Breathable Inner Bag Vacuum Insulation for Glass Wool Handling
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Solution Overview
Problem
Existing methods for manufacturing vacuum insulation materials using glass wool face challenges such as deformation, high equipment costs, and reduced thermal performance due to the need for high-temperature processing or the use of binders, as well as difficulties in handling and inserting thick glass wool into cover materials.
Innovation Solution
A method involving the use of a binder-free pure glass wool core material dried and molded in a vacuum chamber, combined with an air-permeable inner bag and a cover material coated with a vinyl-based resin for improved gas barrier and moisture absorption, along with a getter for enhanced moisture management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If glass wool is heated to glass transition temperature and compressed, then compression can be achieved, but high equipment costs and deformation occur
Solution Approach 1:
The patent changes the temperature parameter from high temperature (500°C or more) to low temperature compression, eliminating the need for expensive drying ovens while achieving effective compression of glass wool without deformation
Solution Approach 2:
The patent removes the binder component from the glass wool composition, extracting the problematic element that caused deformation at high temperatures while maintaining compression capability through pure physical compression of binder-free glass wool
2Productivity
If binder is used to promote coupling between fibers, then compression efficiency improves, but thermal capabilities deteriorate
Solution Approach 1:
The patent extracts and removes the binder from the glass wool composition, eliminating the source of thermal capability deterioration while maintaining compression efficiency through optimized physical compression methods and vacuum packing
3Reliability
If thick glass wool material is used, then insulation performance improves, but handling and insertion difficulty increase
Solution Approach 1:
The patent uses nested packaging where glass wool is first enclosed in an inner bag, then the entire assembly is placed within a cover material, enabling easy handling and insertion of thick insulation material while maintaining its insulating properties
Solution Approach 2:
The patent segments the packaging system into distinct components (inner bag and cover material), allowing the thick glass wool to be handled as a modular unit that is easy to insert while maintaining insulation performance
4Ease of manufacture
If glass wool fibers contact film layers, then insertion is simple, but cover material damage occurs
Solution Approach 1:
The patent introduces an inner bag as an intermediary layer between the glass wool fibers and the cover material film, allowing simple insertion while preventing direct contact that would cause damage to the cover material
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach simplifies the manufacturing process, prevents glass wool deformation, reduces equipment costs, and maintains excellent thermal performance while allowing for the reuse of glass wool, resulting in efficient and cost-effective production of vacuum insulation materials with improved durability.
Implementation Method 1
a method involving the use of a binder-free pure glass wool core material dried and molded in a vacuum chamber
Implementation Method 2
a cover material coated with a vinyl-based resin for improved gas barrier and moisture absorption
Implementation Method 3
along with a getter for enhanced moisture management
Data Source
AI summary
The present invention relates to a vacuum insulation material including an inner bag and to a method for manufacturing same. The method for manufacturing the vacuum insulation material includes: a step of manufacturing a core material; a step of compressing and packing the entire surface of the core material using an inner bag made of a breathable film material; a step of disposing a getter on the upper portion of the inner bag; and a step of vacuum-packing a covering material on the upper portion of the inner bag. The inner bag is made of polypropylene (PP), polyester (PET), and/or polyethylene. Since the inner bag is manufactured using a breathable film having fine holes, the method for manufacturing the vacuum insulation material may have improved efficiency, and the vacuum insulation material may be improved in terms of the long-term durability and vacuum insulation properties thereof.