3D Metallic Vacuum Insulation Piece for Durable Thermal Barriers
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Solution Overview
Problem
Existing thermal management solutions for vacuum insulated panels, particularly in harsh environments like the naval and automotive fields, face challenges in durability and longevity due to restrictive manufacturing processes that do not guarantee multi-decade reliability under severe thermal, chemical, and mechanical stresses.
Innovation Solution
A manufacturing process for thermal insulation parts under controlled atmosphere involves forming double-walled metal plates with locally concave and convex shapes, welding them in a vacuum chamber without filler materials, and incorporating a core material for enhanced insulation and mechanical strength, ensuring low thermal conductivity and leak rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional manufacturing processes are used for vacuum insulated panels, then production is simpler and faster, but durability and reliability under severe environmental conditions deteriorate
Solution Approach 1:
The patent applies preliminary action by forming the metal plates with hollow structures and surface treatments before the vacuum sealing process. The interior and exterior metal plates are pre-formed with specific geometries, including hollow regions that will later contain the vacuum space. This preliminary preparation ensures that when the plates are sealed together in the vacuum chamber, the structural integrity and thermal insulation performance are already optimized, leading to durable panels that can withstand severe environmental conditions.
Solution Approach 2:
The patent employs parameter changes by controlling the atmospheric conditions during the sealing process. The metal plates are welded or sealed together in a controlled atmosphere chamber where pressure and gas composition are carefully regulated. This parameter control during manufacturing ensures hermetic sealing without contamination, significantly improving panel reliability and longevity under operational vacuum conditions compared to traditional atmospheric sealing methods.
2Loss of energy
If metal plate thickness is reduced to lower thermal conductivity, then thermal insulation performance improves, but mechanical strength deteriorates
Solution Approach 1:
The patent applies composite materials by combining multiple thin metal plates with hollow structures to create a multi-layered assembly. Instead of using a single thick metal plate, the invention uses several thinner plates (interior plate, exterior plate, and intermediate plates) with hollow regions between them. This composite structure reduces overall thermal conductivity through the air gaps and hollow regions while maintaining mechanical strength through the distributed plate architecture and vacuum pressure support.
Solution Approach 2:
The patent implements the nested doll principle by placing the interior metal plate with hollow regions inside the exterior metal plate structure. The hollow regions of the interior plate are positioned within the hollow regions of the exterior plate, creating a nested configuration. This nesting arrangement maximizes the vacuum insulation space while using thin plates, achieving low thermal conductivity without sacrificing mechanical integrity since the vacuum pressure acts uniformly on the nested structure.
3Loss of energy
If hollow forming is applied to metal plates to reduce thermal diffusion, then thermal insulation improves, but manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the metal plate structure into multiple discrete hollow-formed components rather than using solid plates. Each metal plate is formed with separate hollow regions that are strategically positioned to create thermal barriers. This segmentation approach reduces thermal diffusion paths while allowing each individual plate component to be manufactured using standard hollow forming techniques, making the overall process more manageable despite the increased structural complexity.
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 provides a hermetically sealed, long-lasting thermal insulation with high thermal resistance and reduced thermal transfers, suitable for applications like engine casings and heat exchangers, maintaining effective insulation and mechanical strength over extended periods.
Implementation Method 1
put in place the first and second metal plates preferably in a vacuum and/or controlled atmosphere chamber
Implementation Method 2
welded together, peripherally, so that is created between them, at location of said space, an enclosure in depression and/or under a controlled atmosphere
Data Source
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AI summary
The invention relates to the thermal creation of a part, including steps of: using at least one first and one second metal plate (30, 31), hollow-forming the first plate so as to form at least part of said inner wall, and hollow-forming the second plate (31) so as to form at least part of said outer wall. During the forming, the shapes of the first and second plates are adjusted such that they can be placed in contact with each other while leaving a space therebetween inside said periphery, and then the first and second plates are placed in a negative-pressure and/or controlled-atmosphere chamber (65), where said plates are brought together and peripherally sealed together such that, in said space, a negative-pressure and/or controlled-atmosphere enclosure is created.