Vacuum Insulation Panel Frictional Bonding Method
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Solution Overview
Problem
Composite elements used for thermal insulation, such as vacuum insulation panels, face challenges with mechanical stability and thermal insulation performance due to damage to the covering, which can lead to loss of vacuum and reduced insulation efficiency, especially with core materials like fumed silica and glass fibers.
Innovation Solution
A method involving a one-part or multi-part core made of evacuable organic material, partially covered with a thermoplastic material cladding, where the composite element precursor is treated to achieve partial softening of the core and cladding, forming a non-positive frictional connection without additional adhesives or layers, allowing for enhanced mechanical stability and vacuum retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive layers are used to bond the film and core material, then mechanical stability and vacuum retention are improved, but manufacturing complexity and process cost increase
Solution Approach 1:
The invention extracts and eliminates the adhesive layer from the composite element structure. Instead of using adhesive to bond the thermoplastic film to the core material, the film is welded directly to the core material surface, removing the intermediate adhesive component and simplifying the manufacturing process while maintaining mechanical stability and vacuum retention.
Solution Approach 2:
The invention merges the bonding function and sealing function into a single welding process. The thermoplastic film is welded directly to the core material, combining the adhesive bonding step and the sealing step into one operation, thereby reducing manufacturing complexity and process cost while ensuring mechanical stability and vacuum retention.
2Reliability
If multiple layers and adhesives are used to ensure vacuum retention, then reliability is improved, but manufacturing cost and process time increase
Solution Approach 1:
The invention removes the adhesive layer from the multi-layer structure, reducing the number of layers from three (core material + adhesive + film) to two (core material + film). This extraction simplifies the manufacturing process and reduces process time while maintaining vacuum retention through direct welding of the film to the core material.
Solution Approach 2:
The invention performs the bonding and sealing action simultaneously through the welding process. The thermoplastic film is welded directly to the core material in a single step, eliminating the need for separate adhesive application and sealing steps, thereby improving manufacturing efficiency while ensuring reliable vacuum retention.
3Quantity of substance
If the covering is made thin to reduce material cost, then manufacturing cost decreases, but mechanical stability and damage resistance worsen
Solution Approach 1:
The invention utilizes the phase transition of the thermoplastic film material during the welding process. The film is heated to melt and bond directly to the core material, creating a strong mechanical connection that compensates for the reduced film thickness, thereby maintaining mechanical stability while using less material.
Solution Approach 2:
The invention creates a composite structure where the thermoplastic film is directly bonded to the core material through welding. This direct bonding creates a strong interface that enhances the overall mechanical stability of the composite element, allowing the use of thinner film while maintaining strength and damage resistance.
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 simplifies the production process and maintains structural integrity and thermal insulation performance even if the covering is damaged, as the frictional connection between the core and covering ensures the vacuum is retained and mechanical stability is maintained.
Implementation Method 1
treating the composite element precursor for a duration that leads to at least partial softening of the evacuable organic material and the surface of the covering in contact with the core
Implementation Method 2
at least partial softening of the evacuable organic material and the surface of the covering in contact with the core
Implementation Method 3
Evacuated composite systems, so-called vacuum insulation panels
Implementation Method 4
the frictional connection between the core and covering ensures the vacuum is retained and mechanical stability is maintained
Data Source
AI summary
The invention relates to a method for manufacturing a composite element containing a single-piece or multi-piece core and a cover which are frictionally connected to each other, said method at least involving: providing a single-piece or multi-piece core made of an organic material that can be evacuated; at least partially covering the core with a cover so as to obtain a composite element precursor; and treating the composite element precursor for a certain duration such that the organic material that can be evacuated and the surface of the cover that is in contact with the core soften at least partly. The invention further relates to composite elements obtainable or obtained according to a disclosed method as well as to the use of a disclosed composite element as a vacuum insulation panel or thermal insulation material.