Foil-wrapped vacuum insulation element
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Solution Overview
Problem
The production of vacuum insulation bodies faces challenges with particles being dislodged from the core during evacuation, contaminating sealing seams and damaging evacuation equipment, and existing solutions like using a fleece are complex and inefficient, especially for powdered core materials.
Innovation Solution
A film-covered vacuum insulation body using cellulose-containing paper or cardboard materials with specific grammage ranges and structural features, such as multiple layers and corrugated designs, to retain particles and provide thermal insulation, allowing for machine-based production and efficient evacuation without particle contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a nonwoven fabric is used to encase the core during evacuation, then particle retention is improved, but manufacturing complexity increases and machine-based production becomes difficult
Solution Approach 1:
The patent changes the material parameter from nonwoven fabric to paper-based materials (paper, cardboard, corrugated board) with specific grammage ranges (15-200 g/m²). This parameter change maintains particle retention functionality while enabling machine-based production through standard paper processing techniques like cutting, folding, and gluing.
Solution Approach 2:
The patent employs disposable paper-based encasement structures that are simple to manufacture and discard after use. These paper elements serve their particle retention purpose during evacuation and can be easily replaced, simplifying the overall manufacturing process compared to reusable or complex fabric encasements.
2Reliability
If the core is evacuated to remove air for thermal insulation, then thermal insulation performance is improved, but particles are dislodged and contaminate sealing seams and damage equipment
Solution Approach 1:
The patent introduces paper-based encasement structures (paper bags, cardboard boxes, corrugated board containers) as intermediary elements between the core and the external environment. These intermediaries contain the core particles during evacuation, allowing the vacuum to be achieved for thermal insulation while preventing particle dislodgment and contamination of sealing seams and equipment.
Solution Approach 2:
The patent applies particle retention features locally at the core enclosure level rather than requiring global system modifications. The paper-based structures provide localized particle containment exactly where needed (around the core), enabling effective evacuation without affecting the overall system complexity or introducing widespread contamination risks.
3Ease of manufacture
If paper or cardboard materials are used to encase the core, then manufacturing simplicity and machine-based production are improved, but particle retention effectiveness must be maintained
Solution Approach 1:
The patent specifies precise parameter ranges for paper-based materials, including grammage (15-200 g/m²), layer structure (single or multiple layers), and structural configurations (flat, corrugated, folded). These parameter specifications ensure that the simple paper-based encasements maintain sufficient mechanical strength and particle retention effectiveness while enabling easy machine-based production through standard paper processing methods.
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
The solution enables reliable particle retention, simplified production, and effective thermal insulation with reduced material weight and thickness, while maintaining the structural integrity and stability of the insulation panel.
Implementation Method 1
Their functionality is based on the presence of open, i.e., interconnected, pores within the core material supporting the outer shell. These pores are evacuated during manufacturing. Therefore, heat cannot be transported within these pores by either conduction or convection.
Implementation Method 2
The result is extremely good thermal insulation, allowing such vacuum insulation panels to achieve the same thermal insulation properties as conventional insulation boards, requiring only about one-tenth the thickness.
Data Source
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AI summary
The invention relates to a foil-wrapped vacuum insulation element that comprises a core and an air-tight shell surrounding said core, one or more additional layers consisting of paper, card and/or paperboard being provided between said core and shell, and these layers completely enveloping the core, preferably to make it powder-tight.