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 limits the miniaturization and increases production expenses.
Innovation Solution
A miniaturizable vacuum insulation panel manufacturing device that uses a chamber with an open bottom, a quartz glass window, a holding unit with magnetic sealing member attachment, and a laser welding unit outside the chamber to evacuate and seal the panel without the need for a heating unit, allowing for compact design and reduced costs.
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 heating unit is extracted from the chamber and relocated to the exterior. The laser welding unit performs brazing from outside the chamber through the quartz glass window, eliminating the need for internal heating equipment while maintaining sealing quality.
Solution Approach 2:
The quartz glass window acts as an intermediary that allows laser energy to pass through from the exterior to the interior of the chamber, enabling heating and welding operations without requiring the heating unit to be physically inside the chamber.
2Reliability
If a heating unit is installed in the chamber for brazing, then proper sealing can be achieved, but the device size and manufacturing cost increase
Solution Approach 1:
The heating unit is extracted from the chamber and relocated to the exterior. The laser welding unit performs brazing from outside the chamber through the quartz glass window, eliminating the need for internal heating equipment while maintaining sealing quality.
Solution Approach 2:
The mechanical heating system inside the chamber is replaced with an optical system (laser) that can heat and weld from the exterior through the quartz glass window, simplifying the device structure and reducing manufacturing costs.
3Reliability
If the chamber is designed to accommodate the entire laminated body, then complete evacuation can be performed, but the chamber size and device footprint increase
Solution Approach 1:
The heating and welding operations are moved from the interior space dimension to the exterior space dimension. The laser welding unit operates from outside the chamber through the quartz glass window, allowing complete evacuation within a smaller chamber while still achieving proper sealing.
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 enables the production of compact, cost-effective vacuum insulation panels with improved heat insulation performance by eliminating the need for a heating unit and reducing the size of the chamber, facilitating efficient evacuation and sealing with laser welding.
Implementation Method 1
applying a vacuum to evacuate inside of the packaging member from the evacuation port
Implementation Method 2
a laser welding unit provided outside of the chamber
Data Source
AI summary
A vacuum insulation panel manufacturing method that makes it possible to manufacture low-cost, high-performance vacuum insulation panels, and a vacuum insulation panel are provided. This method of manufacturing a vacuum insulation panel (1) involves: a stacking step in which a first metal plate (20) is overlaid on one side of a thermally insulating core material (10), and in which a backing member (50) having an opening (51) and a second metal plate (30) having an exhaust port (32) are placed, with the opening (51) and the exhaust port (32) overlapping, overlaid on each other on the other surface of the core member (10) in the order of backing member (50) and second metal plate (30) from the core member (10) side; a first welding step for welding outwards of where the core member (10) is disposed in the first metal plate (20) and the second metal plate (30); a vacuum creating step for evacuating air from the exhaust pert (32) to create a vacuum in an inner area which is held between the first metal plate (20) and the second metal plate (30) and in which the core member (10) is arranged; and a laser welding step in which, in a state in which the inner area is made into a vacuum by the vacuum creating step, the exhaust port (32) is sealed by means of a sealing material (60) and the sealing material (60), the second metal plate (30) and the backing member (50) are laser welded.