Vacuum insulation material including an inner bag, and method for manufacturing same
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Solution Overview
Problem
Existing methods for manufacturing vacuum insulation materials face challenges such as deformation of glass wool, high equipment costs, and deterioration of thermal capabilities due to the use of binders or the need for high-temperature processing, as well as difficulties in handling and inserting thick glass wool into cover materials.
Innovation Solution
A method involving the use of binder-free glass wool compressed with an air-permeable inner bag and vacuum-packing with a cover material, including a getter for moisture absorption, eliminates the need for high-temperature processing and reduces equipment costs while maintaining excellent insulation characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If glass wool is heated to glass transition temperature for compression, then compression efficiency is improved, but equipment cost increases due to need for high-temperature drying oven
Solution Approach 1:
The patent changes the temperature parameter from high-temperature (500°C or more) to room temperature compression by using a binder that becomes active at lower temperatures, thereby eliminating the need for expensive high-temperature drying ovens while maintaining compression efficiency
Solution Approach 2:
The patent replaces the thermal compression system (heating to glass transition temperature) with a chemical-bonding-based compression system using a binder that forms strong bonds at room temperature, substituting thermal energy with chemical bonding mechanisms
2Productivity
If binder is used to promote coupling between fibers upon compression, then compression efficiency is improved, but thermal capabilities deteriorate due to binder interference
Solution Approach 1:
The patent applies local quality by using binder only at specific locations (between glass wool fibers during compression) rather than throughout the entire structure, allowing compression efficiency to be improved at the fiber interfaces while maintaining the overall thermal capabilities of the glass wool insulation material
Solution Approach 2:
The patent creates a composite material system combining glass wool fibers with a specially designed binder that has complementary properties - the binder provides compression and bonding functionality while being thermally inert, allowing the composite to achieve both compression efficiency and thermal performance
3Reliability
If thick glass wool material is used for 8 mm thick vacuum insulation material, then insulation performance is improved, but handling and insertion difficulty increase
Solution Approach 1:
The patent applies preliminary action by pre-compressing the glass wool material to the required thickness and density before insertion into the vacuum insulation panel, making the material easier to handle and insert while maintaining the necessary insulation performance for 8 mm thick panels
4Stability of the object's composition
If glass wool is compressed without binder or high temperature, then glass wool deformation is prevented and reuse is enabled, but compression efficiency decreases
Solution Approach 1:
The patent introduces a binder as an intermediary substance that facilitates compression by bonding glass wool fibers together at room temperature, enabling efficient compression without direct high-temperature heating of the glass wool itself, thereby preventing deformation and enabling reuse while maintaining compression efficiency
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 simplifies the manufacturing process, prevents glass wool deformation, and enhances the reuse of glass wool, achieving efficient and cost-effective production of vacuum insulation materials with improved thermal conductivity and long-term durability.
Implementation Method 1
a vacuum insulation material includes binder-free glass wool which is compressed without being heated to glass transition temperature
Implementation Method 2
a getter of lime powder is used to maximize moisture absorption
Implementation Method 3
A vacuum insulation panel is manufactured by decompressing an encapsulant
Data Source
Figure 1~2
Figure 3
AI summary
The present invention relates to a vacuum insulation material including an inner bag and to a method for manufacturing same. The method for manufacturing the vacuum insulation material includes: a step of manufacturing a core material; a step of compressing and packing the entire surface of the core material using an inner bag made of a breathable film material; a step of disposing a getter on the upper portion of the inner bag; and a step of vacuum-packing a covering material on the upper portion of the inner bag. The inner bag is made of polypropylene (PP), polyester (PET), and/or polyethylene. Since the inner bag is manufactured using a breathable film having fine holes, the method for manufacturing the vacuum insulation material may have improved efficiency, and the vacuum insulation material may be improved in terms of the long-term durability and vacuum insulation properties thereof.