Vacuum Board With Variable Height Supports
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing vacuum plates with uneven surfaces and uniform support structures are prone to damage, leading to potential security risks due to ineffective support and sealing issues during manufacturing.
Innovation Solution
A vacuum plate design featuring multiple layers with support structures of varying heights, sealed with a sealing mixture and covered in an organic film, where the support structures are aligned to match the surface undulations of the plates, ensuring each structure is clamped and effectively supports the layers, and the sealing mixture is melted at a temperature of 700°C or less to create an air-tight vacuum space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If uniform support structures are used among different plate layers, then the manufacturing process is simple, but the support structures cannot effectively support the plates due to surface undulation, causing the vacuum plate to be easy to be damaged
Solution Approach 1:
The patent applies local quality by varying the heights of support structures at different positions according to the surface undulation characteristics of the plates. Instead of using uniform support structures throughout, the invention creates location-specific support heights that match the local surface variations, ensuring each support structure can effectively contact and support the plates at its specific position.
Solution Approach 2:
The patent implements parameter changes by modifying the height parameter of support structures based on the measured surface undulation of the plates. The support structure heights are adjusted to correspond to the spacing variations at different positions, transforming a uniform parameter (height) into a variable parameter that adapts to surface conditions, thereby ensuring effective support across the entire plate area.
2Reliability
If the sealing mixture is melted at high temperature to seal the peripheries, then the sealing is effective, but the manufacturing process requires high temperature equipment and energy consumption increases
Solution Approach 1:
The patent applies parameter changes by selecting a sealing mixture with a lower melting point that can be melted at 700°C or below. This changes the temperature parameter of the sealing process from conventional high temperatures to a reduced temperature range, achieving effective sealing while reducing energy consumption and equipment requirements.
Solution Approach 2:
The patent uses a composite sealing mixture comprising an inorganic substrate and inorganic particles. This composite material formulation allows the sealing mixture to maintain effective sealing properties while having a lower melting point, enabling the sealing process to occur at reduced temperatures compared to conventional single-material sealing approaches.
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 design enhances the structural integrity and reduces the risk of damage by ensuring each support structure plays a supporting role, thereby improving the safety and durability of the vacuum plate.
Implementation Method 1
melting a substrate of the sealing mixture at a temperature of equal to or less than 700°C, to make the cavity form an air-tight vacuum space
Data Source
Figure 1~2
Figure 3~5-1
Figure 5-2~7
AI summary
The present invention discloses a vacuum plate and a method for manufacturing it. The vacuum plate comprises at least two layers of plate, a plurality of support structures with different heights, and an organic film. The plates in adjacent layers are separated by a plurality of the support structures with different heights, peripheries of the at least two layers of plate are connected and sealed via a sealing mixture; and the peripheries of the at least two layers of plate and the outside of the sealing mixture are covered with the organic film. According to surface undulation of the plate, the supporting structures with corresponding heights are arranged on corresponding positions between the layers of plate, and the heights of the support structures match with the spacings at corresponding positions in the vacuum plate, so that each support structure can be clamped by the upper and the lower plate layers, and effectively plays a supporting role, thereby reducing the security risk from damage of the vacuum plate.