressing, the top cloth 132 is bonded to the waterproof membrane 12 , and the bottom cloth 131 is bonded to the core material 14 .

[0023] The waterproof membrane 12 is made of silicone and is applied to the outside of the top layer fabric 132 .

[0024] The barrier film 11 includes a thin film layer 113, a dense coating 112 is arranged outside the thin film layer 113, and a barrier layer 111 is arranged outside the dense coating 112. The thin film layer 113, the dense coating 112 and the barrier layer 111 are stacked in order from outside to inside and bonded together by an adhesive.

[0025] The material of the film layer 113 is polyethylene, the material of the dense coating layer 112 is silicon dioxide, and the material of the barrier layer 111 is aluminum foil.

[0026] The pore size of the core plate 141 is distributed in a gradient manner, and the pore size gradually increases from the surface of the core plate 141 to the inside of the core plate 141. The pore size of the core plate 141 is distributed in a gradient manner, and the density gradually decreases from the surface of the core plate 141 to the inside of the core plate 141.

[0027] A one-step forming process for manufacturing an edge-perforated vacuum insulation panel comprises the following steps: Step 1: Opening a hole in the core material: cutting a semicircular hole 143 on the core material 14 according to the required position; Step 2: Wrapping with non-woven fabric: Wrap the surface of the core material 14 with holes opened in step 1 with non-woven fabric 13, and wrap the waterproof film 12 on the outside of the wrapped non-woven fabric 13; Step 3: Wrapping with barrier film: Wrapping the core material 14 wrapped with the non-woven fabric 13 in step 2 with the barrier film 11; Step 4, vacuum forming: Place the product wrapped with the barrier film 11 in the mold 2 for vacuuming. The shape of the mold 2 is designed according to the size of the hole 143 of the core material 14. The position of the hole 143 will be filled with the mold 2 outside the corresponding barrier film 11, so that the inner layer is the core material 14, the middle is the barrier film 11, and the outside of the barrier film 11 is the mold 2. After vacuuming, the corresponding hole 143 position is directly formed without secondary processing.

[0028] Working principle: The vacuum insulation panel is mainly composed of two parts: a plate 1 and a mold 2. The plate 1 is composed of a barrier film 11, a waterproof film 12, a non-woven fabric 13 and a core material 14 from the outside to the inside, and each layer is tightly bonded by an adhesive. The core plate 141 in the core material 14 is made of silica, and the tenons 142 at the upper and lower ends can enhance the structural stability of the core material 14, and the semicircular holes 143 in the wall are used for specific functions. The barrier film 11 is composed of a barrier layer 111, a dense coating 112 and a film layer 113 from the outside to the inside. The aluminum foil provides extremely low gas permeability, the silica dense coating 112 enhances the barrier performance and improves scratch resistance and other properties, and the polyethylene film layer 113 provides basic support and flexibility. The waterproof film 12 is applied to the outside of the top layer 132 of the non-woven fabric 13, which effectively prevents moisture from entering the interior of the insulation board, protects the core material 14 and other structures from the influence of humidity, and ensures the stability of the insulation performance. The non-woven fabric 13 is made of a top layer fabric 132 and a bottom layer fabric 131 of different materials and structures, which are heat-pressed and laminated. The bottom layer fabric 131 has a small fiber diameter and a small weaving gap, and is tightly bonded to the core material 14 to better prevent the powder leakage of the core material 14. The top layer fabric 132 is bonded to the waterproof membrane 12 to jointly play a protective and auxiliary function, block dust pollution, and improve sealing performance. First, the core material 14 has a hole 143. A semicircular hole 143 is cut at a specific position of the core material 14. This is a key step in realizing the function of the edge hole 143. Then, the non-woven fabric 13, the waterproof film 12, and the barrier film 11 are wrapped in sequence. Each layer is tightly wrapped to form a relatively sealed structure. Then, the product wrapped with the barrier film 11 is placed in the mold 2. The shape of the mold 2 is designed according to the size of the hole 143 in the core material 14, so that when vacuuming, the position of the hole 143 corresponds to the mold 2 outside the barrier film 11. During the vacuuming process, the mold 2 supports the barrier film 11 and the internal structure to prevent deformation or damage of the structure due to the pressure difference between the inside and the outside. As the air is extracted, a vacuum environment is formed inside the insulation board, and the barrier film 11 prevents the outside air from re-entering. At this time, the position of the hole 143 is directly formed due to the design of the mold 2, without the need for secondary processing, reducing the production process and cost, while ensuring that the barrier film 11 at the edge of the hole 143 and the edge of the hole 143 of the core material 14 are well fitted, effectively preventing air leakage and ensuring the insulation performance of the insulation board. In the whole process, the characteristics and structure of each layer of material and the cooperation of the mold 2 jointly realize the efficient production and excellent performance of the edge-opening vacuum insulation board formed in one step.

[0029] Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field and related fields without creative work should fall within the scope of protection of the present invention. The structures, devices and operating methods not specifically described and explained in the present invention are implemented according to the conventional means in the field unless otherwise specified and limited.

Claims

1. A one-step formed edge-opening vacuum insulation panel, characterized in that: include: A plate (1), wherein the outer wall of the plate (1) is slidably connected to a mold (2), and the mold (2) is used to support the plate (1) to perform a vacuum operation inside; The plate (1) comprises a barrier film (11), a waterproof film (12), a non-woven fabric (13) and a core material (14), and is stacked in order from outside to inside, the barrier film (11) is wrapped around the surface of the core material (14) after the opening, the waterproof film (12) is located at the bottom end of the barrier film (11), the non-woven fabric (13) is located between the core material (14) and the waterproof film (12), and the barrier film (11), the waterproof film (12), the non-woven fabric (13) and the core material (14) are bonded together by an adhesive; The core material (14) comprises a core plate (141), the outer walls at the upper and lower ends of the core plate (141) are fixedly connected with tenon strips (142), and a hole (143) is opened in the wall of the core plate (141).

2. The one-step formed edge-perforated vacuum insulation panel according to claim 1, characterized in that: The material of the core plate (141) is silicon dioxide, the number of the hole (143) is one, and the structure of the hole (143) is semicircular.

3. The one-step formed edge-perforated vacuum insulation panel according to claim 1, characterized in that: The non-woven fabric (13) comprises a top layer fabric (132) and a bottom layer fabric (131); the top layer fabric (132) is made of polyester fibers, and the bottom layer fabric (131) is made of polypropylene fibers.

4. The one-step formed edge-perforated vacuum insulation panel according to claim 3, characterized in that: The fiber diameter of the bottom layer cloth (131) is smaller than that of the top layer cloth (132); the weaving gap of the bottom layer cloth (131) is smaller than that of the top layer cloth (132); the top layer cloth (132) and the bottom layer cloth (131) are compositely formed by hot pressing; the top layer cloth (132) is bonded to the waterproof membrane (12); and the bottom layer cloth (131) is bonded to the core material (14).

5. The one-step formed edge-perforated vacuum insulation panel according to claim 4, characterized in that: The waterproof membrane (12) is made of organic silicon and is applied to the outside of the top layer of fabric (132).

6. The one-step formed edge-perforated vacuum insulation panel according to claim 1, characterized in that: The barrier film (11) comprises a thin film layer (113), a dense coating (112) is arranged outside the thin film layer (113), and a barrier layer (111) is arranged outside the dense coating (112), and the thin film layer (113), the dense coating (112) and the barrier layer (111) are stacked in order from outside to inside and bonded together by an adhesive.

7. The one-step formed edge-perforated vacuum insulation panel according to claim 6, characterized in that: The material of the film layer (113) is polyethylene, the material of the dense coating (112) is silicon dioxide, and the material of the barrier layer (111) is aluminum foil.

8. The one-step formed edge-perforated vacuum insulation panel according to claim 2, characterized in that: The pore size of the core plate (141) is distributed in a gradient manner, and the pore size gradually increases from the surface of the core plate (141) to the inside of the core plate (141); the pore size of the core plate (141) is distributed in a gradient manner, and the density gradually decreases from the surface of the core plate (141) to the inside of the core plate (141).

9. A process for manufacturing a one-step formed edge-perforated vacuum insulation panel, used for manufacturing the one-step formed edge-perforated vacuum insulation panel according to claims 1 to 8, characterized in that: The following steps are involved: Step 1: Opening a hole in the core material: cutting a semicircular hole (143) in the core material (14) at a desired position; Step 2: Wrapping with non-woven fabric: Wrapping the surface of the core material (14) with holes in step 1 with non-woven fabric (13), and wrapping the waterproof film (12) on the outside of the wrapped non-woven fabric (13); Step 3: Wrapping with a barrier film: Wrapping the core material (14) wrapped with the non-woven fabric (13) in step 2 with a barrier film (11); Step 4: vacuum forming: placing the product wrapped with the barrier film (11) in the mold (2) for vacuuming, and directly forming the insulation board at the corresponding opening position after vacuuming.

Images