Method for manufacturing vacuum insulation panel using synthetic resin having optical transparency, vacuum insulation panel manufactured thereby, add-on window using same, method for manufacturing same, and insulation shutter installation method

Abstract

The present invention relates to a method for manufacturing a vacuum insulation panel using a synthetic resin having optical transparency, a vacuum insulation panel manufactured thereby, an add-on window using same, a method for manufacturing same, and an insulation shutter installation method. According to the present invention, the method for manufacturing a vacuum insulation panel using a synthetic resin having optical transparency comprises: an upper and lower plate stacking step of stacking an upper plate and a lower plate such that a plurality of spacers are provided between the upper plate and the lower plate to provide a space therebetween, the upper plate and the lower plate being made of a transparent synthetic resin; an edge bonding step of bonding the edges of the upper plate and the lower plate; and a vacuum layer forming step of forming a vacuum layer by discharging air through an exhaust hole formed in the upper plate or the lower plate and closing the exhaust hole. Accordingly, the upper plate and the lower plate made of a synthetic resin having high optical transparency, such as polycarbonate, have lower thermal conductivity than glass, thereby improving the insulation performance of the vacuum insulation panel, and, when the vacuum insulation panel is used as a door of a commercial refrigerator, condensation due to a temperature difference is prevented on the outer surface, thereby providing a use environment in which items stored in the refrigerator can be checked without opening the door.

Description

Method for manufacturing a vacuum insulation panel using a visible synthetic resin, a vacuum insulation panel manufactured thereby, an overlay window using the same, a method for manufacturing the same, and a method for installing an insulation overlay.

[0001] The present invention relates to a method for manufacturing a vacuum insulation panel using a visible synthetic resin, a vacuum insulation panel manufactured thereby, an overlay window using the same, a method for manufacturing the same, and a method for installing an insulating overlay. More specifically, the invention relates to a method for manufacturing a vacuum insulation panel using a visible synthetic resin that has excellent thermal insulation and impact resistance while providing visibility by forming a vacuum layer between an upper plate and a lower plate made of a transparent synthetic resin, and which can be used as a transparent door for a hot and cold storage device, an overlay glass for a window, or an insulating overlay, a vacuum insulation panel manufactured thereby, an overlay window using the same, a method for manufacturing the same, and a method for installing an insulating overlay.

[0002] Generally, a refrigerator is equipped with a storage space for storing items such as food, beverages, and medicines, and this storage space needs to be maintained at a low temperature to preserve the freshness of the stored items. Accordingly, the refrigerator supplies cold air generated by the operation of a refrigeration cycle to the storage space, and insulation is installed around the storage space to prevent the loss of cold air.

[0003] In particular, commercial refrigerators installed in supermarkets or restaurants are equipped with a door on the front to open and close the storage space, and consumers or users open the storage space to not only put in and take out items but also check the items stored inside. Therefore, it is common to install transparent glass doors for commercial refrigerators to ensure visibility.

[0004] However, conventional glass doors installed in commercial refrigerators lacked excellent thermal insulation, leading to a problem where condensation occurred on the surface due to the temperature difference between the indoor temperature and the outer surface of the glass door. Consequently, consumers could not identify stored items without opening the door, and since it was difficult for restaurant users to remember the location of every item, the frequency and duration of opening the door to check items increased. This resulted in significant energy loss due to the cold air escaping during the time the door was open.

[0005] Considering these problems, a refrigerator that allows checking the contents stored inside without opening the door by applying vacuum insulated glass to the door of the refrigerator has been proposed in Korean Published Patent No. 10-2012-0048425 (published on May 15, 2012, hereinafter referred to as 'Prior Art Document 1'). In the insulation unit for a refrigerator according to Prior Art Document 1, as shown in FIG. 1a, a pair of insulating glass (IG) is arranged to face each other with a plurality of spacers (SP) in between, thereby forming a gap of a certain width between the pair of insulating glass (IG), and the gap is closed by a sealing part (SL) provided between the pair of insulating glass (IG) so as to extend along the edge of the insulating glass (IG).

[0006] As such, the insulation unit for a refrigerator, comprising a pair of insulating glass (IG), a spacer (SP), and a sealing part (SL), is transparent, allowing the contents inside to be checked without opening the refrigerator door. Additionally, a low thermal conductivity is achieved through the vacuum layer (VL) formed between the pair of insulating glass (IG), thereby improving insulation performance, which reduces cold air loss and minimizes the occurrence of condensation.

[0007] However, vacuum insulating glass such as that described in the prior art literature attempts to achieve low thermal conductivity by providing a vacuum layer, but there are limitations in improving the condensation phenomenon of vacuum insulating glass due to the relatively high thermal conductivity of the glass.

[0008] In particular, there is a manufacturing limitation in that forming low pressure inside through an exhaust port to create the aforementioned vacuum layer increases the probability of spontaneous breakage of the insulating glass (IG). Recently, there have been cases where insulating glass is manufactured inside a vacuum chamber to form a vacuum layer, but this requires large-scale production facilities and has the problem of increasing costs.

[0009] Above all, since glass has a fundamental problem of being highly susceptible to breakage from repeated impacts during the process of opening and closing the refrigerator door, the aforementioned insulating glass (IG) must inevitably be of a certain thickness to ensure impact resistance; however, this leads to an increase in weight, which presents a limitation in that it is not easy to handle during manufacturing and maintenance processes.

[0010] Meanwhile, a significant number of buildings are severely deteriorated, and are exposed to an inefficient thermal energy environment due to the complete omission of insulation or extremely low insulation efficiency. In other words, most aging buildings exhibit limitations in building energy usage, such as relatively high base consumption, because the insulation efficiency of windows, doors, walls, and roofs is very low. Consequently, despite the operation of heating and cooling systems, it is difficult to expect sufficient cooling effects due to the relatively low insulation efficiency, and significant costs are incurred for these functions.

[0011] In addition, when applying green remodeling technology to improve the energy efficiency of aging buildings, there are often cases where windows, doors, walls, and ceilings cannot be completely removed due to structural problems of the aging buildings, and there are limitations to practical implementation due to various issues such as narrow distances between buildings, discrepancies between residents and actual building owners, and costs.

[0012] Meanwhile, by installing additional windows on existing windows or attaching window film to block sunlight, the energy consumption efficiency of aging buildings can be improved at a low cost without spatial or structural constraints.

[0013] As a prior art document related to such an overlay window, Korean Registered Patent No. 10-2548623 (registered on June 23, 2023, hereinafter referred to as 'Prior Art Document 2') was proposed as the applicant's previously registered patent. As illustrated in FIG. 1b, the overlay window according to Prior Art Document 2 comprises an overlay window (AW) that forms an air layer (AL) by being spaced at a certain distance from the interior glass (InG) of an existing window (EW), a frame (FR) installed to surround the edge of the overlay window (AW), and an adhesive means provided on the frame (FR) to be attached to the interior glass (InG).

[0014] The additional window of Prior Art Document 2 described above is attached to the existing window (EW) so that an air layer (AL) is formed between the existing window (EW) and the additional window (AW), thereby enabling improved thermal insulation performance without changing the structure of the existing window. As such, Prior Art Document 2 improves the thermal insulation performance of the existing window by forming an air layer through the additional installation of the additional window (AW); however, it is difficult to maintain the sealing of the air layer, and since air contains a large number of molecules compared to a vacuum, there are inevitably limitations in improving thermal insulation performance due to convection of molecules.

[0015] Meanwhile, vacuum insulation panels (VIPs) are being used as insulation materials for construction or for heating and cooling equipment. Regarding such vacuum insulation panels, Korean Registered Patent No. 10-2211452 (registered on January 28, 2021, hereinafter referred to as 'Prior Art Document 3') has been proposed. As shown in FIG. 1c, the vacuum insulation panel of Prior Art Document 3 comprises a core material (CM) and a sealing film (BF) that surrounds the core material (CM). This vacuum insulation panel can be manufactured by placing the core material (CM) into the sealing film (BF) and then sealing the sealing film (BF) in a vacuum state.

[0016] Prior art document 3 describes a method to minimize material loss during the manufacturing process of vacuum insulation by connecting a vacuum nozzle to a vacuum film without using an expensive vacuum chamber. However, fundamentally, in the case of vacuum insulation where the core material is wrapped in an outer shell, it is difficult to ensure visibility due to the core material, so it cannot be used as a window covering, and above all, the outer shell is very vulnerable to scratches or external impacts, so a protective layer is required.

[0017] In particular, since it is difficult to manufacture vacuum insulation materials into panels of a certain size or larger, they are produced by joining multiple individually manufactured unit panels together, which results in thermal bridging between the unit panels and requires a process of wrapping them with a separate finishing material for aesthetic purposes. Additionally, while large panels are required to produce general-purpose panels, there is a problem in that manufacturing requires a lot of cost and time as they are composed of multiple unit panels.

[0018] In addition, in the case of vacuum insulation materials consisting of a core and an outer shell, there are problems such as deterioration in thermal insulation performance and deformation of the shape of the vacuum insulation material due to changes over time caused by gases generated from the core over the long term.

[0019] The present invention was devised to solve the above-mentioned problems, and the objective of the present invention is to provide a method for manufacturing a vacuum insulation panel using a synthetic resin with visibility that can provide a lightweight insulation panel with improved thermal conductivity by using a synthetic resin panel of a transparent material with relatively low thermal conductivity, and yet is easy to manufacture into various shapes, has a low risk of shrinkage and expansion due to temperature changes and damage due to impact, can form a vacuum layer of sufficiently low pressure without spontaneous breakage during the process of forming the vacuum layer, and allows for easy regeneration of the vacuum even if the vacuum is partially lost, the vacuum insulation panel manufactured thereby, an overlay window using the same, a method for manufacturing the same, and a method for installing an insulation overlay.

[0020] Another objective of the present invention is to provide a method for manufacturing a vacuum insulation panel using a visible synthetic resin that can easily improve the thermal insulation performance of existing windows or fire doors and has excellent utility as it is easy to manufacture large panels, a vacuum insulation panel manufactured thereby, an overlay window using the same, a method for manufacturing the same, and a method for installing an insulation overlay.

[0021] A method for manufacturing a vacuum insulation panel using a visible synthetic resin according to a first embodiment of the present invention, which performs the task of achieving the above-mentioned purpose and eliminating conventional problems, is characterized by comprising: a step of stacking upper and lower plates (S110) in which a plurality of spacers (20) spaced apart from each other are provided between an upper plate (11) and a lower plate (12) made of a transparent synthetic resin so that a space is provided between the upper plate (11) and the lower plate (12); a step of joining the edges of the upper plate (11) and the lower plate (12) to seal the space; and a step of forming a vacuum layer (S130) in which air between the upper plate (11) and the lower plate (12) is discharged through an exhaust hole (13) formed in the upper plate (11) or the lower plate (12) so that a vacuum layer is formed in the space between the upper plate (11) and the lower plate (12), and the exhaust hole (13) is closed.

[0022] Meanwhile, a method for manufacturing a vacuum insulation panel using a visible synthetic resin according to a second embodiment of the present invention is characterized by comprising: a step of stacking upper and lower plates (S210) in which a plurality of spacers (20) spaced apart from each other are provided between an upper plate (11) and a lower plate (12) made of a transparent synthetic resin in a vacuum chamber (C) so that a space is provided between the upper plate (11) and the lower plate (12); and a step of joining the edges of the upper plate (11) and the lower plate (12) to seal the space.

[0023] Meanwhile, a method for manufacturing a vacuum insulation panel using a visible synthetic resin according to the third embodiment of the present invention relates to a method for manufacturing a vacuum insulation panel (120) in which a vacuum layer is formed between an upper plate (11) and a lower plate (12) made of a transparent synthetic resin plate, comprising: a plate forming step (S310) of forming a synthetic resin plate such that a plurality of protrusions (14) spaced apart from each other are integrally formed on at least one of the synthetic resin plates forming the upper plate (11) and the lower plate (12); an upper and lower plate stacking step (S320) of stacking the upper plate (11) and the lower plate (12) such that a space is provided between the upper plate (11) and the lower plate (12) by the protrusions (14); and a edge joining step (S330) of joining the edges of the upper plate (11) and the lower plate (12) to seal the space. The method is characterized by including a vacuum layer formation step (S340) of discharging air between the upper plate (11) and the lower plate (12) through an exhaust hole (13) formed in the upper plate (11) or the lower plate (12) so as to form a vacuum layer in the space between the upper plate (11) and the lower plate (12), and closing the exhaust hole (13).

[0024] Meanwhile, the method for manufacturing a vacuum insulation panel using a visible synthetic resin according to the fourth embodiment of the present invention relates to a method for manufacturing a vacuum insulation panel (120) in which a vacuum layer is formed between an upper plate (11) and a lower plate (12) made of a transparent synthetic resin plate, and is characterized by comprising: a plate forming step (S410) of forming a synthetic resin plate such that a plurality of protrusions (14) spaced apart from each other are integrally formed on at least one of the synthetic resin plates forming the upper plate (11) and the lower plate (12); an upper and lower plate stacking step (S420) of stacking the upper plate (11) and the lower plate (12) in a vacuum chamber (C) such that a space is provided between the upper plate (11) and the lower plate (12) by the protrusions (14); and a edge joining step (S430) of joining the edges of the upper plate (11) and the lower plate (12) to seal the space.

[0025] In addition, the edge joining steps (S120)(S220)(S330)(S430) can heat-fuse the edges of the upper plate (11) and lower plate (12) using a heater (30).

[0026] Additionally, the heater (30) has a U-shaped structure to surround the edge of the top plate (11) or bottom plate (12), and one inner surface (31) that comes into contact with the top plate (11) or bottom plate (12) can be heated to a temperature of 130°C or higher and 150°C or lower.

[0027] Additionally, in the above edge joining steps (S120)(S220)(S330)(S430), a groove (43) is formed along the edge of the upper plate (11) or lower plate (12), a sealing material (41) is inserted into the groove (43), and a screw (42) is fastened into a screw hole (44) formed along the edge of the upper plate (11) and lower plate (12) to press the sealing material (41) between the upper plate (11) and the lower plate (12).

[0028] In addition, the above edge bonding steps (S120)(S220)(S330)(S430) can be bonded so that the edges are integrated by applying a methylene chloride solution to the edges of the upper plate (11) and the lower plate (12) and maintaining the bonding surfaces of the upper plate (11) and the lower plate (12) in close contact under conditions of room temperature and pressure.

[0029] Additionally, in the above edge joining steps (S120)(S220)(S330)(S430), a ring-shaped metal plate (60) extending along the edges of the upper plate (11) and lower plate (12) is installed between the upper plate (11) and the lower plate (12) so that it is positioned at the joining portion, and the metal plate (60) can be joined to the upper plate (11) and the lower plate (12) by high-frequency induction heating.

[0030] Additionally, a thread is formed on the inner surface of the exhaust hole (13) formed in the upper plate (11) or lower plate (12), and a bolt-type cap (51) having a thread formed on the outer surface can be fastened to the exhaust hole (13).

[0031] Additionally, a valve-type cap (52) is provided in the exhaust hole (13) formed in the upper plate (11) or lower plate (12), and the valve-type cap (52) is provided with an exhaust port (53) to which a syringe (S) is coupled, wherein the exhaust port (53) can be automatically closed by the internal and external pressure difference of the vacuum insulation panel (120) when the syringe (S) is removed.

[0032] In addition, the spacer (20) may have a ventilation hole (21) formed therein to allow air flow.

[0033] In addition, the spacer (20) is made of a porous bar having a plurality of fine air holes formed therein, and a plurality of spacers (20) can be arranged in a grid shape.

[0034] Additionally, the spacer (20) is formed in the shape of a bar of synthetic resin identical to the upper and lower plates (11)(12), and can be arranged so that an opening (22) is provided between adjacent spacers (20) to allow air flow.

[0035] In addition, the protrusion (14) may have a horn-like shape that narrows toward the end.

[0036] In addition, the above protrusion (14) may have a vacuum groove (15) formed between adjacent protrusions (14) to have a dome-shaped curved surface.

[0037] Additionally, the above-mentioned protrusions (14) are formed to extend in one direction, and a groove (16) extending in one direction is formed between adjacent protrusions (14), and a connecting groove (17) can be formed in each protrusion (14) to allow air flow to the adjacent groove (16).

[0038] In addition, the bone portion (16) may have a tunnel-shaped curved surface.

[0039] In addition, the upper plate (11) and the lower plate (12) are each made of synthetic resin plates in which a protrusion (14) is integrally formed, and the upper and lower plate stacking step (S320) (S420) can be arranged so that the protrusions (14) of the upper plate (11) and the lower plate (12) come into contact with each other at corresponding positions.

[0040] Meanwhile, the vacuum insulation panel of the present invention is characterized by being manufactured by a method for manufacturing a vacuum insulation panel using a synthetic resin having the above visibility.

[0041] Meanwhile, the additional window using a vacuum insulation panel according to the fifth embodiment of the present invention relates to an additional window (100) that is additionally installed on an existing window (W) to improve building energy consumption efficiency, and is characterized by comprising: a window frame (110) that is installed so as to be detachably attached to an existing window (W) by means of a detachable attachment means (130); and a vacuum insulation panel (120) which is coupled to the window frame (110) by forming a joint portion so that the edges of the upper plate (11) and the lower plate (12), made of a transparent synthetic resin plate, are stacked so that a space is provided by being spaced apart at a predetermined interval, a vacuum layer is formed in the space between the upper plate (11) and the lower plate (12), and the upper plate (11) and the lower plate (12) are sealed.

[0042] And, the above joint can be formed by heat-fusing the edges of the top plate (11) and the bottom plate (12) with a heater (30).

[0043] Meanwhile, the method for manufacturing an additional window frame according to the 6th embodiment of the present invention relates to a method for manufacturing an additional window frame (100) that is additionally installed on an existing window frame (W) to improve building energy consumption efficiency, and is characterized by comprising: an upper and lower plate stacking step (S510) in which an upper plate (11) and a lower plate (12) made of transparent synthetic resin are stacked so that a space is provided by being spaced apart at a predetermined interval; a rim joining step (S520) in which the rims of the upper plate (11) and the lower plate (12) are joined to seal the space; a vacuum layer forming step (S530) in which air between the upper plate (11) and the lower plate (12) is discharged through an exhaust hole (13) formed in the upper plate (11) or the lower plate (12) so that a vacuum layer is formed in the space between the upper plate (11) and the lower plate (12), and the exhaust hole (13) is closed; and a window frame joining step (S540) in which a window frame (110) is joined to surround the joint.

[0044] Meanwhile, the method for constructing an insulating door according to the 7th embodiment of the present invention is a method for constructing an insulating door (200) that is additionally installed on an existing fire door (F) to improve building energy consumption efficiency, wherein the insulating door (200) is formed by stacking an upper plate (11) and a lower plate (12) made of synthetic resin plates so that a space is provided by being spaced apart at a predetermined interval, a vacuum layer is formed in the space between the upper plate (11) and the lower plate (12), and a joint is formed so that the edges of the upper plate (11) and the lower plate (12) are sealed, and the insulating door (200) is cut to correspond to the shape of the existing fire door (F) and attached to the existing fire door (F) using a fastening means.

[0045] And, after cutting the insulation door (200), the cut portion can be sealed to suppress the inflow of air through the cut portion, and after exhausting air through the exhaust hole (13) formed during the manufacturing process of the top plate (11) or bottom plate (12), the exhaust hole (13) can be closed to restore the vacuum layer.

[0046] According to the method for manufacturing a vacuum insulation panel using a synthetic resin having visibility of the present invention, the vacuum insulation panel manufactured thereby, the window and door using the same, the method for manufacturing the same, and the method for installing an insulation door, the top and bottom plates made of a synthetic resin such as polycarbonate having high visibility have a significantly lower thermal conductivity than glass, thereby significantly improving the insulation performance of the vacuum insulation panel, and when used as a door for a commercial refrigerator, condensation caused by a temperature difference does not occur on the outer surface, so a user environment can be provided in which items stored inside can be easily checked without opening the door.

[0047] In particular, the top and bottom plates, made of synthetic resin, can respond flexibly to temperature changes and impacts, thereby preventing damage caused by sudden temperature changes and impacts. Furthermore, even when exhaust holes are formed in the top or bottom plates, the risk of spontaneous breakage due to the exhaust holes during the vacuum layer formation process is significantly reduced, eliminating the need for a separate protective layer. This allows for the simplification of the vacuum insulation panel structure while providing a vacuum layer with sufficiently low pressure.

[0048] Furthermore, due to the top and bottom plates made of synthetic resin and the simplified vacuum insulation panel structure, the overall weight of the panel is reduced, making it easy to handle and allowing for the easy production of panels of various shapes.

[0049] In addition, the top and bottom plates, made of synthetic resin, facilitate vacuum restoration even when the panel's vacuum is lost, thereby improving maintenance convenience.

[0050] In addition, particularly when a protrusion securing a space for forming a vacuum layer is integrally formed on at least one of the upper and lower plates made of synthetic resin sheet material, visibility can be improved and the formation of a vacuum layer is easier compared to a vacuum insulation panel in which a separate spacer is installed between the upper and lower plates.

[0051] Moreover, the protrusion having a horn-shaped form that narrows toward the end reduces the joint area with the synthetic resin plate joined to it, thereby further improving the visibility of the vacuum insulation panel.

[0052] In addition, the vacuum groove formed around the protrusion has an arched cross-sectional structure in which various curved surfaces are organically combined to distribute the load so that it does not concentrate on a specific area, thereby effectively suppressing damage to the vacuum insulation panel caused by external impact or vacuum pressure and improving the durability of the vacuum insulation panel.

[0053] Furthermore, by using a vacuum insulation panel that has high visibility and thermal insulation performance, formed by creating a vacuum layer between a top plate and a bottom plate made of a synthetic resin such as polycarbonate with high visibility, and by manufacturing an overlay window or an insulated shutter and additionally installing it on the windows or fire doors of an aging building, the energy consumption efficiency of the aging building can be improved.

[0054] In addition, vacuum insulation panels formed by joining the edges of upper and lower plates made of synthetic resin sheets are easy to enlarge, so they can be used to form additional windows or insulation shutters of various sizes, making them highly versatile.

[0055] Finally, when the top and bottom plates of the vacuum insulation panel are formed from polycarbonate, the risk of damage is low due to excellent scratch and impact resistance, and cost reduction can be achieved as separate finishing materials are unnecessary since the top and bottom plates themselves function as finishing materials.

[0056] FIG. 1a is a cross-sectional view of an insulation unit for a refrigerator disclosed in a prior art document,

[0057] FIG. 1b is a perspective view of a patch window disclosed in a prior art document,

[0058] FIG. 1c is a cross-sectional view of a vacuum insulation material disclosed in a prior art document,

[0059] FIG. 2 is a block diagram illustrating, in chronological order, a method for manufacturing a vacuum insulation panel according to a first embodiment of the present invention.

[0060] FIG. 3 is a perspective view illustrating a state in which an upper plate and a lower plate are stacked with a cylindrical spacer in between, according to a first embodiment of the present invention.

[0061] FIG. 4 is a perspective view illustrating a stacked state in which an upper plate and a lower plate are arranged in a grid-like structure with a spacer in between, according to a first embodiment of the present invention.

[0062] FIG. 5 is a plan view illustrating a state in which a bar-shaped spacer according to a first embodiment of the present invention is arranged to form an opening.

[0063] FIG. 6 is a cross-sectional view illustrating a state in which a ventilation hole is formed in a spacer according to a first embodiment of the present invention, and an exhaust hole is formed to be connected to the ventilation hole.

[0064] FIG. 7a is an exemplary diagram illustrating a state in which a heater according to a first embodiment of the present invention heats the edges of an upper plate and a lower plate.

[0065] FIG. 7b is an example diagram illustrating a state in which the edges of the top plate and the bottom plate are joined by being pressed after being heated.

[0066] FIG. 8 is a cross-sectional view illustrating a state in which the edges of an upper plate and a lower plate are joined so as to be sealed by a sealing material and a screw according to a first embodiment of the present invention.

[0067] FIG. 9 is a cross-sectional view illustrating a state in which a metal plate is installed between the edges of an upper plate and a lower plate according to a first embodiment of the present invention.

[0068] FIG. 10 is an exemplary diagram illustrating a state in which air in the space between the upper plate and the lower plate is discharged by a vacuum pump according to the first embodiment of the present invention.

[0069] FIG. 11 is an exemplary diagram illustrating the combined structure of a valve-type cap and a vacuum pump according to a first embodiment of the present invention.

[0070] FIG. 12 is a block diagram illustrating, in chronological order, a method for manufacturing a vacuum insulation panel according to a second embodiment of the present invention.

[0071] FIG. 13 is an exemplary diagram illustrating a state in which an upper plate and a lower plate are arranged in a vacuum chamber facing each other with a spacer in between, according to a second embodiment of the present invention.

[0072] FIG. 14 is a block diagram illustrating, in chronological order, a method for manufacturing a vacuum insulation panel according to a third embodiment of the present invention.

[0073] FIG. 15 is a cross-sectional view illustrating the structure of an upper plate and a lower plate constituting a vacuum insulation panel according to a third embodiment of the present invention.

[0074] FIG. 16 is a cross-sectional view illustrating another structure of the top plate and bottom plate constituting the vacuum insulation panel according to the third embodiment of the present invention.

[0075] FIG. 17 is a perspective view of a synthetic resin plate having a protrusion integrally formed thereon according to a third embodiment of the present invention.

[0076] FIG. 18 is a perspective view of a synthetic resin plate having a protrusion of another structure integrally formed according to a third embodiment of the present invention,

[0077] FIG. 19 is an exemplary diagram illustrating a state in which a heater according to a third embodiment of the present invention heats the edges of an upper plate and a lower plate.

[0078] FIG. 20 is an example diagram illustrating a state in which the edges of the top plate and the bottom plate are heated and then pressed to be joined.

[0079] FIG. 21 is a cross-sectional view illustrating a state in which the edges of an upper plate and a lower plate are joined so as to be sealed by a sealing material and a screw according to a third embodiment of the present invention.

[0080] FIG. 22 is a cross-sectional view illustrating a state in which a metal plate is installed between the edges of an upper plate and a lower plate according to a third embodiment of the present invention.

[0081] FIG. 23 is an exemplary diagram illustrating the state in which air in the space between the upper plate and the lower plate is discharged by a vacuum pump according to the third embodiment of the present invention.

[0082] FIG. 24 is an exemplary diagram illustrating the combined structure of a valve-type cap and a vacuum pump according to a third embodiment of the present invention.

[0083] FIG. 25 is a block diagram illustrating, in chronological order, a method for manufacturing a vacuum insulation panel according to a fourth embodiment of the present invention.

[0084] FIG. 26 is an exemplary diagram illustrating a state in which an upper plate and a lower plate are arranged in a vacuum chamber so as to face each other with a protrusion between them, according to a fourth embodiment of the present invention.

[0085] FIG. 27 is a perspective view of an overlay window according to a fifth embodiment of the present invention,

[0086] FIG. 28 is a cross-sectional view of an overlay window according to a fifth embodiment of the present invention,

[0087] FIG. 29 is a perspective view of an overlay window equipped with a cylindrical spacer according to a fifth embodiment of the present invention,

[0088] FIG. 30 is a perspective view of an overlay window equipped with a spacer having a grid-like structure according to a fifth embodiment of the present invention,

[0089] FIG. 31 is a cross-sectional view illustrating a state in which a protrusion is integrally formed on a lower plate constituting an overlay window frame according to the fifth embodiment of the present invention.

[0090] FIG. 32 is a cross-sectional view illustrating a state in which a protrusion is integrally formed on an upper plate and a lower plate constituting an overlay window according to the fifth embodiment of the present invention.

[0091] FIG. 33 is a perspective view of a synthetic resin plate having a protrusion integrally formed thereon according to a fifth embodiment of the present invention,

[0092] FIG. 34 is a block diagram illustrating, in chronological order, a method for manufacturing a window frame with an overlay according to the 6th embodiment of the present invention.

[0093] FIG. 35 is a perspective view illustrating a state in which an insulating shutter according to the 7th embodiment of the present invention is installed on a fire door.

[0094] FIG. 36 is a perspective view illustrating a state in which an insulating shutter according to the 7th embodiment of the present invention is cut to correspond to a fire door.

[0095] In the following, preferred embodiments of the present invention will be described in detail based on the details illustrated in the drawings; however, specific descriptions of related known functions or configurations are omitted if it is determined that such descriptions may unnecessarily obscure the essence of the present invention.

[0096] The method for manufacturing a vacuum insulation panel using a visible synthetic resin according to the first embodiment of the present invention utilizes a transparent synthetic resin plate, such as polycarbonate or acrylic, which has transparent optical properties like glass and can flexibly respond to temperature changes and impacts, and a spacer (20) is interposed between a pair of synthetic resin plates to stably support the pair of synthetic resin plates stacked facing each other so that a vacuum layer is formed between them, while ensuring that a uniform vacuum layer is formed overall, thereby providing excellent thermal insulation and durability, and thus enabling the production of a panel that can be used as vacuum glass or a vacuum insulation panel through a simple process. As shown in FIG. 2, the process proceeds sequentially, including an upper and lower plate stacking step (S110), a rim bonding step (S120), and a vacuum layer formation step (S130).

[0097] The upper and lower plate stacking step (S110) described above is a process in which an upper plate (11) and a lower plate (12), made of transparent synthetic resin plates as shown in FIG. 3, are arranged to be stacked facing each other with a plurality of spacers (20) spaced apart from each other. The upper plate (11) and the lower plate (12) may be made of transparent synthetic resin plates such as polycarbonate or acrylic, and an exhaust hole (13) through which air is discharged may be formed in one of the upper plate (11) and the lower plate (12).

[0098] The above spacer (20) is interposed between the upper plate (11) and the lower plate (12) to support the upper plate (11) and the lower plate (12) so that a vacuum layer of uniform thickness is formed overall. As shown in FIG. 3, a plurality of spacers (20) formed in the shape of cylinders or polyhedra can be distributed and installed between the upper plate (11) and the lower plate (12).

[0099] Meanwhile, in order to stably suppress deformation of the upper plate (11) and lower plate (12), which are made of synthetic resin having relatively more flexible properties than glass, due to temperature changes or impacts, it is preferable that the spacer (20) be formed in a grid-like arrangement or a grid-like structure.

[0100] More specifically, the spacer (20) has a bar shape extending in the longitudinal or transverse direction as shown in FIG. 4, and a plurality of bar-shaped spacers (20) can be arranged to intersect each other to form a grid structure. This grid structure can be formed by arranging bar-shaped spacers (20) in a grid shape on the bottom plate (12), or by arranging spacers (20) that have been manufactured to have a grid structure in advance on the bottom plate (12). Depending on the embodiment, the spacers (20) arranged on the bottom plate (12) may be joined to the top plate (11) and the bottom plate (12) by partial fusion or bonding, but in the manufacturing process 10 2 to 10 -7 Since sufficient low pressure of Torr is formed, if sufficient pressure is provided in the vertical direction so that the spacer (20) does not move, it goes without saying that a separate bonding process can be omitted.

[0101] Meanwhile, in order for the air within the cell formed by the grid structure to flow freely to an adjacent cell, it is preferable that each spacer (20) be formed as a porous bar having a plurality of fine air holes.

[0102] The spacer (20) formed in this way can be manufactured using a transparent porous block in which numerous fine air holes are formed, or using a porous block in which transparent wires are intertwined to form numerous fine air holes.

[0103] The above spacer (20) may have a bar shape as shown in FIG. 5, and may be arranged such that a plurality of spacers (20) are parallel and an opening (22) is provided between adjacent spacers (20) to allow air flow. In this case, a vacuum layer that is continuous in a snake-like structure may be formed between the upper plate (11) and the lower plate (12).

[0104] In addition, as shown in FIG. 6, a ventilation hole (21) may be formed in the spacer (20), and the ventilation hole (21) allows air to flow through the spacer (20), thereby inducing a smoother airflow when discharging air to form a vacuum layer. Furthermore, if the exhaust hole (13) is formed above or below the spacer (20) so as to be connected to the ventilation hole (21), the self-destruction of the upper plate (11) and lower plate (12) caused by the exhaust hole (13) can be effectively suppressed.

[0105] The spacer (20) described above may be formed of a transparent synthetic resin, identical to the top plate (11) and bottom plate (12), for visibility.

[0106] The above edge joining step (S120) is a process of joining the edges of the upper plate (11) and lower plate (12) stacked facing each other with a spacer (20) in between so as to seal them. The edges of the upper plate (11) and lower plate (12) can be joined by a heat fusion process using a heater (30) as shown in FIGS. 7a and 7b, joined by an adhesive, joined by filling the edges of the upper plate (11) and lower plate (12) with a molten synthetic resin, or joined by heat fusion with an additional synthetic resin bar interposed in the edges of the upper plate (11) and lower plate (12) and melted.

[0107] Meanwhile, the heater (30) has a U-shaped structure to wrap around the edge of the top plate (11), the edge of the bottom plate (12), or the edges of the stacked top plate (11) and bottom plate (12), and after locally heating the edges of the top plate (11) and bottom plate (12) to a temperature close to the melting point, the edges of the top plate (11) and bottom plate (12) can be joined by thermal fusion by applying pressure so that the top plate (11) and bottom plate (12) are in close contact with each other.

[0108] In performing the edge bonding step (S120) using the heater (30) in this manner, the heater (30) is provided with an inner surface (31) that contacts the bonding surface of the upper plate (11) or the lower plate (12) so as to minimize damage to the upper plate (11) and the lower plate (12) caused by heat. It is preferable that the inner surface (31) be heated to a temperature of 130°C or higher and 150°C or lower to locally heat the bonding surface of the upper plate (11) or the lower plate (12), but depending on the embodiment, the edges of the upper plate (11) and the lower plate (12) may both be heated by the heater (30), or only one of the edges of the upper plate (11) or the lower plate (12) may be heated by the heater (30).

[0109] In addition, the edge joining step (S120) can be joined so that the edges of the top plate (11) and the bottom plate (12) are sealed using a sealing material (41) and a screw (42) as shown in FIG. 8.

[0110] That is, the upper plate (11) and lower plate (12) are formed with a groove (43) extending along the edge into which a sealing material (41) is inserted and installed, and a plurality of screw holes (44) into which screws (42) are fastened are formed spaced apart along the edge of the upper plate (11) and lower plate (12), so that the sealing material (41) installed in the groove (43) is pressed in by the fastening pressure of the screws (42), thereby sealing and joining the edges of the upper plate (11) and lower plate (12).

[0111] In addition, as shown in FIG. 9, a ring-shaped metal plate (60) extending along the edges of the upper plate (11) and lower plate (12) may be installed between the upper plate (11) and lower plate (12), and the metal plate (60) may be heated by high-frequency induction to heat the bonding surface of the upper plate (11) and lower plate (12) to a temperature close to the melting point, and then the edges of the upper plate (11) and lower plate (12) may be bonded by applying pressure so that the upper plate (11) and lower plate (12) are bonded in close contact with the metal plate (60). In this case, the bonding surface located at the edges of the upper plate (11) and lower plate (12) may be locally and rapidly heated to minimize heat damage to the upper plate (11) and lower plate (12), and since the metal plate (60) is positioned along the edges of the manufactured vacuum insulation panel, an additional effect of reinforcing the edges of the vacuum insulation panel may also be achieved.

[0112] Additionally, the edge bonding step (S130) may also bond the edges of the upper plate (11) and the lower plate (12) by chemical dissolution. That is, after applying a methylene chloride solution to the bonding surface located along the edges of the upper plate (11) and the lower plate (12), the upper plate (11) and the lower plate (12) are maintained so that the bonding surfaces of the upper plate (11) and the lower plate (12) face each other and adhere closely under conditions of room temperature and pressure. Then, the bonding surfaces of the upper plate (11) and the lower plate (12), which are made of synthetic resin (polycarbonate), are chemically dissolved by the methylene chloride solution and subsequently hardened. During this process, the molecules of the upper plate (11) and the lower plate (12) are bonded and integrated, thereby allowing the edges of the upper plate (11) and the lower plate (12) to be bonded.

[0113] The above vacuum layer formation step (S130) is a process of discharging air between the upper plate (11) and the lower plate (12) so that a vacuum layer is formed between the upper plate (11) and the lower plate (12). As shown in FIG. 10, a vacuum layer can be formed by connecting a vacuum pump (P) to the exhaust hole (13) formed in the upper plate (11) and discharging the air between the upper plate (11) and the lower plate (12) to the outside. After the desired vacuum pressure is formed between the upper plate (11) and the lower plate (12), the exhaust hole (13) is closed. At this time, the exhaust hole (13) can be closed in a structure that allows it to be opened and closed by fastening a bolt-type cap (51) with a thread formed on the inner surface of the exhaust hole (13) and a thread formed on the outer surface to the exhaust hole (13), or the exhaust hole (13) can be closed by heating and melting a connector installed in the exhaust hole (13) for connecting the vacuum pump (P).

[0114] Meanwhile, depending on the embodiment, as shown in FIG. 11, a valve-type cap (52) having a thread formed on the inner surface of the exhaust port (13) and a thread formed on the outer surface to be screw-coupled to the exhaust port (13) may be fastened to the exhaust port (13). The valve-type cap (52) may be equipped with an exhaust port (53) to which a syringe (S) is coupled so that a vacuum can be formed using only a vacuum pump (P) and a syringe (S) without large-scale equipment, and the exhaust port (53) may be formed as a valve structure so that it is automatically closed by the internal and external pressure difference of the vacuum insulation panel when the syringe (S) is removed.

[0115] Furthermore, a thin polycarbonate piece may be dissolved and bonded to the upper part of the valve-type cap (52) with methylene chloride to permanently seal the valve-type cap (52), and if necessary, the valve-type cap (52) may be reused to allow air to be added or removed by removing the polycarbonate piece attached to the valve-type cap (52).

[0116] This vacuum layer formation step (S130) is 10 2 to 10 -7After exhausting air to form a vacuum layer of Torr, the exhaust port (13) is closed to form a vacuum layer.

[0117] Meanwhile, the vacuum insulation panel of the present invention is composed of a synthetic resin such as polycarbonate, and a spacer (20) is provided between them so that there is no risk of spontaneous breakage due to vacuum pressure, thereby forming a high vacuum in the vacuum layer to maximize the thermal insulation performance of the vacuum insulation panel. The vacuum pressure of the vacuum layer is 10 2 to 10 -7 It can be formed in the range of Torr, but preferably the vacuum pressure of the vacuum layer is 10 -3 It can be implemented to have a high vacuum layer of Torr or less, and even when forming such a high vacuum layer, damage to the synthetic resin plate or edges can be prevented.

[0118] As described above, the vacuum insulation panel manufactured by the method for manufacturing a vacuum insulation panel using a visible synthetic resin according to the first embodiment of the present invention is a lightweight panel comprising an upper plate (11) and a lower plate (12) made of a relatively light synthetic resin, so it is easy to handle during the manufacturing and use process. In particular, the upper plate (11) and the lower plate (12) made of synthetic resin are organically combined with a porous spacer (20) that forms a grid-like structure, thereby preventing damage to the upper plate (11) and the lower plate (12) during the exhaust process for forming a vacuum layer, and thus a vacuum layer with a higher vacuum pressure can be realized, thereby maximizing the insulation performance of the vacuum insulation panel.

[0119] Therefore, the vacuum insulation panel of the present invention can be utilized as vacuum glass or vacuum insulation material used for overglaze or overglaze insulation, and can also be effectively used in cold storage equipment such as commercial freezers, refrigerators, and warming cabinets.

[0120]

[0121] A method for manufacturing a vacuum insulation panel using a synthetic resin having visibility according to the second embodiment of the present invention proceeds sequentially, including an upper and lower plate lamination step (S210) and a rim joining step (S220), as illustrated in FIG. 12.

[0122] The upper and lower plate stacking step (S210) described above is a process of arranging an upper plate (11) and a lower plate (12), made of transparent synthetic resin as shown in FIG. 13, within a vacuum chamber (C) so that they face each other with a plurality of spacers (20) in between. The upper plate (11) and the lower plate (12) are made of a transparent synthetic resin such as polycarbonate or acrylic. The spacers (20) may be formed in a cylindrical shape and installed in a plurality so as to be dispersed between the upper plate (11) and the lower plate (12), or may be formed in a bar shape and installed between the upper plate (11) and the lower plate (12) to form a grid structure. Unless otherwise specified, the upper plate (11), the lower plate (12), and the spacers (20) described below are the upper plate (11) and the lower plate (12) used in the upper and lower plate stacking step (S110) of the first embodiment. Since it is identical to the spacer (20), the same reference numeral is used, and a detailed description of its configuration is omitted.

[0123] The above edge joining step (S220) is a process of joining the edges of the upper plate (11) and the lower plate (12) placed inside the vacuum chamber (C) so as to seal them, and 10 inside the vacuum chamber (C) 2 to 10 -7In a state where a vacuum pressure of Torr is formed, the edges of the upper plate (11) and lower plate (12) can be heated with a heater (30) and then pressed to bond them together, thereby joining the edges of the upper plate (11) and lower plate (12). Of course, the edge joining step (S220) can be performed by pressing a sealing material (41) installed in the groove (43) into the upper plate (11) and lower plate (12) by the fastening pressure of a screw (42) to seal the edges of the upper plate (11) and lower plate (12), or by applying methylene chloride to the edges of the upper plate (11) and lower plate (12) to dissolve and join the edges of the upper plate (11) and lower plate (12).

[0124]

[0125] A method for manufacturing a vacuum insulation panel using a synthetic resin having visibility according to the third embodiment of the present invention has a major technical differentiation in that a plurality of protrusions (14) are integrally formed on the synthetic resin plate so that a space for forming a vacuum layer is secured by separating a pair of synthetic resin plates stacked facing each other, thereby providing excellent visibility, thermal insulation, and durability. As shown in FIG. 14, the method proceeds sequentially including a plate forming step (S310), an upper and lower plate stacking step (S320), an edge joining step (S330), and a vacuum layer forming step (S340).

[0126] The above-mentioned plate forming step (S310) is a process of forming a synthetic resin plate that constitutes the upper plate (11) and lower plate (12) of a vacuum insulation panel as shown in FIGS. 15 and 16. The synthetic resin plate may be made of a transparent synthetic resin such as polycarbonate or acrylic, and basically has a flat structure, and at least one of the synthetic resin plates constituting the upper plate (11) and lower plate (12) may have a plurality of protrusions (14) integrally formed thereon and an exhaust hole (13) through which air is discharged may be formed.

[0127] That is, as shown in FIG. 15, a plurality of protrusions (14) may be integrally formed only on the synthetic resin plate constituting the lower plate (12), or as shown in FIG. 16, a plurality of protrusions (14) may be integrally formed on both the upper plate (11) and the lower plate (12) constituting the synthetic resin plate.

[0128] As shown in FIGS. 15 to 17, the above protrusion (14) has a horn-shaped form that narrows toward the end, and a plurality of protrusions (14) having a horn-shaped form may be formed dispersed in the longitudinal and transverse directions. At this time, between the protrusions (14) adjacent in the longitudinal and transverse directions, a vacuum groove (15) having a dome-shaped curved surface is formed.

[0129] The vacuum groove (15) formed between the protrusions (14) having a horn-shaped form in this manner has an arch-shaped cross-sectional structure that disperses the load by combining a plurality of curved surfaces forming the surface of the surrounding protrusions (14) to bend into a dome shape. As a result, the load generated by vacuum pressure or external impact is dispersed rather than concentrated in a specific area, thereby effectively suppressing damage to the synthetic resin plate due to stress concentration. This allows the vacuum pressure of the vacuum layer formed between the upper plate (11) and the lower plate (12) to be increased, thereby further improving the thermal insulation performance of the vacuum insulation panel. The vacuum pressure of the vacuum layer is 10 2 to 10 -7 It can be formed in the range of Torr, but preferably the vacuum pressure of the vacuum layer is 10 -3 It can be implemented to have a high vacuum layer of Torr or less, and even when forming such a high vacuum layer, damage to the synthetic resin plate or edges can be prevented.

[0130] Additionally, as shown in FIG. 18, the protrusion (14) may have a cross-section in the shape of a horn that narrows toward the end, extends long in the longitudinal direction, and is formed to be spaced apart in the transverse direction. At this time, between adjacent protrusions (14), a vacuum groove (15) is extended in the longitudinal direction to form a groove (16), and one or more connecting grooves (17) may be formed in each protrusion (14) to enable air flow between the grooves (16).

[0131] Meanwhile, it is preferable that the above-mentioned bone portion (16) be formed to have a tunnel-shaped curved surface and to suppress damage to the synthetic resin plate due to stress concentration based on an arch-shaped cross-sectional structure.

[0132] The upper and lower plate stacking step (S320) is a process of stacking an upper plate (11) and a lower plate (12) made of transparent synthetic resin plates so that they face each other, and the upper plate (11) and the lower plate (12) are stacked such that a space for forming a vacuum layer between them is naturally provided by the protrusion (14), as shown in FIGS. 15 and 16.

[0133] Meanwhile, when stacking an upper plate (11) and a lower plate (12) made of a synthetic resin plate with a protrusion (14) formed integrally, it is preferable to arrange and stack the upper plate (11) and the lower plate (12) so that the protrusions (14) of the upper plate (11) and the lower plate (12) come into contact at corresponding positions as shown in FIG. 16.

[0134] The above edge joining step (S330) is a process of joining the edges of an upper plate (11) and a lower plate (12) stacked facing each other with a protrusion (14) in between so as to seal them. The edges of the upper plate (11) and the lower plate (12) may be joined by a heat fusion process using a heater (30) as shown in FIG. 19 and FIG. 20, joined by an adhesive, joined by filling the edges of the upper plate (11) and the lower plate (12) with a molten synthetic resin, joined by heat fusion with an additional synthetic resin bar interposed in the edges of the upper plate (11) and the lower plate (12), joined by sealing the edges of the upper plate (11) and the lower plate (12) using a sealing material (41) and a screw (42) as shown in FIG. 21, or joined by a ring-shaped metal plate (60) extending along the edges of the upper plate (11) and the lower plate (12) as shown in FIG. 22. The upper plate (11) and the lower plate (12) may be joined by high-frequency induction heating, or may be joined by applying a methylene chloride solution to the surface of the joint located along the edges of the upper plate (11) and the lower plate (12). Since such an edge joining step (S330) can be performed in the same way as the edge joining step (S130), a more detailed description is omitted.

[0135] The above vacuum layer formation step (S340) is a process of discharging air between the upper plate (11) and the lower plate (12) so that a vacuum layer is formed between the upper plate (11) and the lower plate (12). As shown in FIG. 23, a vacuum layer can be formed by connecting a vacuum pump (P) to the exhaust port (13) to discharge air between the upper plate (11) and the lower plate (12) to the outside. After the vacuum layer is formed, the exhaust port (13) can be closed in a structure that can be opened and closed by a bolt-type cap (51), closed by heating and melting a connector installed in the exhaust port (13), automatically closed by a valve-type cap (52) having an exhaust port (53) that is screw-coupled to the exhaust port (13) and to which a syringe (S) is coupled, as shown in FIG. 24, or closed by attaching a thin polycarbonate piece to the upper part of the valve-type cap (52). Such a vacuum layer formation step (S340) is the vacuum layer Since it can be carried out in the same way as the formation step (S130), a more detailed explanation is omitted.

[0136] This vacuum layer formation step (S340) is 10 2 to 10 -7 After exhausting air to form a vacuum layer of Torr, the exhaust port (13) is closed to form the vacuum layer. At this time, the upper plate (11) and the lower plate (12) are heat-fused by a heater (30) so that a bonding surface having a predetermined area is formed along the edge, and each protrusion (14) is spaced apart at equal intervals, so that the vacuum pressure is dispersed in all directions during the process of forming the vacuum layer, thereby preventing deformation of the edge or specific vulnerable parts.

[0137] As such, the vacuum insulation panel of the third embodiment is composed of a synthetic resin such as polycarbonate, and the protrusion (14) and the vacuum groove (15) formed between them are formed with a curved structure to prevent stress concentration, so there is no risk of spontaneous breakage due to vacuum pressure, and thus the vacuum layer can be formed as a high vacuum to maximize the insulation performance of the vacuum insulation panel.

[0138] Meanwhile, the vacuum insulation panel manufactured by the method for manufacturing a vacuum insulation panel using a synthetic resin with improved visibility according to the present embodiment is a lightweight panel comprising an upper plate (11) and a lower plate (12) made of a relatively light synthetic resin, so it is easy to handle during the manufacturing and use process, and in particular, since a protrusion (14) is integrally formed on the synthetic resin plate material forming the upper plate (11) or the lower plate (12), a spacer (20) to secure space between the upper plate (11) and the lower plate (12) is not required, thus improving the visibility of the vacuum insulation panel, and the vacuum groove (15) formed between the protrusion (14) and the protrusion is formed with a curved structure to prevent stress concentration, so that the upper plate (11) or the lower plate (12) can be effectively prevented from being damaged by vacuum pressure or impact based on an arched cross-sectional structure.

[0139]

[0140] The method for manufacturing a vacuum insulation panel using a synthetic resin with improved visibility according to the fourth embodiment of the present invention is an embodiment using a synthetic resin panel having a protrusion (14) formed integrally and a vacuum chamber (C), and as shown in FIG. 25, the process proceeds sequentially including a plate forming step (S410), an upper and lower plate stacking step (S420), and an edge joining step (S430).

[0141] The above-mentioned plate forming step (4210) is a process for forming a synthetic resin plate that constitutes the upper plate (11) and lower plate (12) of a vacuum insulation panel. The synthetic resin plate that constitutes the upper plate (11) and lower plate (12) is manufactured using a transparent synthetic resin such as polycarbonate or acrylic, and the synthetic resin plate is manufactured such that a plurality of protrusions (14) are integrally formed on at least one of the synthetic resin plates that constitute the upper plate (11) and lower plate (12).

[0142] Since such a sheet metal forming step (S410) can be performed in the same way as the sheet metal forming step (S310), a more detailed explanation thereof is omitted.

[0143] The above upper and lower plate stacking step (S420) is a process of arranging an upper plate (11) and a lower plate (12), which are made of transparent synthetic resin plates as shown in FIG. 26, in a vacuum chamber (C) so that they face each other with a protrusion (14) in between. The upper plate (11) and the lower plate (12) are stacked in the vacuum chamber (C) so that the end of the protrusion (14) integrally formed on the lower plate (12) is in close contact with the flat bottom surface of the upper plate (11), or the upper plate (11) and the lower plate (12) are stacked in the vacuum chamber (C) so that the end of the protrusion (14) integrally formed on the lower plate (12) faces and is in close contact with the end of the protrusion (14) integrally formed on the upper plate (11).

[0144] The above edge joining step (S420) is a process of joining the edges of the upper plate (11) and the lower plate (12) placed inside the vacuum chamber (C) so as to seal them, and 10 inside the vacuum chamber (C) 2 to 10 -7 In a state where a vacuum pressure of Torr is formed, the edges of the upper plate (11) and lower plate (12) can be heated by a heater (30) and then pressed to bond them together. In the edge bonding step (S420), the sealing material (41) installed in the groove (43) can be pressed in by the fastening pressure of the screw (42) to seal the edges of the upper plate (11) and lower plate (12), and it is also possible to melt and bond the edges of the upper plate (11) and lower plate (12) by applying methylene chloride to the edges of the upper plate (11) and lower plate (12).

[0145]

[0146] An overlay window (100) using a vacuum insulation panel according to the fifth embodiment of the present invention is additionally mounted on the inner or outer side of an existing window (W) as shown in FIGS. 27 and 28 to supplement the thermal insulation performance of the existing window (W), and includes a window frame (110) and a vacuum insulation panel (120).

[0147] The above window frame (110) supports a vacuum insulation panel (120) and can be attached to an existing window (W) by means of a detachable means (130). At this time, the detachable means (130) may be provided in the form of a magnet or Velcro tape, and depending on the embodiment, the window frame (110) may be attached to and fixed to an existing window (W) by means of double-sided tape.

[0148] Such a window frame (110) can be installed to wrap around and finish the two opposing sides or the entire perimeter of the vacuum insulation panel (120), and can be formed from various materials such as metal or synthetic resin.

[0149] The above vacuum insulation panel (120) is constructed using a transparent synthetic resin plate such as polycarbonate or acrylic, which has transparent optical properties like glass and can flexibly respond to temperature changes and impacts. An upper plate (11) and a lower plate (12) made of transparent synthetic resin plates are stacked so that a space is provided between them at a predetermined interval, and the edges of the upper plate (11) and the lower plate (12) are joined to be sealed in order to form a vacuum layer having a predetermined vacuum pressure between the upper plate (11) and the lower plate (12).

[0150] Such a vacuum insulation panel (120) is manufactured by a method for manufacturing a vacuum insulation panel using a synthetic resin having the above visibility, and a spacer (20) is installed between the top plate (11) and the bottom plate (12), and an exhaust hole (13) can be formed in the top plate (11) or the bottom plate (12).

[0151] Additionally, as shown in FIG. 29, a plurality of spacers (20) formed in the shape of cylinders or polyhedra may be distributed and installed between the upper plate (11) and the lower plate (12).

[0152] Additionally, the spacer (20) may be formed in a grid arrangement or grid structure as shown in FIG. 30.

[0153] In addition, in order for the air within the cell formed by the grid structure to flow freely into an adjacent cell, it is preferable that each spacer (20) be formed as a porous bar having a plurality of fine air holes, and the spacer (20) formed as a porous bar can be manufactured using a transparent porous block having numerous fine air holes formed therein, or can be manufactured using a porous block in which transparent wires are intertwined to form a plurality of fine air holes.

[0154] Additionally, the spacer (20) may have a bar shape as shown in FIG. 5, and may be arranged so that a plurality of spacers (20) are parallel and an opening (22) is provided between adjacent spacers (20) to allow air flow, thereby forming a continuous vacuum layer in a cylindrical structure between the upper plate (11) and the lower plate (12).

[0155] Of course, a protrusion (14) replacing the spacer (20) can be integrally formed on at least one of the top plate (11) and the bottom plate (12).

[0156] That is, as shown in FIG. 31, a plurality of protrusions (14) may be integrally formed on the synthetic resin plate constituting the lower plate (12), or as shown in FIG. 32, a plurality of protrusions (14) may be integrally formed on both the upper plate (11) and the lower plate (12).

[0157] As previously described, the protrusion (14) has a horn-shaped form that narrows toward the end, and a plurality of protrusions (14) having a horn-shaped form may be formed in a distributed manner in the longitudinal and transverse directions. At this time, a vacuum groove (15) having a dome-shaped curved surface is formed between the protrusions (14) adjacent in the longitudinal and transverse directions.

[0158] Additionally, as shown in FIG. 33, the protrusion (14) has a cross-section in the shape of a horn that narrows toward the end, extends long in the longitudinal direction, and is spaced apart in the transverse direction so that a groove (16) is formed between them, and one or more connecting grooves (17) may be formed in each protrusion (14). At this time, it is preferable that the groove (16) be formed to have a tunnel-shaped curved surface to suppress damage to the synthetic resin plate due to stress concentration.

[0159]

[0160] The method for manufacturing an overlay window (100) according to the 6th embodiment of the present invention, which manufactures an overlay window (100) as described above, involves manufacturing the overlay window (100) using a vacuum insulation panel (120) made of synthetic resin, and proceeds sequentially including an upper and lower plate stacking step (S510), a rim joining step (S520), a vacuum layer forming step (S530), and a window frame joining step (S540), as shown in FIG. 34.

[0161] The above upper and lower plate stacking step (S510) is a process of stacking the upper plate (11) and the lower plate (12) so that a space is provided between the upper plate (11) and the lower plate (12). As shown in FIGS. 3 and 4, the upper plate (11) and the lower plate (12) may be arranged to be stacked facing each other with a plurality of spacers (20) in between, or as shown in FIGS. 15 and 16, the upper plate (11) and the lower plate (12) may be stacked so that a space for forming a vacuum layer is provided between them by a protrusion (14). Since this upper and lower plate stacking step (S510) can be performed by stacking the upper and lower plates (11)(12) in an atmospheric environment, just like the previously described upper and lower plate stacking step (S110) and upper and lower plate stacking step (S320), or by stacking the upper and lower plates (11)(12) in a vacuum chamber (C), just like the upper and lower plate stacking step (S210) and upper and lower plate stacking step (S420), a more detailed description is omitted.

[0162] The above edge joining step (S520) is a process of joining the edges of the upper plate (11) and lower plate (12), which are stacked with a space between them, so that the edges are sealed. The edges of the upper plate (11) and lower plate (12) may be joined by a heat fusion process using a heater (30) as shown in FIGS. 7a and 7b, joined by an adhesive, joined by filling the edges of the upper plate (11) and lower plate (12) with a molten synthetic resin, joined by heat fusion with an additional synthetic resin bar interposed in the edges of the upper plate (11) and lower plate (12), joined by a sealing material (41) and a screw (42) as shown in FIGS. 8 and 21, or joined by a ring-shaped metal plate (60) extending along the edges of the upper plate (11) and lower plate (12) as shown in FIGS. 9 and 22 The upper plate (11) and the lower plate (12) may be joined by high-frequency induction heating, or may be joined by applying a methylene chloride solution to the surface of the joint located along the edges of the upper plate (11) and the lower plate (12). Since such an edge joining step (S330) can be performed in the same way as the edge joining step (S130), a more detailed description is omitted.

[0163] The above vacuum layer formation step (S530) is a process of discharging air between the upper plate (11) and the lower plate (12) so that a vacuum layer is formed between the upper plate (11) and the lower plate (12). As shown in FIG. 10 and FIG. 23, a vacuum layer can be formed by connecting a vacuum pump (P) to the exhaust port (13) to discharge air between the upper plate (11) and the lower plate (12) to the outside. After the vacuum layer is formed, the exhaust port (13) can be closed in a structure that can be opened and closed by a bolt-type cap (51), closed by heating and melting a connector installed in the exhaust port (13), automatically closed by a valve-type cap (52) having an exhaust port (53) that is screw-coupled to the exhaust port (13) and to which a syringe (S) is coupled, as shown in FIG. 24, or closed by attaching a thin polycarbonate piece to the upper part of the valve-type cap (52). Such a vacuum layer formation step (S340) is the vacuum layer Since it can be carried out in the same way as the formation step (S130), a more detailed explanation is omitted.

[0164] The above window frame joining step (S140) is a process of installing a window frame (110) around the perimeter of a manufactured vacuum insulation panel (120), wherein the window frame (110) is installed to surround the joint on two opposing sides or the entire perimeter of the vacuum insulation panel (120), thereby manufacturing an overlay window (100) using the vacuum insulation panel (120).

[0165]

[0166] The method of constructing an insulating door (200) according to the 7th embodiment of the present invention utilizes an insulating door (200) manufactured such that a vacuum layer is provided between an upper plate (11) and a lower plate (12) made of synthetic resin plates, as shown in FIGS. 35 and 36, and the energy consumption efficiency of the building can be improved by additionally installing the insulating door (200) on a fire door (F).

[0167] Meanwhile, the above-mentioned insulating shutter (200) is formed by stacking an upper plate (11) and a lower plate (12) made of synthetic resin sheet material so that they are spaced apart at a predetermined interval to provide a space between them, and the edges of the upper plate (11) and the lower plate (12) are sealed and joined so that a vacuum layer can be formed in the space, and in the space 10 2 to 10 -7 A vacuum layer of Torr is formed.

[0168] The insulating door (200) of this type can be manufactured through the upper and lower plate stacking step (S110), the edge joining step (S120) and the vacuum layer forming step (S130), or the upper and lower plate stacking step (S210) to the edge joining step (S220), just like the vacuum insulating panel (120) described above. However, the upper plate (11) and the lower plate (12) constituting the insulating door (200) may also be made of non-transparent synthetic resin plates, and the upper plate (11) and the lower plate (12) may be stacked so as to face each other with a spacer (20) or a protrusion (14) in between.

[0169] The insulating door (200) manufactured in the manner described above can be cut to correspond to the shape of the existing fire door (F), and then attached and fixed to the existing fire door (F) by means of fastening means such as magnets, Velcro tape, double-sided tape, or screws (42) to improve the thermal insulation performance of the existing fire door (F).

[0170] Meanwhile, the cutting work of the insulating shutter (200) can be carried out at a manufacturing plant or a construction site, and the cutting part is sealed with heat fusion or a sealing material to suppress the inflow of air through the cutting part, and air is discharged through the exhaust hole (13) formed in the top plate (11) or bottom plate (12) 10 2 to 10 -7 After forming a vacuum layer of Torr, the vacuum lost due to the cutting can be restored by closing the exhaust port (13) again.

[0171]

[0172] A person skilled in the art will understand that the method for manufacturing a vacuum insulation panel using a visible synthetic resin according to the present invention, the vacuum insulation panel manufactured thereby, the window and door using the same, the method for manufacturing the same, and the method for installing an insulation door, as described above, can be implemented in other specific forms without changing the technical concept or essential features of the present invention.

[0173] Therefore, the embodiments described above should be understood as illustrative in all respects and not limiting, and the scope of the invention is defined by the claims set forth below rather than by the foregoing detailed description, and all modifications or variations derived from the meaning and scope of the claims and equivalents should be interpreted as being included within the scope of the invention.

[0174] The present invention comprises a method for manufacturing a vacuum insulation panel utilizing a visible synthetic resin, comprising: a step of stacking upper and lower plates made of transparent synthetic resin by providing a plurality of spacers spaced apart from each other between the upper and lower plates to create a space between the upper and lower plates; a step of joining the edges of the upper and lower plates to seal the space; and a step of forming a vacuum layer by discharging air between the upper and lower plates through an exhaust hole formed in the upper or lower plate and closing the exhaust hole so that a vacuum layer is formed in the space between the upper and lower plates.

[0175] The top and bottom plates, made of synthetic resins such as polycarbonate with high visibility, have significantly lower thermal conductivity than glass, thereby significantly improving the thermal insulation performance of vacuum insulation panels. When used as doors for commercial refrigerators, condensation caused by temperature differences does not occur on the outer surface, providing a user environment where items stored inside can be easily checked without opening the door. Therefore, there is industrial applicability, as they can be used not only in cold storage equipment such as commercial freezers, refrigerators, and warmers, but also in additional glass or additional insulation.

Claims

1. A stacking step (S110) of upper and lower plates made of transparent synthetic resin, wherein a plurality of spacers (20) spaced apart from each other are provided between the upper plate (11) and the lower plate (12) to form a space between the upper plate (11) and the lower plate (12); A rim joining step (S120) for joining the rims of the upper plate (11) and lower plate (12) to seal the space; and A vacuum layer forming step (S130) of discharging air between the upper plate (11) and the lower plate (12) through an exhaust hole (13) formed in the upper plate (11) or the lower plate (12) so as to form a vacuum layer in the space between the upper plate (11) and the lower plate (12), and closing the exhaust hole (13); A method for manufacturing a vacuum insulation panel using a synthetic resin having visibility, characterized by including 2. A step of stacking upper and lower plates (S210) in which a plurality of spacers (20) spaced apart from each other are provided between an upper plate (11) and a lower plate (12) made of transparent synthetic resin within a vacuum chamber (C) so that a space is provided between the upper plate (11) and the lower plate (12); and A rim joining step (S220) that joins the rims of the upper plate (11) and lower plate (12) to seal the space; A method for manufacturing a vacuum insulation panel using a synthetic resin having visibility, characterized by including 3. A method for manufacturing a vacuum insulation panel (120) in which a vacuum layer is formed between an upper plate (11) and a lower plate (12) made of a transparent synthetic resin plate, A plate forming step (S310) of forming a synthetic resin plate such that at least one of the synthetic resin plates forming the upper plate (11) and lower plate (12) has a plurality of protrusions (14) spaced apart from each other integrally formed thereon; An upper and lower plate stacking step (S320) of stacking the upper plate (11) and the lower plate (12) so that a space is provided between the upper plate (11) and the lower plate (12) by means of a protrusion (14); A rim joining step (S330) for joining the rims of the upper plate (11) and lower plate (12) to seal the space; and A vacuum layer formation step (S340) in which air between the upper plate (11) and the lower plate (12) is discharged through an exhaust hole (13) formed in the upper plate (11) or the lower plate (12) so as to form a vacuum layer in the space between the upper plate (11) and the lower plate (12), and the exhaust hole (13) is closed; A method for manufacturing a vacuum insulation panel using a synthetic resin having visibility, characterized by including 4. A method for manufacturing a vacuum insulation panel (120) in which a vacuum layer is formed between an upper plate (11) and a lower plate (12) made of a transparent synthetic resin plate, A plate forming step (S410) of forming a synthetic resin plate such that at least one of the synthetic resin plates forming the upper plate (11) and lower plate (12) has a plurality of protrusions (14) spaced apart from each other integrally formed thereon; Upper and lower plate stacking step (S420) of stacking the upper plate (11) and the lower plate (12) in a vacuum chamber (C) such that a space is provided between the upper plate (11) and the lower plate (12) by means of a protrusion (14); A rim joining step (S430) that joins the rims of the upper plate (11) and lower plate (12) to seal the space; A method for manufacturing a vacuum insulation panel using a synthetic resin having visibility, characterized by including 5. In any one of paragraphs 1 through 4, The above edge joining steps (S120)(S220)(S330)(S430) are, A method for manufacturing a vacuum insulation panel using a synthetic resin having visibility, characterized by heat-fusing the edges of the upper plate (11) and lower plate (12) using a heater (30).

6. In Paragraph 5, A method for manufacturing a vacuum insulation panel using a synthetic resin having visibility, characterized in that the heater (30) has a U-shaped structure to surround the edge of the top plate (11) or bottom plate (12), and one inner surface (31) that contacts the top plate (11) or bottom plate (12) is heated to a temperature of 130°C or higher and 150°C or lower.

7. In any one of paragraphs 1 through 4, The above edge joining steps (S120)(S220)(S330)(S430) are, A groove (43) is formed along the edge of the upper plate (11) or lower plate (12), and a sealing material (41) is inserted into the groove (43). A method for manufacturing a vacuum insulation panel using a synthetic resin having visibility, characterized by fastening a screw (42) into a screw hole (44) formed along the edge of the top plate (11) and the bottom plate (12) to press a sealing material (41) between the top plate (11) and the bottom plate (12).

8. In any one of paragraphs 1 through 4, The above edge joining steps (S120)(S220)(S330)(S430) are, A method for manufacturing a vacuum insulation panel using a visible synthetic resin, characterized by applying a methylene chloride solution to the edges of the upper plate (11) and lower plate (12) and maintaining the joint surfaces of the upper plate (11) and lower plate (12) in close contact under conditions of room temperature and pressure, thereby joining the edges so that they become an integral unit.

9. In any one of paragraphs 1 through 4, The above edge joining steps (S120)(S220)(S330)(S430) are, A method for manufacturing a vacuum insulation panel using a synthetic resin having visibility, characterized in that a ring-shaped metal plate (60) extending along the edges of the upper plate (11) and lower plate (12) is installed between the upper plate (11) and lower plate (12) so as to be positioned at the joint, and the metal plate (60) is heated by high-frequency induction to be joined to the upper plate (11) and lower plate (12).

10. In Paragraph 1 or 3, A method for manufacturing a vacuum insulation panel using a synthetic resin having visibility, characterized in that a thread is formed on the inner surface of an exhaust hole (13) formed in the upper plate (11) or lower plate (12), and a bolt-type cap (51) having a thread formed on the outer surface is fastened to the exhaust hole (13).

11. In Paragraph 1 or 3, A method for manufacturing a vacuum insulation panel using a synthetic resin having visibility, wherein an exhaust hole (13) formed in the upper plate (11) or lower plate (12) is provided with a valve-type cap (52), and the valve-type cap (52) is provided with an exhaust port (53) to which a syringe (S) is coupled, wherein the exhaust port (53) is automatically closed by the internal and external pressure difference of the vacuum insulation panel (120) when the syringe (S) is removed.

12. In Paragraph 1 or 2, A method for manufacturing a vacuum insulation panel using a synthetic resin having visibility, characterized in that a ventilation hole (21) is formed in the spacer (20) to allow air flow.

13. In Paragraph 12, A method for manufacturing a vacuum insulation panel using a synthetic resin having visibility, characterized in that the above spacer (20) is made of a porous bar having a plurality of fine air holes, and a plurality of spacers (20) are arranged in a grid shape.

14. In Paragraph 1 or 2, A method for manufacturing a vacuum insulation panel using a synthetic resin having visibility, characterized in that the above spacer (20) is formed in the shape of a bar of the same synthetic resin as the upper and lower plates (11)(12), and is arranged so that an opening (22) is provided between adjacent spacers (20) to allow air flow.

15. In Paragraph 3 or 4, A method for manufacturing a vacuum insulation panel using a synthetic resin having visibility, characterized in that the above-mentioned protrusion (14) has a horn-shaped form that narrows toward the end.

16. In Paragraph 15, A method for manufacturing a vacuum insulation panel using a synthetic resin having visibility, characterized in that the above-mentioned protrusions (14) have a vacuum groove (15) formed between adjacent protrusions (14) to have a dome-shaped curved surface.

17. In Paragraph 3 or 4, A method for manufacturing a vacuum insulation panel using a synthetic resin having visibility, characterized in that the above-mentioned protrusions (14) are formed to extend in one direction, and a groove (16) extending in one direction is formed between adjacent protrusions (14), and a connecting groove (17) is formed in each protrusion (14) to allow air flow to the adjacent groove (16).

18. In Paragraph 17, A method for manufacturing a vacuum insulation panel using a synthetic resin having visibility, characterized in that the above-mentioned bone portion (16) has a tunnel-shaped curved surface.

19. In Paragraph 3 or 4, The upper plate (11) and lower plate (12) are each synthetic resin plates in which a protrusion (14) is integrally formed. A method for manufacturing a vacuum insulation panel using a synthetic resin having visibility, characterized in that the upper and lower plate stacking steps (S320) (S420) are arranged so that the protrusions (14) of the upper plate (11) and the lower plate (12) come into contact with each other at corresponding positions.

20. A vacuum insulation panel characterized by being manufactured by a method for manufacturing a vacuum insulation panel using a synthetic resin having the visibility of any one of claims 1 to 19.

21. This relates to an additional window (100) that is additionally installed on an existing window (W) to improve building energy consumption efficiency, A window frame (110) that is detachably installed on an existing window (W) by means of a detachable means (130); and A vacuum insulation panel (120) formed by a transparent synthetic resin plate, wherein an upper plate (11) and a lower plate (12) are stacked at a predetermined distance to provide a space, a vacuum layer is formed in the space between the upper plate (11) and the lower plate (12), and a joint is formed so as to seal the edges of the upper plate (11) and the lower plate (12) and is joined to a window frame (110); A window frame using a vacuum insulation panel characterized by including 22. In Paragraph 21, A window frame using a vacuum insulation panel, characterized in that the above joint is formed by heat-fusing the edges of the top plate (11) and the bottom plate (12) with a heater (30).

23. A method for manufacturing an additional window (100) that is additionally installed on an existing window (W) to improve building energy consumption efficiency, An upper and lower plate stacking step (S510) in which an upper plate (11) and a lower plate (12) made of transparent synthetic resin are stacked so that a space is provided by being spaced apart at a predetermined interval; A rim joining step (S520) that joins the rims of the upper plate (11) and lower plate (12) to seal the space; A vacuum layer forming step (S530) of discharging air between the upper plate (11) and the lower plate (12) through an exhaust hole (13) formed in the upper plate (11) or the lower plate (12) so as to form a vacuum layer in the space between the upper plate (11) and the lower plate (12), and closing the exhaust hole (13); and A window frame joining step (S540) for joining the window frame (110) to surround the joint; A method for manufacturing a window frame with a padding, characterized by including 24. A method for installing an insulating additional door (200) to be additionally installed on an existing fire door (F) to improve building energy consumption efficiency, The above-described insulating door (200) is formed by stacking an upper plate (11) and a lower plate (12) made of synthetic resin plates so that a space is provided by being spaced apart at a predetermined interval, a vacuum layer is formed in the space between the upper plate (11) and the lower plate (12), and a joint is formed so that the edges of the upper plate (11) and the lower plate (12) are sealed. A method for constructing an insulating door, characterized by cutting the insulating door (200) to correspond to the shape of the existing fire door (F) and attaching it to the existing fire door (F) using a fastening means.

25. In Paragraph 24, After cutting the above-mentioned insulating shutter (200), A method for constructing an insulating shutter, characterized by sealing the cut portion to suppress the inflow of air through the cut portion, exhausting air through the exhaust hole (13) formed during the manufacturing process of the top plate (11) or bottom plate (12), and then closing the exhaust hole (13) to restore the vacuum layer.

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