Vacuum Insulation Panel Manufacturing Compression
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Solution Overview
Problem
Existing methods for manufacturing vacuum insulation panels with plastic composite foil sleeves face issues of non-gas-tightness, mechanical sensitivity, and thermal bridging, which lead to reduced insulating effectiveness and increased manufacturing complexity, especially when compared to metal foil sleeves.
Innovation Solution
Applying a compression pressure of greater than 1 bar to the fiber core ensures a smooth, extended foil surface, maintaining the foil's form until sealing, eliminating the need for additional support plates and reducing process effort, while using binder-free fibers and controlled drying to enhance insulation properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If plastic composite foil sleeves are used, then cost and ease of manufacture are improved, but gas-tightness and mechanical resistance deteriorate
Solution Approach 1:
The foil sleeve is pre-formed and positioned around the core blank before compression and sealing operations, ensuring proper alignment and preventing wrinkles during subsequent manufacturing steps
Solution Approach 2:
The patent specifies controlled compression pressure parameters and drying conditions to achieve the desired balance between foil smoothness and core stability without compromising gas-tightness
2Ease of manufacture
If plastic composite foil sleeves are used, then cost and ease of manufacture are improved, but mechanical resistance deteriorates
Solution Approach 1:
The foil sleeve is pre-formed and positioned around the core blank before compression and sealing operations, ensuring proper alignment and preventing wrinkles during subsequent manufacturing steps
Solution Approach 2:
The patent specifies controlled compression pressure parameters and drying conditions to achieve the desired balance between foil smoothness and core stability without compromising mechanical resistance
3Reliability
If metal foil sleeves are used, then gas-tightness and mechanical resistance are improved, but thermal bridging and manufacturing complexity increase
Solution Approach 1:
The patent employs plastic composite foil sleeves that are cost-effective and easier to manufacture, accepting their limited service life in exchange for reduced manufacturing complexity and cost
Solution Approach 2:
The patent specifies controlled compression pressure parameters and drying conditions to achieve the desired balance between foil smoothness and core stability
4Shape
If compression pressure is applied to extend foil surface, then wrinkling is prevented, but process complexity increases
Solution Approach 1:
The foil sleeve is pre-formed and positioned around the core blank before compression and sealing operations, ensuring proper alignment and preventing wrinkles during subsequent manufacturing steps
Solution Approach 2:
The patent specifies controlled compression pressure parameters and drying conditions to achieve the desired balance between foil smoothness and core stability
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 prevents wrinkling of plastic composite foil sleeves, maintains dimensional stability, and achieves improved insulation performance with reduced manufacturing complexity and cost, while maintaining the advantages of plastic foils, such as low thermal bridges and cost-effectiveness.
Implementation Method 1
This processing is performed depending on the respective composition of the mineral material as a rule in a temperature range between 400° C and 600° C, and thus takes place in the range of the softening point thereof. Associated therewith is a plastic deformation of the mineral fibers which results in fiber mingling of the raw material, on the one hand, and in a kind of fusion, on the other hand.
Implementation Method 2
Such vacuum insulation panels are characterized by good heat insulation properties with a comparatively small insulation thickness. Therefore, they are used primarily in areas in which the space available is restricted.
Implementation Method 3
Applying a compression pressure of greater than 1 bar to the fiber core ensures a smooth, extended foil surface, maintaining the foil's form until sealing
Implementation Method 4
If organic binders are used, they may disintegrate in the vacuum, so that the insulating effect then decreases due to increasing gas heat conduction. Although inorganic binders usually do not have this effect, they are difficult to handle and expensive.
Data Source
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AI summary
The invention relates to a method for manufacturing vacuum insulation panels (1) with a fiber core (3), comprising the steps of: providing a core blank of fibers, arranging foil sections on large faces of the core blank, compressing the core blank to a predetermined thickness for forming the core (3), wherein in the compression step the core blank is arranged between the foil sections, wherein the mechanical compression of the core (3) is maintained until the foil sleeve (2) is sealed, and wherein the compression step is performed at the place of manufacture at room temperature without thermal impact, connecting the foil sections for forming the foil sleeve (2), wherein a partial section of the foil sleeve (2) still remains open, evacuating the foil sleeve (2) enveloping the core (3) up to a pressure of ≤ 1 mbar, and complete closing of the foil sleeve (2), wherein the foil sleeve (2) is made of a plastic composite foil. This method distinguishes itself by the fact that the mechanical compression is carried out at a pressure of greater than 1 bar. Thereby a vacuum insulation panel (1 ) is obtained which can be manufactured with low expenditure and without the insulation effect suffering therefrom.