Vacuum Insulation Sealant Layer Alternating Wall Structure
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Solution Overview
Problem
Conventional vacuum insulation materials face challenges in maintaining a high degree of vacuum over time due to insufficient gas adsorption capacity and gas infiltration through the laminate film's sealant layer, leading to reduced adiabatic performance.
Innovation Solution
The vacuum insulation material features a sealing part with alternating thin-wall and thick-wall sections in the sealant layer, where the thin-wall parts are heated and fused to reduce gas infiltration, and the thickness of the sealant layer is continuously varied to minimize gas and moisture invasion, while maintaining structural integrity and adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the sealant layer is made thinner to reduce gas infiltration, then gas permeability is reduced, but sealing strength and structural integrity deteriorate
Solution Approach 1:
The patent applies local quality by creating alternating thin-wall and thick-wall sections along the sealing part. The thin-wall sections (where the sealant layer thickness is reduced) are positioned to intercept gas infiltration paths, while the thick-wall sections maintain sealing strength and structural integrity. This localized variation in thickness allows different regions to serve different functions: gas barrier and mechanical strength.
Solution Approach 2:
The sealing part is segmented into multiple thin-wall and thick-wall sections rather than being uniformly thick. This segmentation creates a series of alternating regions that collectively provide both gas infiltration resistance and mechanical strength. The segmented structure allows the sealing part to perform multiple functions simultaneously across different locations.
2Reliability
If adsorbent capacity is increased to maintain vacuum, then gas adsorption improves, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent extracts the gas infiltration problem from the interior vacuum maintenance problem and addresses it at the boundary (sealing part). By reducing gas infiltration through the sealing part's alternating thin/thick structure, the burden on adsorbents is reduced. This allows the use of simpler, more conventional adsorbent configurations while still achieving reliable vacuum maintenance.
3Object-affected harmful factors
If the sealant layer is heated and fused to reduce gas permeability, then gas barrier property improves, but moisture permeability and adhesion may deteriorate
Solution Approach 1:
The heating and fusing is applied locally to create the alternating thin-wall and thick-wall sections, rather than uniformly throughout the entire sealant layer. The thin-wall sections are heated and fused to reduce gas permeability, while the thick-wall sections retain better adhesion properties. This localized treatment allows different regions to have different properties optimized for their specific functions.
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 configuration significantly reduces gas and moisture infiltration, enhancing the adiabatic performance by increasing the resistance to gas invasion and maintaining the vacuum state for a longer period without compromising the structural integrity of the laminate film.
Implementation Method 1
the thin-wall parts are heated and fused to reduce gas infiltration
Implementation Method 2
a part of a resin for composing the sealant layer in a specific position may be moved to the sealant layer adjacent to a sealant layer at a specific position
Implementation Method 3
a method of sealing a gas adsorbent or a moisture adsorbent, together with a core material, inside the vacuum insulation material at a reduced pressure
Implementation Method 4
the inside of the laminate film is sealed at a reduced pressure. The vacuum insulation material is capable of expressing a high adiabatic effect by keeping the inside space at a high degree of vacuum
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
A plurality of thin-wall parts (9a) of a sealant layer (7) are formed in a portion continuously changed in the interval of one sealing part (8) and a gas barrier layer (6) of other laminate film (4). At the inner circumferential side between the adjacent thin-wall parts (9a) and the thin-wall part (9a) at the innermost circumferential side and at the outer circumferential side of the thin-wall part (9a) of the outermost circumferential side, a thick-wall part (9b) of the sealant layer (7) is formed. All of the opposing sealant layers (7) between the two adjacent thin-wall parts (9a) are mutually heated and fused, so that an excellent adiabatic performance is maintained for a long period.