Electrostatic vacuum plate structure and filling type electrostatic vacuum plate

Abstract

The utility model discloses an electrostatic vacuum plate structure and a filling type electrostatic vacuum plate, and relates to the field of vacuum plates, the electrostatic vacuum plate structure comprises an upper vacuum plate and a lower vacuum plate, the space between the two vacuum plates is in a vacuumized state to form a vacuum cavity, and the two ends of the vacuum cavity are subjected to heat edge sealing treatment; the upper vacuum plate, the lower vacuum plate and the sealing edges at the two ends are attached through flexible insulating aluminum plastic films containing PTFE layers; inner-layer aluminum foils are pasted on the upper vacuum plate and the lower vacuum plate in the vacuum cavity respectively, the two inner-layer aluminum foils sense same-polarity negative static electricity, external air pressure is resisted through electrostatic repulsive force, and the thickness of the vacuum cavity is maintained to be in the preset size. Compared with a traditional glass fiber vacuum plate, heat transfer of an inner core material is avoided, the heat conductivity is reduced, the thickness of the vacuum plate can be reduced to be within 0.5 mm, high-performance heat-insulation ultrathin performance is achieved, a hard plate is changed into a flexible film material, and the fitting adaptability of a product on different surfaces is greatly improved.

Description

Technical Field

[0001] This application relates to the field of vacuum plates, and particularly to an electrostatic vacuum plate structure and a filled electrostatic vacuum plate. Background Technology

[0002] Vacuum insulation panels are a high-performance thermal insulation material with a thermal conductivity 10-20 times lower than conventional insulation cotton. The technology involves evacuating the core material into a vacuum and then heat-sealing it with an aluminum-plastic film. This design eliminates air conduction within the core material, significantly improving its insulation performance. The outer aluminum-plastic film protects the internal vacuum, preventing external gases from entering, and also reflects external heat radiation, further enhancing its insulation properties. Vacuum insulation panels are currently widely used in industries such as refrigerators and cold chain logistics.

[0003] Currently, vacuum panels produced on the market generally suffer from drawbacks such as high production costs, difficulty in reducing thickness, high overall hardness, and poor adhesion adaptability. Summary of the Invention

[0004] This application provides an electrostatic vacuum plate structure and a filled electrostatic vacuum plate to solve the problems of difficulty in reducing thickness, high overall hardness, and poor adhesion adaptability.

[0005] On the one hand, this application provides an electrostatic vacuum plate structure, including an upper vacuum plate and a lower vacuum plate, with the space between the two vacuum plates in a vacuum state to form a vacuum cavity, and the two ends of the vacuum cavity are heat-sealed.

[0006] The upper vacuum plate, lower vacuum plate, and end sealing are bonded with a flexible insulating aluminum-plastic film containing a polytetrafluoroethylene (PTFE) layer; inner aluminum foil is pasted on the upper and lower vacuum plates inside the vacuum cavity, and the two inner aluminum foils are induced with the same negative static electricity, which resists the external air pressure through electrostatic repulsion and maintains the thickness of the vacuum cavity within the preset size.

[0007] Specifically, the insulating aluminum-plastic film comprises, in sequence, an outer nylon protective layer, an upper adhesive film layer, an aluminum foil layer, a PTFE insulating layer, a lower adhesive film layer, and an inner polyethylene (PE) layer;

[0008] The upper adhesive film layer is used to bond the outer nylon protective layer and the aluminum foil layer, while the lower adhesive film layer is used to bond the PTFE insulating layer and the inner PE layer. The PTFE insulating layer isolates the aluminum foil layer and the inner PE layer.

[0009] Specifically, the thickness of the PTFE insulation layer is 2-4 μm, the thickness of the aluminum foil layer is 7-15 μm, the thickness of the inner PE layer is 10-80 μm, and the thickness of the inner aluminum foil layer is 1-10 μm.

[0010] The upper and lower adhesive layers are made of polyurethane or acrylic adhesive.

[0011] Specifically, the inner aluminum foil inside the vacuum cavity is smaller than the upper and lower vacuum plates, and the inner aluminum foil does not contact the sealing edge.

[0012] Specifically, a getter is placed inside the vacuum cavity near the sealing edge, and the thickness of the electrostatic vacuum plate maintained by electrostatic repulsion does not exceed 0.5mm.

[0013] On the other hand, this application provides a filling type electrostatic vacuum plate, including an upper vacuum plate and a lower vacuum plate, with the two vacuum plates in a vacuum state to form a vacuum cavity, and the two ends of the vacuum cavity are heat-sealed.

[0014] The upper vacuum plate, lower vacuum plate, and end caps are bonded together using a flexible insulating aluminum-plastic film containing a polytetrafluoroethylene (PTFE) layer.

[0015] The vacuum cavity is filled with core material, and the contact surfaces between the core material and the upper and lower vacuum plates are induced with the same negative electrostatic charge.

[0016] Specifically, the core material includes glass fiber, basalt fiber, ceramic fiber, fumed silica, or polyurethane foam;

[0017] The thickness of the electrostatic vacuum plate after being filled with core material and maintained by electrostatic repulsion does not exceed 0.5 mm.

[0018] The beneficial effects of the technical solutions provided in this application include at least the following:

[0019] 1. Compared with traditional fiberglass vacuum panels, electrostatic vacuum panels have no core material inside and greatly simplify the manufacturing process of vacuum panels (core material manufacturing, cutting, baking, etc.), reducing the overall cost by 60%.

[0020] 2. The electrostatic vacuum plate has no internal core material, which eliminates heat transfer through the internal core material, and the thermal conductivity can be further reduced by more than 2 times.

[0021] 3. Due to the coreless design of the electrostatic vacuum plate, the thickness of the vacuum plate can be reduced to less than 0.5mm, achieving ultra-thin high-performance thermal insulation. At the same time, the vacuum insulation material is changed from a rigid plate to a flexible membrane material, which greatly improves the product's adaptability to different surfaces. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the electrostatic vacuum plate structure provided in this application;

[0023] Figure 2 This is a schematic diagram of the structure of the flexible insulating aluminum-plastic film provided in the embodiments of this application;

[0024] Figure 3 This is a schematic diagram of a filled electrostatic vacuum plate structure in another embodiment;

[0025] Figure 4 This is a flowchart of the electrostatic vacuum plate structure plating method provided in this application. Detailed Implementation

[0026] To make the objectives, technical solutions, and advantages of this application clearer, the embodiments of this application will be described in further detail below with reference to the accompanying drawings.

[0027] This application provides an electrostatic vacuum plate structure, such as Figure 1 As shown, it consists of two parts: an upper vacuum plate and a lower vacuum plate. After heat sealing at both ends of the two vacuum plates, a vacuum is drawn between the two plates to form a vacuum cavity.

[0028] The upper vacuum plate, lower vacuum plate, and end seals are all bonded with a flexible insulating aluminum-plastic film containing a polytetrafluoroethylene (PTFE) layer. The flexible insulating aluminum-plastic film bonding structure determines its flexibility, effectively reducing the rigidity of the vacuum plate.

[0029] Inside the vacuum cavity, inner aluminum foil layers are adhered to both the upper and lower vacuum plates (i.e., two flexible insulating aluminum-plastic films), and these inner aluminum foil layers are induced with the same negative static electricity. Under the influence of this induced static electricity, the two aluminum-plastic films support the vacuum cavity and resist external atmospheric pressure through electrostatic repulsion, maintaining the cavity thickness within a preset dimension. In actual industrial systems, the magnitude of the static charge depends on the size and thickness of the vacuum plates. Because the flexible insulating aluminum-plastic films incorporate a PTFE layer, they possess excellent insulation properties, effectively isolating the induced static electricity from the inner aluminum foil layers and preventing it from leaking to the outside of the vacuum plates. With proper sealing, the electrostatic support effect can be maintained for over ten years, fully meeting industrial requirements.

[0030] In addition, the inner aluminum foil not only supports the cavity by induction of static electricity, but also effectively isolates the heat exchange between the inside and outside, achieving strong heat insulation.

[0031] Compared to traditional fiberglass vacuum panels, which typically use a rigid aluminum-plastic film and incorporate fiberglass cores to maintain vacuum levels and dimensional requirements, this application eliminates the core material entirely. Instead, two electrostatically inductive aluminum foil layers are directly embedded into the vacuum cavity. Electrostatic repulsion maintains and resists external atmospheric pressure, significantly simplifying the manufacturing process (core material manufacturing, cutting, baking, etc.). This reduces overall costs by 60% and allows for a substantial reduction in the effective thickness of the vacuum panel, achieving ultra-thin high-performance thermal insulation.

[0032] Furthermore, because the filling core material method has more physical contact surfaces, namely the high-density contact between the glass fiber and the aluminum-plastic film, heat conduction is accelerated. Compared with the cavity structure of this application, heat transfer through the internal core material of the vacuum plate is eliminated, and the thermal conductivity can be further reduced by more than 2 times.

[0033] Moreover, since this application uses a flexible insulating aluminum-plastic film containing a PTFE membrane layer instead of a traditional rigid aluminum-plastic film, the flexibility of the vacuum plate surface is increased, making it more convenient to cut, seal, and fold.

[0034] Figure 2 This is a schematic diagram of the structure of the flexible insulating aluminum-plastic film provided in the embodiments of this application. The structure consists of an outer nylon protective layer, an upper adhesive film layer, an aluminum foil layer, a PTFE insulating layer, a lower adhesive film layer, and an inner polyethylene (PE) layer in sequence.

[0035] The nylon material is located on the outermost layer, providing flexibility and a protective structure. The upper and lower adhesive film layers are mainly used for film bonding. The upper adhesive film layer bonds the outer nylon protective layer and the aluminum foil layer, while the lower adhesive film layer bonds the PTFE insulating layer and the inner PE layer. The PTFE insulating layer isolates the aluminum foil layer and the inner PE layer. The aluminum foil layer here mainly prevents gas molecules from entering and disrupting the internal vacuum, while the PTFE insulating layer prevents internal static electricity and losses from being transferred to the outside. These two film layers achieve internal and external isolation, ensuring the long-term maintenance of the vacuum level.

[0036] The inner PE layer is primarily designed to work in conjunction with the inner aluminum foil layer. Because the inner aluminum foil layer is charged with static electricity, it needs to isolate charge transfer from the flexible aluminum-plastic film; hence, the PE film layer is used. Furthermore, the inner aluminum foil layer maintains a vacuum cavity under static electricity, eliminating contact with filler materials and further enhancing the thermal insulation effect.

[0037] In some embodiments, in order to achieve a better sealing effect, the inner aluminum foil layer is designed to be smaller than the size of the upper and lower vacuum plates when it is pasted. That is, the inner aluminum foil does not extend and contact the sealing edge position. This ensures that the internal electrostatic repulsion force of the same polarity does not extend to the sealing edge and will not damage the sealing strength of the sealing edge.

[0038] In some other embodiments, a getter or getter bag may be installed in the vacuum cavity and placed at the cavity sealing edge or other locations to keep the interior dry.

[0039] In some specific implementations, the PTFE insulation layer is designed to be 2-4 μm thick, the aluminum foil layer to be 7-15 μm thick, the inner PE layer to be 10-80 μm thick, and the inner aluminum foil layer to be 1-10 μm thick. The upper and lower adhesive film layers are bonded using polyurethane or acrylic adhesive. This allows the thickness of the electrostatic vacuum plate, maintained by electrostatic repulsion, to be kept below 0.5 mm. Compared to the thickness of traditional filled vacuum plates, this allows for ultra-thin high-performance thermal insulation, significantly improving the product's adaptability to various surfaces.

[0040] Based on the design scheme of using electrostatic repulsion to maintain cavity stability provided in this application, this application can also design a filled electrostatic vacuum plate to adapt to special scenarios such as special high pressure resistance.

[0041] Figure 3 This is a schematic diagram of a filled electrostatic vacuum plate structure. Compared to traditional filled vacuum plates, both the upper and lower vacuum plates use the flexible insulating aluminum-plastic film described in the previous embodiment. Although there is a vacuum cavity between the upper and lower vacuum plates, the cavity is filled with a core material. The contact surfaces of the core material and the upper and lower vacuum plates induce the same negative static electricity, and the ends of the vacuum cavity are heat-sealed.

[0042] The upper vacuum plate, lower vacuum plate, and end caps are bonded together using a flexible insulating aluminum-plastic film containing a polytetrafluoroethylene (PTFE) layer. This structure differs from traditional structures in that the core material filling can be reduced under electrostatic support, significantly lowering the fiber density within the cavity. This low-density fiber filling reduces the actual contact area, thereby reducing heat conduction. In this embodiment, the core material can include one or more of glass fiber, basalt fiber, ceramic fiber, fumed silica, and polyurethane foam. Under electrostatic support, the reduced filling amount also allows the thickness of the electrostatic vacuum plate to be compressed to less than 0.5 mm.

[0043] Figure 4 This is a flowchart of the electrostatic vacuum plate structure plating method provided in this application, the method including the following steps:

[0044] S1. Prepare aluminum foil with a thickness of 7-15 μm and PTFE film with a thickness of 2-4 μm. After degreasing and cleaning, combine the PTFE film with the aluminum foil coated with adhesive using a hot press and shape it.

[0045] S2. Prepare nylon plastic film with a thickness of 12-100 μm and polyethylene plastic film with a thickness of 10-80 μm. Clean and remove dirt from the composite aluminum foil using chemical solvents, and perform corona treatment on the surface of the plastic film.

[0046] S3. Apply adhesive evenly to each layer of plastic film. After application, remove chemical solvents using a drying device to pre-cure the adhesive.

[0047] S4. The cured plastic film is laminated and shaped with the aluminum foil surface and PTFE film using a hot press to produce a flexible insulating aluminum-plastic film.

[0048] In the specific manufacturing process, the aluminum foil and PTFE film must have clean, oil-free surfaces. The hot-pressing process requires a temperature of 300-400°C, a pressure of 0.5-2 MPa, and a time of 1-5 minutes. After hot pressing, the material is cooled and shaped using cooling rollers to ensure it is flat and free from deformation.

[0049] When selecting plastic film layers, the outer nylon layer is chosen for its abrasion resistance and puncture resistance, while the inner PE layer only needs to be flexible. Polyurethane adhesive or acrylic adhesive is commonly used for the composite of the various layers.

[0050] Aluminum foil is typically cleaned using chemical solvents or ultrasonic cleaning equipment to remove oil and oxide layers from its surface, ensuring a clean surface and improving adhesion. For plastic films, corona treatment is required to increase surface energy and enhance adhesive strength.

[0051] The specific method of applying adhesive to plastic film depends on the requirements, and mainly includes the following:

[0052] Roller coating: Applying adhesive evenly to the material surface using a coating roller;

[0053] Spraying: The adhesive is atomized and sprayed onto the material surface using spraying equipment;

[0054] Scraping: Applying adhesive evenly to the material surface using a scraper.

[0055] After coating, the material is cured, followed by a lamination process. The plastic film is hot-pressed onto the aluminum foil surface, and then onto the PTFE film at temperatures of 100-150°C and pressures of 0.5-1.5 MPa to ensure a tight bond between the layers. Each layer needs to be cooled and set after lamination to ensure the material is flat and free from deformation. Finally, the laminated material is placed in a curing chamber to allow the adhesive to fully cure. In this embodiment, the curing temperature is set at 50-80°C, and the curing time is 24-48 hours. After curing, the bonding strength between the layers is significantly improved.

[0056] In some embodiments, once the vacuum plate dimensions are determined, a slitting machine is needed to cut the wide aluminum-plastic film into the width required by the customer, with a slitting accuracy controlled within ±0.1 mm. Optional quality inspection may also be performed, specifically including:

[0057] Thickness inspection: Use a thickness gauge to ensure that the thickness of each layer is uniform.

[0058] Adhesion strength test: Use a tensile testing machine to test the bond strength between each layer.

[0059] Barrier performance test: Test the water vapor and oxygen permeability to ensure that the barrier performance meets the standards.

[0060] Visual inspection: Ensure there are no scratches, bubbles, impurities, or other defects.

[0061] This specific embodiment is merely an explanation of the present invention and is not intended to limit the invention. After reading this specification, those skilled in the art can make modifications to this embodiment without contributing any inventive step, but such modifications are protected by patent law as long as they are within the scope of the claims of the present invention.

Claims

1. An electrostatic vacuum panel structure, characterized by, The upper vacuum plate and the lower vacuum plate are connected by a vacuum cavity, and the two ends of the vacuum cavity are heat sealed; The upper vacuum plate, the lower vacuum plate and the two end seals are connected by a flexible insulating aluminum plastic film containing a polytetrafluoroethylene (PTFE) layer.

2. The electrostatic vacuum panel structure of claim 1, wherein, The upper vacuum plate and the lower vacuum plate inside the vacuum cavity are respectively pasted with inner aluminum foils, and the two inner aluminum foils are inductive to the same negative static electricity, resist external air pressure through electrostatic repulsion, and maintain the thickness of the vacuum cavity at a preset size. The insulating aluminum plastic film comprises, in order, an outer nylon protective layer, an upper adhesive film layer, an aluminum foil layer, a PTFE insulating layer, a lower adhesive film layer, and an inner polyethylene (PE) layer.

3. The electrostatic vacuum panel structure of claim 2, wherein, The upper adhesive film layer pastes the outer nylon protective layer and the aluminum foil layer, and the lower adhesive film layer pastes the PTFE insulating layer and the inner PE layer. The thickness of the PTFE insulating layer is 2-4 μm, the thickness of the aluminum foil layer is 7-15 μm, the thickness of the inner PE is 10-80 μm, and the thickness of the inner aluminum foil is 1-10 μm.

4. The electrostatic vacuum panel structure of claim 1, wherein, The upper adhesive film layer and the lower adhesive film layer are polyurethane glue or acrylic glue.

5. The electrostatic vacuum panel structure of claim 4, wherein, The size of the inner aluminum foil inside the vacuum cavity is smaller than that of the upper and lower vacuum plates, and the inner aluminum foil does not contact the sealing edge position.

6. A filled electrostatic vacuum panel, characterized in that An air suction agent is arranged inside the vacuum cavity near the sealing edge position, and the thickness of the electrostatic vacuum plate after being maintained by electrostatic repulsion does not exceed 0.5 mm. The upper vacuum plate and the lower vacuum plate are connected by a vacuum cavity, and the two ends of the vacuum cavity are heat sealed; The upper vacuum plate, the lower vacuum plate and the two end seals are connected by a flexible insulating aluminum plastic film containing a polytetrafluoroethylene (PTFE) layer.

7. The filled electrostatic vacuum panel of claim 6, wherein, The core material is filled inside the vacuum cavity, and the core material is inductive to the same negative static electricity on the contact surface with the upper and lower vacuum plates. The core material comprises glass fiber, basalt fiber, ceramic fiber, fumed silica or polyurethane foam; The thickness of the electrostatic vacuum plate after being maintained by electrostatic repulsion does not exceed 0.5 mm.

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