Vacuum heat-insulating material
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Solution Overview
Problem
The existing methods for forming a concave-convex shape in vacuum insulators require molds in a vacuum chamber, increasing costs, complicating the chamber, reducing productivity, and potentially damaging the gas barrier layer, leading to decreased thermal insulation performance.
Innovation Solution
A vacuum insulator with a core member and a concave-convex film, where the concave-convex shape is formed on the packaging member without using molds, by laminating the concave-convex film on the core member and sealing it within a packaging member, allowing for pressure reduction to form the concave-convex shape without additional processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a vacuum insulator is sealed by pressure reduction, then thermal insulation performance is improved, but the packaging member becomes very rigid and is easily damaged when bending or shaping is attempted
Solution Approach 1:
The patent applies preliminary action by pre-forming concave-convex shapes on the packaging member surface before vacuum sealing. This allows the packaging to accommodate bending requirements in advance, preventing damage when the vacuum-insulated product is later bent or shaped. The concave-convex structure is created on the packaging film before it undergoes vacuum insulation treatment.
2Shape
If bending is performed on a vacuum insulator, then three-dimensional shaping is achieved, but the core member density increases and thermal insulation performance deteriorates
Solution Approach 1:
The patent applies preliminary action by pre-forming concave-convex shapes on the packaging member surface before vacuum sealing. This allows the packaging to accommodate bending requirements in advance, preventing damage when the vacuum-insulated product is later bent or shaped. The concave-convex structure is created on the packaging film before it undergoes vacuum insulation treatment.
Solution Approach 2:
The patent applies local quality by creating localized concave-convex structures only in specific regions where bending will occur. This localized structuring allows bending to be accommodated in specific areas without affecting the overall density or thermal insulation performance of the core member in non-bent regions.
3Shape
If molds with concave-convex shape are used in vacuum chamber, then concave-convex shape is formed on packaging member, but vacuum chamber size increases and cost increases
Solution Approach 1:
The patent applies taking out by removing the molds from the vacuum chamber entirely. Instead of using complex molded structures inside the vacuum chamber, the concave-convex shapes are pre-formed on the packaging member itself before sealing. This extraction of the molding operation from the vacuum chamber simplifies the chamber design and reduces costs.
Solution Approach 2:
The patent applies preliminary action by pre-forming concave-convex shapes on the packaging member surface before vacuum sealing. This allows the packaging to accommodate bending requirements in advance, preventing damage when the vacuum-insulated product is later bent or shaped. The concave-convex structure is created on the packaging film before it undergoes vacuum insulation treatment.
4Reliability
If concave-convex shape is formed by pressure reduction sealing with molds, then thermal insulation performance is maintained, but productivity deteriorates due to additional processing time
Solution Approach 1:
The patent applies merging by combining the concave-convex shape formation process with the vacuum sealing process. Instead of separately molding the packaging and then vacuum sealing it, the packaging is vacuum-sealed in its flat state, and the concave-convex shapes are formed by the pressure differential during or after sealing. This integration eliminates additional processing steps and improves productivity.
Solution Approach 2:
The patent applies preliminary action by pre-forming concave-convex shapes on the packaging member surface before vacuum sealing. This allows the packaging to accommodate bending requirements in advance, preventing damage when the vacuum-insulated product is later bent or shaped. The concave-convex structure is created on the packaging film before it undergoes vacuum insulation treatment.
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 approach reduces costs, maintains thermal insulation performance, and prevents productivity deterioration by eliminating the need for molds and additional processing, while ensuring the gas barrier properties are not compromised.
Implementation Method 1
a packaging member (4) covering the core member (2), and sealed by pressure reduction
Implementation Method 2
the packaging member (4) is sealed by pressure reduction to form a concave-convex shape corresponding to the concave-convex shape of the concave-convex film (1) on a surface of the packaging member (4)
Data Source
Figure 1(a)~2
Figure 3~5
Figure 6(a)~7
AI summary
A vacuum insulator includes: a core member (2) obtained by laminating a fiber material; a concave-convex film (1) in which a concave-convex shape is formed; and a packaging member (4) covering the concave-convex film (1) laminated on the core member (2), and sealed by pressure reduction to form a concave-convex shape (3) corresponding to the concave-convex shape of the concave-convex film (1) on a surface of the packaging member (4).