Through-Hole Heat Insulating Sheet for Lightweight Vacuum Insulation
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Solution Overview
Problem
Existing heat insulating materials face challenges in achieving both weight reduction and effective heat insulation, particularly in vacuum environments, where they often compromise on either weight or thermal performance.
Innovation Solution
A heat insulating sheet comprising a resin film with a metal layer and a nonwoven fabric, where the resin film and nonwoven fabric are joined by through holes, with a specific ratio of hole distances to optimize slack and contact points, reducing weight while suppressing heat conduction and radiant heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a heat insulating material uses a stacked structure of resin films with metal layers and nonwoven fabrics joined by through holes, then weight reduction is achieved, but heat insulation performance deteriorates due to increased contact points and reduced slack between layers
Solution Approach 1:
The patent changes the geometric parameters of the through holes, specifically setting the ratio of average distance between through holes in the resin film (La) to average distance between through holes in the nonwoven fabric (Lb) within the range of 0.85 ≤ La/Lb ≤ 1.15. This parameter optimization balances the slack and contact points between layers, reducing heat conduction while maintaining weight reduction benefits
Solution Approach 2:
The patent uses a composite structure combining resin film with metal layer and nonwoven fabric, where each material contributes its properties: the metal layer provides radiation shielding, the resin film provides structural integrity, and the nonwoven fabric provides thermal insulation. The through-hole joining method creates a composite material system that achieves both light weight and effective heat insulation
2Ease of manufacture
If the ratio of average distance between through holes in resin film to average distance between through holes in nonwoven fabric is outside the optimal range, then manufacturing is easier, but heat insulation performance deteriorates due to improper slack and contact point distribution
Solution Approach 1:
The patent establishes specific parameter ranges for the through hole distribution (0.85 ≤ La/Lb ≤ 1.15) that optimize both manufacturing feasibility and heat insulation performance. This parameter specification ensures that the through holes are distributed in a manner that creates appropriate slack between layers while maintaining manufacturability through standard hot protrusion processes
3Loss of energy
If the heat insulating sheet has excessive slack between layers, then heat insulation performance improves, but handleability and compression resistance deteriorate
Solution Approach 1:
The patent optimizes the through hole distribution parameters (La/Lb ratio) to create a balanced structure with moderate slack that provides good heat insulation while maintaining adequate handleability. The controlled through hole pattern ensures the sheet has enough flexibility for handling but sufficient structural integrity for compression resistance
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 material weight while maintaining excellent heat insulation properties, improving handleability and efficiency in vacuum applications, and is suitable for high-performance vacuum containers.
Implementation Method 1
a resin film having a metal layer... suppressing heat conduction and radiant heat transfer
Implementation Method 2
a penetrating step of providing a through hole penetrating the resin film and the nonwoven fabric by using a hot protrusion
Data Source
AI summary
Provided are heat insulating sheets that may include a resin film having a metal layer and a nonwoven fabric including resin fiber, wherein the resin film and the nonwoven fabric are joined by through holes penetrating the resin film and the nonwoven fabric, and wherein a ratio (La/Lb) of an average distance (La) between the through holes in the resin film to an average distance (Lb) between the through holes in the nonwoven fabric is 1.001 or more and 1.10 or less. Further provided are manufacturing methods of a heat insulating sheet that may include a resin film having a metal layer and a nonwoven fabric including a resin fiber.