Vacuum insulation panel manufacturing device
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Solution Overview
Problem
Existing vacuum insulation panel manufacturing devices are large and costly due to the need for a chamber for evacuation and brazing, which increases the size and expense of the equipment.
Innovation Solution
A miniaturizable vacuum insulation panel manufacturing device that uses a chamber with an open bottom, a quartz glass window, a holding unit for the sealing member, and a laser welding unit outside the chamber, allowing for evacuation and sealing without the need for a heating unit within the chamber, and utilizing a laser to seal the evacuation port externally.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If evacuation and brazing are performed in the chamber, then the vacuum insulation panel can be manufactured with proper sealing, but the chamber size and device complexity increase
Solution Approach 1:
The patent divides the manufacturing process into two separate locations: evacuation is performed inside the chamber, while brazing is performed outside the chamber using a laser welding unit. This segmentation allows the chamber to be simpler in structure without needing to accommodate heating units for brazing, thereby reducing device complexity while maintaining reliable sealing through proper evacuation and external brazing.
Solution Approach 2:
The patent introduces a quartz glass window as an intermediary that allows laser beams to pass through from outside the chamber to the evacuation port area. This enables the laser welding unit to perform brazing operations on the sealing member without requiring the heating unit to be physically inside the chamber, thus simplifying the chamber structure while ensuring proper sealing.
2Ease of manufacture
If a heating unit is placed inside the chamber for brazing, then sealing can be performed, but the chamber size and manufacturing cost increase
Solution Approach 1:
The patent extracts the heating function from inside the chamber by using a laser welding unit positioned outside the chamber. The laser beam passes through the quartz glass window to perform brazing on the sealing member at the evacuation port. This extraction eliminates the need for a heating unit inside the chamber, reducing chamber volume and manufacturing cost while maintaining full sealing capability.
Solution Approach 2:
The patent replaces the traditional mechanical heating system (heating unit inside chamber) with an optical system (laser welding unit outside chamber). The laser beam provides the necessary heat for brazing without requiring physical heating equipment inside the chamber, thereby reducing chamber size and manufacturing complexity while achieving the same sealing result.
3Volume of stationary object
If the chamber is miniaturized, then device cost and size are reduced, but the ability to perform both evacuation and brazing within the chamber is compromised
Solution Approach 1:
The patent moves the brazing operation from the internal three-dimensional space of the chamber to an external position, utilizing the space outside the chamber. The laser welding unit is positioned externally and directs the laser beam through the quartz glass window to the evacuation port area. This dimensional shift allows the chamber to be miniaturized while maintaining both evacuation and brazing capabilities through the combination of internal evacuation and external brazing operations.
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 device reduces the size and cost of the manufacturing equipment, enables efficient sealing of the evacuation port without heating, and maintains the vacuum state effectively, resulting in a compact and cost-effective production process.
Implementation Method 1
a laser welding unit provided outside of the chamber... an upper end of the support rods is fixed to a lifting plate of the lifting mechanism, passing through the upper portion of the chamber, around the quartz glass... enabling efficient sealing of the evacuation port without heating
Implementation Method 2
a vacuum suction unit... applying a vacuum to evacuate inside of the packaging member from the evacuation port... maintains the vacuum state effectively
Data Source
Figure 1
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AI summary
A miniaturizable vacuum insulation panel manufacturing device is provided. In this vacuum insulation panel manufacturing device (2), a vacuum insulation panel (11) is manufactured by wrapping an insulating core member (10) with a packaging member (20, 30) in which an evacuation port (32) is provided, applying a vacuum to evacuate inside of the packaging member (20, 30) from the evacuation port (32), and sealing the evacuation port (32) with a sealing member (60), wherein this vacuum insulation panel manufacturing device is provided with: a chamber (210) with an opened bottom; a chamber evacuation hole (215) provided in the chamber (210); a quartz glass window unit (214) provided in the top of the chamber (210); a holding unit (251) which can hold the sealing member (60); a lifting mechanism (250) which raises/lowers the holding unit (251); a frame member (301) which holds and raises/lowers the chamber (210); and a laser welding unit (300) provided outside of the chamber (210).