Thermos Cup Vacuumizing Device And Method
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Solution Overview
Problem
The existing thermos cup vacuumizing process is energy-intensive, time-consuming, and inefficient, with high energy consumption and long processing cycles, and it relies on expensive, environmentally harmful glass-based brazing materials that are difficult to work with, leading to poor sealing and high scrap rates.
Innovation Solution
A thermos cup vacuumizing device with a pre-vacuumizing, heating, and welding chamber sequence, using a controllable laser welding device and high-temperature resistant transparent windows for efficient vacuum sealing, eliminating the need for glass-based materials by employing metal welding balls and optimizing the vacuum pumping process for reduced energy consumption and improved automation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If glass-based brazing material is used for sealing the vacuumizing hole, then the sealing performance is improved, but the cost increases and environmental pollution occurs due to heavy metals
Solution Approach 1:
The patent replaces expensive glass-based brazing material with a metal welding ball that can be easily replaced. The welding ball is made of metal material that is environmentally friendly and does not contain heavy metals, thus eliminating environmental pollution while maintaining sealing performance.
Solution Approach 2:
The patent changes the material parameter from glass-based brazing material to metal welding ball. This parameter change eliminates heavy metals and environmental pollution while maintaining the sealing function through laser welding technology.
2Reliability
If glass-based brazing material is used, then sealing is achieved, but the melting temperature exceeds 500°C and welding efficiency decreases
Solution Approach 1:
The patent changes the material from glass-based brazing material to metal welding ball, which has a lower melting point and better weldability. The metal material allows for more efficient welding processes with better control over melting temperature.
Solution Approach 2:
The patent replaces the traditional brazing process with laser welding technology. The laser welding device provides precise control over the welding process, improving welding efficiency and quality compared to conventional brazing methods.
3Reliability
If the existing vacuumizing process is used, then vacuum insulation is achieved, but energy consumption is high and processing cycle exceeds 5 hours
Solution Approach 1:
The patent divides the vacuumizing process into separate stages: pre-vacuumizing in one chamber, then heating and welding in another chamber. This segmentation allows each process to be optimized independently, reducing the overall processing time while maintaining vacuum insulation quality.
Solution Approach 2:
The patent performs pre-vacuumizing in the first chamber before heating and welding. This preliminary action removes most of the gas load before the heating process, allowing for faster vacuum recovery and reducing the total processing cycle time.
4Manufacturing precision
If multiple chambers are used for pre-vacuumizing, heating, and cooling, then process control is improved, but device complexity increases
Solution Approach 1:
The patent uses separate chambers for different processes: pre-vacuumizing chamber, heating chamber, and cooling chamber. This segmentation allows each chamber to be optimized for its specific function, improving process control while keeping each chamber relatively simple in design.
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 significantly reduces energy consumption, eliminates the use of heavy metals, improves welding stability and efficiency, enhances product quality, and enables automated mass production with reduced scrap rates and improved thermal insulation performance.
Implementation Method 1
A laser beam of the laser welding device passes through the transparent windows to melt a welding ball provided at a hole in the center of the bottom of the thermos cup
Implementation Method 2
The heating chamber and the welding chamber are connected to a high-vacuum pumping system
Implementation Method 3
The pre-vacuumizing chamber and the cooling chamber are connected to a low-vacuum pumping system
Implementation Method 4
The pre-vacuumizing chamber, the heating chamber, and the welding chamber each are provided with a heating device
Implementation Method 5
The pre-vacuumizing chamber and the cooling chamber are connected to a low-vacuum pumping system
Data Source
AI summary
A thermos cup vacuumizing device and method are provided. The thermos cup vacuumizing device includes a pre-vacuumizing chamber, a heating chamber, a welding chamber, and a cooling chamber. A continuous conveying device is provided at a bottom of each of the chambers. The thermos cup vacuumizing device further includes a controllable and movable laser welding device and multiple transparent windows. A laser beam of the laser welding device passes through the transparent windows to melt a welding ball at provided at a hole in the center of the bottom of the thermos cup. A vertically movable inlet valve is provided at an inlet of the pre-vacuumizing chamber, and a vertically movable outlet valve is provided at an outlet of the cooling chamber. The present disclosure realizes the continuous vacuumizing operation on the thermos cups, improves the product qualification rate and processing efficiency, and realizes automatic mass production.