Vacuum Insulation Panel Shell Heat Treatment Welding
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Solution Overview
Problem
Vacuum insulation panels face challenges in maintaining internal vacuum due to physical impact vulnerability at unwelded shell edges, leading to rupturing, and existing technologies do not effectively improve the welding ratio of thermal welding portions.
Innovation Solution
A vacuum insulation panel with a shell structure comprising a surface protective layer, metal barrier layer, and thermal welding layer, including LLDPE or CPP, is manufactured using a method that involves heat treatment to weld unwelded portions, achieving a sealing strength of 5 kgf to 15 kgf and forming through-holes for improved durability and heat insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the shell is sealed at high vacuum to maintain internal vacuum level, then vacuum insulation performance is improved, but the unwelded portions become vulnerable to physical impact and rupturing
Solution Approach 1:
The patent applies heat treatment to change the physical state of the thermal welding layer from unwelded to welded state, transforming the shell structure to eliminate vulnerable unwelded portions while maintaining the vacuum seal. This parameter change (from unwelded to welded) resolves the contradiction by strengthening the shell without compromising vacuum integrity.
Solution Approach 2:
The patent performs heat treatment during the manufacturing process to pre-weld the thermal welding layer before the shell is subjected to physical impact or long-term use. This preliminary welding action eliminates potential rupture points in advance, ensuring both vacuum maintenance and structural strength.
2Ease of manufacture
If thermal welding is used to seal the shell, then sealing is achieved, but unwelded portions remain vulnerable to physical impact
Solution Approach 1:
The patent uses heat treatment to change the welding state of the thermal welding layer from partial/unwelded to fully welded, thereby improving the welding ratio. This parameter change maintains the ease of thermal welding manufacturing while eliminating the weakness of unwelded portions.
Solution Approach 2:
The patent replaces the mechanical sealing action (compression during assembly) with thermal welding action (heat treatment) to achieve complete sealing. This substitution ensures that the shell is fully welded rather than just mechanically compressed, eliminating unwelded vulnerable portions while maintaining manufacturing simplicity.
3Productivity
If the shell structure is simplified for easy manufacturing, then production efficiency is improved, but rupturing resistance at edges and unwelded portions deteriorates
Solution Approach 1:
The patent incorporates heat treatment as a preliminary step in the manufacturing process to weld the thermal welding layer before the shell is completed and put into service. This preliminary welding action ensures high rupturing resistance is achieved without adding complex structural elements, maintaining manufacturing efficiency.
Solution Approach 2:
The patent uses heat treatment to change the physical state of the thermal welding layer, transforming it from a weak unwelded state to a strong welded state. This parameter change improves rupturing resistance without requiring additional materials or complex structural modifications, thus maintaining high productivity.
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 solution enhances rupturing resistance and maintains excellent heat insulation properties while allowing the panel to be processed into various shapes, ensuring stability and durability by increasing the thermal welding ratio and sealing strength.
Implementation Method 1
heat treating the vacuum insulation panel, wherein the vacuum insulation panel has a sealing strength from about 5 kgf to about 15 kgf
Implementation Method 2
Heat treatment may cause an unwelded portion of the shell to be welded
Implementation Method 3
Vacuum insulation panels include a core, a getter and a shell
Implementation Method 4
the internal vacuum level is maintained by sealing the shell at a high vacuum of 10 Pa or less
Data Source
AI summary
Provided is a vacuum insulation panel comprising: a core material; and a shell material for covering the core material, wherein the shell has a layered structure comprising a surface protective layer, a metal barrier layer, and a thermal deposition layer from the outside, and the sealing strength of the vacuum insulation panel is 5-15 kgf. In addition, provided is a method for preparing the vacuum insulation panel, comprising the steps of: preparing the shell material by sequentially layering the thermal deposition layer, the metal barrier layer and the surface protective layer; inserting the core material between the shell material; reducing pressure and sealing the shell material so as to form a vacuum insulation panel; and heat treating the vacuum insulation panel, wherein the sealing strength of the vacuum insulation panel is 5-15 kgf.