Double vacuum heat insulation material

Abstract

This vacuum heat insulation material is made in small module units which are arranged in a two-dimensional pattern such as a checkerboard shape or a honeycomb shape, and then encompassed by an outer shell to be vacuum sealed to form a double-layer heat insulation material. Then, during nailing, even when a scratch is formed on the outer shell, the region where the vacuum is released does not affect the entire vacuum heat insulation material. Wings are formed toward the bottom surface by using the outer shell material of the vacuum heat insulation material, and pushpin fixing positions are marked on the wings or are formed by perforating holes in the wings. The vacuum heat insulation material formed in this way is arranged at a position to be attached, and then is fixed by driving pushpins into the pushpin fixing positions. Subsequently, when a next vacuum heat insulation material is arranged beside or above the vacuum heat insulation material that has been previously fixed and installed, a stepped portion with a magnet attached is attached to an existing pushpin head portion, thus fixing one side, and the vacuum heat insulation materials are repeatedly installed, thereby enabling convenient construction.

Description

Double vacuum insulation

[0001] The present invention relates to vacuum insulation, and belongs to the technical fields of vacuum technology, insulation manufacturing, architectural insulation, heat transfer inhibition, ease of construction, and magnetic / tack fixing methods. In particular, the present invention provides a double-layer vacuum insulation that maintains its insulation performance even when the outer skin is damaged, and is easy and economical to construct, and a method for manufacturing the same.

[0002] Currently, insulation is used in buildings and refrigerators to reduce energy consumption by blocking thermal bridges. Insulation generally refers to a product with a thermal conductivity of 0.045 W / m K or less, and various types are used. Representative examples include fiberglass insulation (laminated glass fibers, like cotton), bead insulation, urethane foam insulation, phenolic foam insulation, glass wool insulation, mineral wool insulation, and vacuum insulation.

[0003] Characteristics of vacuum insulation materials

[0004] Among these, vacuum insulation has a thermal conductivity of 0.002 to 0.008 W / m K, which is significantly lower than other insulation materials (0.020 to 0.045 W / m K). For example, fiberglass insulation has a thermal conductivity of approximately 0.045 W / m K, and polyurethane foam insulation has a thermal conductivity of approximately 0.020 W / m K, but vacuum insulation boasts a thermal conductivity much lower than these. This means that vacuum insulation blocks heat transfer more effectively, providing excellent insulation performance even with a thin thickness, which greatly benefits space savings.

[0005] merit

[0006] - Excellent insulation performance: Low thermal conductivity, high energy efficiency.

[0007] - Space efficiency: It can achieve the same effect even when installed thinner than existing insulation materials, making it advantageous for use in refrigerators or in space inside buildings.

[0008] disadvantage

[0009] - However, vacuum insulation also has fatal drawbacks.

[0010] - Performance degradation when the outer covering is damaged: If the outer covering is punctured, the vacuum is lost, and the insulation function is largely lost. This creates a constant risk of scratches and other damage in the field, making maintenance difficult.

[0011] - Difficulty in construction: There are many restrictions during the construction process as it is difficult to drive nails or cut.

[0012] - High cost: The cost is 20,000 to 30,000 won / 1m², making it more expensive than other insulation materials.

[0013] - Complicated installation: The construction method mainly uses adhesives, which has the disadvantage of increasing installation time and reducing accuracy.

[0014] If a vacuum insulation material has a hole in the middle, it cannot function as an insulator and is not easy to construct, so it is not popular. We are trying to solve this problem.

[0015] The present invention provides the following technical means to solve the existing problems of vacuum insulation materials, such as performance degradation when the outer skin is damaged, complex construction process, and high cost.

[0016] Double vacuum structure:

[0017] Vacuum insulation is manufactured into small modular units (vacuum cells), arranged in a two-dimensional grid or honeycomb pattern, then wrapped with an outer skin and vacuum-packed for a second time, creating a double-layer vacuum insulation. This structure limits the vacuum release area to one or two vacuum cells in the event of damage to the outer skin, maintaining over 90% of the insulation performance.

[0018] Improved construction convenience:

[0019] Form a fixed wing facing the bottom of the vacuum insulation outer shell, and mark the location of the press-fit pins or drill holes in the wing. During installation, the pins are driven into the fixed wing to secure it in place. The stepped portion with the embedded magnets is temporarily secured by attaching them to the previously installed press-fit pin heads. This allows for continuous installation by driving the pins into the wing, reducing installation time by 50% and increasing accuracy to over 95%.

[0020] The dual-layer vacuum insulation of the present invention overcomes the fatal shortcomings of existing vacuum insulation, significantly improves installation convenience, and provides an innovative solution that enhances space efficiency. Specific benefits include:

[0021] 1. Maintains performance despite damage

[0022] The double-layer vacuum structure allows for over 90% of insulation performance to be maintained even if a hole is punctured in the outer skin. This is because the vacuum release area is limited to the damaged vacuum cell, rather than spreading throughout the entire insulation. This significantly improves the durability and reliability of vacuum insulation, effectively resolving the biggest problem with existing vacuum insulation: performance degradation due to damage.

[0023] 2. Ease of installation

[0024] The installation process has been dramatically simplified by introducing a fixed wing utilizing the outer covering material and a magnetic and push-pin fastening method. Push-pins are driven into the fixed wing to easily secure the insulation. Magnets allow for temporary fastening and subsequent installation, resulting in superior work efficiency. Compared to conventional adhesive methods, installation time is reduced by approximately 50% and installation accuracy is increased to over 95%, ensuring high-quality installation.

[0025] 3. Improved space efficiency

[0026] The present invention provides excellent insulation performance despite its thin thickness, enabling efficient use of space in confined environments, such as apartment interior insulation. This space-saving feature is particularly beneficial in urban residential environments, contributing to expanded living space.

[0027] 4. Various construction options

[0028] - It offers the flexibility to be installed in confined spaces, allowing for installation tailored to a variety of building environments and design requirements. This expands the range of applications for vacuum insulation and supports customized installations tailored to user needs.

[0029] Taken together, these effects suggest that the present invention will promote the popularization of vacuum insulation materials and play a key role in maximizing energy savings and space utilization. It transcends the limitations of existing technologies and presents an innovative solution that simultaneously achieves practicality and efficiency.

[0030] Figure 1 is a double vacuum insulation configuration diagram.

[0031] Figure 2 is a configuration diagram of a vacuum insulation material with a fixed wing.

[0032] Figure 3 shows the existing vacuum insulation structure.

[0033] Figure 4 is a photo of the existing vacuum insulation material after vacuum suction and heat bonding.

[0034] Figure 5 is a photo of the existing vacuum insulation outer layer rolled up and attached to the back.

[0035] Figure 6 is a photo of the existing vacuum insulation outer layer rolled up and taped to the back.

[0036] Figure 7 is a front view of the completed existing vacuum insulation material.

[0037] The present invention relates to a dual-layer vacuum insulation material designed to overcome the limitations of existing vacuum insulation materials (VIPs). This invention encases a vacuum module, composed of individual vacuum cells arranged in a two-dimensional array, with an outer covering and applies a secondary vacuum seal to simultaneously achieve enhanced durability, ease of installation, and cost-effectiveness. This structure minimizes degradation of insulation performance in the event of damage, and its installation method utilizing magnets and fixed wings maximizes on-site construction efficiency.

[0038]

[0039] Explanation of Terms

[0040] - Vacuum cells (3, 3-1): Small units (e.g. 100 mm × 100 mm × 10 mm) filled with insulation, individually vacuum sealed.

[0041] - Vacuum module: A structure in which vacuum cells are arranged in a two-dimensional array.

[0042] - Double vacuum insulation: A finished product in which the vacuum module is sealed with a secondary vacuum outer shell.

[0043] - 2D array vacuum cell container: Directly insert core material (perlite, etc.) or place pre-fabricated vacuum cells.

[0044]

[0045] Structure of the invention

[0046] Unlike the existing single core structure (see also FIG. 1 ), the double vacuum insulation material of the present invention comprises a plurality of vacuum cells (3, 3-1) arranged in a two-dimensional array inside the outer shell. The vacuum cells are filled with a core material such as perlite (specific gravity 0.2) and individually sealed with an aluminum laminate film. These vacuum cells are inserted into a two-dimensional array container (1), and the container can be designed in various grid patterns such as squares, triangles, pentagons, and hexagons. Thereafter, the vacuum module is wrapped with an outer shell (4-1) and secondary vacuum sealed (0.1 Pa) to complete it. This double vacuum structure maintains the overall insulation performance even when individual cells are damaged (e.g., when one cell is damaged in a 4×6 array, the insulation performance decreases by 4.1%).

[0047]

[0048] Technical configuration

[0049] Double vacuum structure:

[0050] 1. Vacuum cell manufacturing:

[0051] - Size: 100mm × 100mm × 10mm (optimized diaphragm size).

[0052] Core material: Expanded perlite (specific gravity 0.2, thermal conductivity 0.06 W / m K), expanded vermiculite, glass fiber, fumed silica, mineral wool, or aerogel (thermal conductivity 0.015 W / m K, specific gravity 0.1). Aerogel offers ultra-low thermal conductivity due to its nanoporous structure, improving insulation performance by 20% compared to conventional core materials (test conditions: same thickness 10 mm, thermal conductivity measurement).

[0053] - Outer shell material: Aluminum laminate film (0.1 mm thick).

[0054] - Process: First vacuum treatment at 0.1 Pa in a vacuum chamber, then heat sealing.

[0055] 2. Secondary vacuum packaging:

[0056] - Array: 10×10 checkerboard pattern (1m×1m).

[0057] - Outer shell: Aluminum laminate film (0.1 mm thick).

[0058] - Process: Automatic heat sealing after secondary vacuum treatment at 0.1 Pa.

[0059] - Effect: 30% improvement in vacuum maintenance stability through secondary vacuum treatment (test conditions: 95% or higher vacuum maintenance rate for 1 year, compared to 65% of prior technology).

[0060]

[0061] Convenience of construction:

[0062] 1. Fixed wing:

[0063] - Specifications: 20mm width, 50mm length, PVC material.

[0064] - Attachment: Adhesive to the bottom of the outer shell, including press fixing holes (50mm apart).

[0065] 2. Magnet / Pushpin Fixation:

[0066] - Magnet: Inserted into the bottom of the vacuum cell (0.1 kg / m²).

[0067] - Press: Insert into the fixed wing marking position, temporarily fixed with iron surface and magnet.

[0068] Outer fabric strip treatment: Guide the strip formed during vacuum suction to the bottom or top surface, heat-compress, and use it as a fixed wing. The upper strip is attached to the adjacent insulation with adhesive, and the lower strip is secured with a press.

[0069]

[0070] Manufacturing process

[0071] 1. Vacuum cell manufacturing:

[0072] Core material: Excellent insulation performance achieved by using perlite (specific gravity 0.2).

[0073] Sealing: Wrapped with aluminum laminate film and vacuum sealed with heat sealing at 0.1 Pa.

[0074] Specifications: Standardized to 100mm × 100mm × 10mm (considering balance between performance and cost)

[0075] 2. Assembling the vacuum module:

[0076] - Array: Place the vacuum cells in a 10×10 grid (1 m × 1 m), etc.

[0077] - Container: Directly insert the core material into a two-dimensional array container or install a pre-fabricated vacuum cell.

[0078] 3. Secondary vacuum sealing:

[0079] - Outer shell: The entire vacuum module is wrapped with aluminum laminate.

[0080] - Vacuum treatment: After vacuum suction at 0.1 Pa, sealing using one of heat sealing, adhesive, or ultrasonic bonding.

[0081]

[0082] How to install

[0083] - Fixed wing (12): A wing formed on the bottom surface of the outer skin. Marking (15) or fixing holes are pre-made so that it can be fixed with a pin, nail, or tacker. After vacuum suction, it is sealed with heat bonding to prevent vacuum leakage even if a hole is made.

[0084] - Magnet (14) Utilization: Insert a magnet (0.1 kg / m²) into the vacuum cell or outer shell and attach it to an iron press or metal surface. Markings or holes are provided on the fixed wing for precise positioning during installation.

[0085] - Processing of the outer covering strip (16): Guide the strip formed during vacuum suction to the bottom or upper surface, use it as a guide, and use it as a fixed wing after thermal compression. The upper strip is attached to the adjacent insulation with adhesive, and the lower strip is fixed with a press.

[0086]

[0087] merit

[0088] - Damage tolerance: 95.9% insulation performance is maintained when one cell is damaged in a 4x6 array, minimizing overall performance degradation.

[0089] - Ease of installation: Continuous installation without adhesive using magnets and fixed wings, 50% reduction in installation time, accuracy of over 95%.

[0090] - Shape diversity: In addition to squares, polygonal arrangements such as triangles, pentagons, and hexagons are possible, providing design flexibility.

[0091]

[0092] Example

[0093] Example 1: Manufacturing a vacuum cell and double vacuum insulation

[0094] - Vacuum cell: Made with perlite (specific gravity 0.2) as core material, measuring 100 mm × 100 mm × 10 mm. Sealed by heat fusion after initial vacuum (0.1 Pa).

[0095] - Double vacuum insulation: Vacuum module composed of 10×10 array (1m×1m), sealed with aluminum outer shell after secondary vacuum treatment (0.1 Pa).

[0096] - Results: Thermal conductivity 0.004 W / m·K, thermal resistance 2.5 m²K / W, 1% performance reduction per cell damage (test conditions: 10% area damage, thermal conductivity measurement).

[0097]

[0098] Example 2: Construction convenience test

[0099] - Environment: Apartment interior insulation construction (1m² area).

[0100] - Method: Fixed wing bonding → Temporary fixing with magnet → Final fixing with pressure.

[0101] - Results: Construction time 30 minutes / 1m² (50% reduction compared to 60 minutes with conventional adhesive method), installation accuracy 98% (within 2% error).

[0102]

[0103] Example 3: Economics and Production Efficiency

[0104] - Process: Vacuum cell manufacturing (core filling, shell sealing, vacuum treatment) and assembly automation.

[0105] - Results: Production time per 1m²: 50 minutes (67% reduction compared to the previous 2-3 hours), cost: KRW 8,600 / m² (material cost: KRW 2,100, manufacturing cost: KRW 5,000, other costs: KRW 1,500).

[0106]

[0107] Example 4: Insulation performance test by diaphragm size

[0108] - Test conditions: 1m × 1m panel, measurement of insulation performance reduction rate when 1 diaphragm is damaged (thermal conductivity measurement).

[0109] - result:

[0110] 1. 50mm × 50mm: 2% reduction.

[0111] 2. 100mm × 100mm: 1% reduction.

[0112] 3. 150mm × 150mm: 1.2% reduction.

[0113] - Conclusion: Insulation performance reduction rate can be maintained at less than 1% in the range of 50 to 150 mm.

[0114]

[0115] Example 5: Fabrication of a double-layer vacuum insulation using an aerogel core.

[0116] - Vacuum cell: Made with aerogel (thermal conductivity 0.015 W / m K) as the core material, measuring 100 mm × 100 mm × 10 mm. Sealed by heat fusion after initial vacuum (0.1 Pa).

[0117] - Double vacuum insulation: Vacuum module composed of 10×10 array (1m×1m), sealed with aluminum outer shell after secondary vacuum treatment (0.1 Pa).

[0118] - Results: Thermal conductivity 0.003 W / m·K, thermal resistance 3.3 m²K / W (32% improvement compared to perlite), 0.8% decrease in performance when one cell is damaged (test conditions: 10% area damage, thermal conductivity measurement).

[0119] [Explanation of symbols]

[0120] 1. Two-dimensional array vacuum cell container

[0121] 2. Adhesive

[0122] 3. Vacuum cell

[0123] 3-1. With the vacuum cell placed in the container

[0124] 4. Vacuum cover

[0125] 5. Vacuum container seal line

[0126] 11. Double vacuum insulation

[0127] 12. Fixed wing

[0128] 13. Lower step

[0129] 14. Magnet

[0130] 15. Fixed marking

[0131] 16. Outer fabric belt

Claims

1. A double vacuum insulation material that improves vacuum maintenance stability by assembling and sealing vacuum cells in a two-dimensional array and then vacuum-sealing them again with a secondary vacuum bag.

2. In the first paragraph, the core material of the vacuum cell is a double vacuum insulation material composed of foamed perlite.

3. In the first paragraph, the core material of the vacuum cell is a double vacuum insulation material composed of foamed vermiculite.

4. In the first paragraph, the core material of the vacuum cell is a double vacuum insulation material composed of glass fiber.

5. In the first paragraph, the core material of the vacuum cell is a double vacuum insulation material composed of fumed silica.

6. In the first paragraph, the core material of the vacuum cell is a double vacuum insulation material composed of aerogel.

7. In the first paragraph, the vacuum cell core is a double vacuum insulation material composed of minerals.

8. In the first paragraph, the vacuum cell is a double vacuum insulation material configured in a polygonal shape.

9. In the first paragraph, a double vacuum insulation material including at least one magnet inside the vacuum cell.

10. A double vacuum insulation material having fixed wings formed on the bottom surface of the outer covering of the vacuum cell in the first paragraph.

11. In the 10th paragraph, a double vacuum insulation material having a lower step formed on the opposite side of the fixed wing.

12. In paragraph 10, a double vacuum insulation material including at least one magnet inside the outer surface of the vacuum insulation material.

13. A double vacuum insulation material having at least one fixed marking on the fixed wing in the 10th paragraph.

14. A double vacuum insulation material having an external finishing material attached to the upper surface in the first paragraph.

15. A double vacuum insulation material in accordance with paragraph 14, wherein the external finishing material is a perlite board.

16. In the 14th paragraph, a double vacuum insulation material in which the external finishing material is a quartz board.

17. A double vacuum insulation material in accordance with paragraph 14, wherein the external finishing material is an aluminum plate.

18. In paragraph 15, a double vacuum insulation material in which the external finishing material is wood plywood.

19. In the 14th paragraph, the external finishing material is a double vacuum insulation material made of Starcoin.

20. In the first paragraph, a double vacuum insulation material having a vacuum cell membrane size of 50 mm × 50 mm or more and 150 mm × 150 mm or less.

21. In the first paragraph, a double vacuum insulation material including a fixed wing and a magnet / pressure fixing method inside the vacuum cell.

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