Vacuum insulating panel
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Vacuum insulating panels (VIPs) face challenges in achieving a balance between thermal performance and dimensional stability, as reducing core density improves thermal conductivity but compromises handling and aesthetic appearance, leading to issues like edge collapse and warping.
Innovation Solution
A hybrid core structure is introduced, featuring a reduced density insulating core reinforced with a porous, rigid material on its upper and/or lower surfaces, which maintains dimensional stability and prevents thermal bridging, allowing for improved thermal performance without compromising handling or aesthetics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the core density is reduced to improve thermal conductivity, then thermal performance is improved, but handling properties and dimensional stability are compromised
Solution Approach 1:
The core is segmented into two distinct layers: a low-density insulating core layer (100-160 kg/m³) for thermal performance and a high-density reinforcing layer (≥180 kg/m³) for structural strength. This segmentation allows each layer to perform its specialized function without compromising the other.
Solution Approach 2:
The patent employs a composite core structure combining two materials with different density characteristics. The insulating core uses low-density microporous material (fumed silica, perlite, or diatomaceous earth) while the reinforcing layer uses high-density material (glass fiber wool or mineral fiber), creating a composite structure that achieves both thermal efficiency and mechanical robustness.
2Loss of energy
If the core density is reduced to improve thermal conductivity, then thermal performance is improved, but the core becomes more prone to breakage and difficult to handle
Solution Approach 1:
The core is segmented into two distinct layers: a low-density insulating core layer (100-160 kg/m³) for thermal performance and a high-density reinforcing layer (≥180 kg/m³) for structural strength. This segmentation allows each layer to perform its specialized function without compromising the other.
Solution Approach 2:
The patent employs a composite core structure combining two materials with different density characteristics. The insulating core uses low-density microporous material (fumed silica, perlite, or diatomaceous earth) while the reinforcing layer uses high-density material (glass fiber wool or mineral fiber), creating a composite structure that achieves both thermal efficiency and mechanical robustness.
3Strength
If a glass fiber board is incorporated to maintain structural integrity, then handling is improved, but thermal conductivity increases and lifetime decreases
Solution Approach 1:
The reinforcing layer is applied locally only on the outer surfaces (top and/or bottom) of the core rather than throughout the entire core volume. This localized reinforcement provides structural integrity where it is most needed for handling while minimizing the thermal conductivity impact, as the low-density insulating material remains predominant in the core interior.
Solution Approach 2:
The patent carefully controls the thickness parameters of both layers: the insulating core layer thickness is 5-50 mm while the reinforcing layer thickness is 0.5-5 mm. By optimizing these dimensional parameters, the design achieves the right balance between structural strength and thermal performance.
4Stability of the object's composition
If reinforcing members are laminated to the insulating core, then dimensional stability is improved, but thermal performance decreases due to thermal bridging
Solution Approach 1:
The reinforcing layer is applied locally only on the outer surfaces (top and/or bottom) of the core rather than throughout the entire core volume. This localized reinforcement provides structural integrity where it is most needed for handling while minimizing the thermal conductivity impact, as the low-density insulating material remains predominant in the core interior.
Solution Approach 2:
The patent carefully controls the thickness parameters of both layers: the insulating core layer thickness is 5-50 mm while the reinforcing layer thickness is 0.5-5 mm. By optimizing these dimensional parameters, the design achieves the right balance between structural strength and thermal performance.
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 hybrid core achieves a thermal conductivity of 3.0 to 4.0 mW/mK, enhancing insulation performance while ensuring the panel's structural integrity and aesthetic appeal, with a compressive strength of 95 kPa to 150 kPa, and a density range of 100 to 160 kg/m³, outperforming conventional VIPs in both thermal efficiency and handling.
Implementation Method 1
an insulating core constructed from a microporous insulating material formed from a powder material
Implementation Method 2
a microporous insulating material formed from a powder material
Implementation Method 3
a barrier envelope, and a vacuum applied to inside the barrier envelope
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The present invention relates to a vacuum insulating panel (VIP). The VIP comprises an insulating core (2) having upper (3) and lower surfaces (4) and at least one substantially planar reinforcing member (5) arranged on the upper (3) or lower surface (4) of the core (2). The reinforcing member (5) is porous and substantially rigid. The VIP further comprises a barrier envelope, optionally in the form of a barrier film (6), arranged to envelop the insulating core (2) and the planar member (5). The present invention also relates to methods of manufacturing a vacuum insulating panel (VIP).