Vacuum insulation panel and method for manufacturing the vacuum insulation panel
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Solution Overview
Problem
Conventional vacuum insulation panel manufacturing processes are lengthy due to high-temperature vacuum chamber operations, and high-temperature radiant heat can damage glass panels during the capping process.
Innovation Solution
The process involves induction heating of a metal sealing cap using a heating coil to melt a sealing material without directly heating the glass panels, and a cylinder is used to position and press the sealing cap onto the material, ensuring a secure join at room temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-temperature heating is used to seal the vacuum insulation panel, then the sealing is achieved, but the production time is prolonged and glass breakage occurs
Solution Approach 1:
The patent applies induction heating to locally heat only the sealing cap and sealing material area, rather than heating the entire vacuum chamber to high temperature. This localized heating approach achieves effective sealing while avoiding the time-consuming process of heating and cooling large areas, thus resolving the contradiction between sealing quality and production time.
Solution Approach 2:
The patent replaces the conventional thermal radiation heating system with an induction heating system that uses electromagnetic fields to directly heat the sealing cap. This substitution eliminates the need for high-temperature vacuum chamber heating and cooling cycles, significantly reducing production time while maintaining reliable sealing.
2Reliability
If high-temperature radiant heat is used to cap the exhaust hole, then the sealing is achieved, but the glass is damaged due to thermal shock
Solution Approach 1:
The induction heating system concentrates thermal energy only on the sealing cap and sealing material, creating a localized high-temperature zone. The rest of the glass panels remain at ambient temperature, avoiding thermal shock while achieving effective sealing. This localized heating approach directly resolves the contradiction between sealing quality and glass damage prevention.
Solution Approach 2:
The sealing cap acts as an intermediary element that receives induction heating and transfers heat only to the sealing material in contact with it. This intermediary approach prevents direct exposure of the glass panels to high-temperature radiant heat, eliminating thermal shock while maintaining effective sealing through the sealing material.
3Reliability
If a high-temperature vacuum chamber is used for manufacturing, then the vacuum process is achieved, but the production efficiency is reduced
Solution Approach 1:
The patent replaces the conventional approach of heating the entire vacuum chamber with an induction heating system that operates at room temperature within the vacuum chamber. The induction heating occurs after vacuum formation, eliminating the need for thermal radiation heating and cooling cycles, thus significantly improving production efficiency while maintaining reliable vacuum formation.
Solution Approach 2:
The patent performs the vacuum formation process first at room temperature, then applies induction heating for sealing afterward. This preliminary action approach allows the vacuum chamber to remain at ambient temperature during the time-consuming vacuum pumping phase, while the subsequent induction heating provides rapid sealing without requiring chamber temperature changes, thereby improving overall production 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 method significantly reduces manufacturing time and prevents glass breakage by avoiding direct high-temperature exposure, allowing for a robust and efficient vacuum insulation panel production.
Implementation Method 1
a heating coil configured to be inductively heating the sealing cap
Implementation Method 2
a heating coil configured to be inductively heating the sealing cap
Implementation Method 3
a sealing cap configured to seal an exhaust hole of the panel assembly
Data Source
Figure 1~2
Figure 3~5
Figure 6~8
AI summary
The present disclosure relates to a vacuum insulation panel, an apparatus for manufacturing vacuum insulation panel, and a method for manufacturing vacuum insulation panel. The vacuum insulation panel according to an embodiment of the present disclosure may include a sealing cap configured to seal an exhaust hole of the panel assembly, and a heating coil capable of inductively heating the sealing cap.