Vacuum Insulation Panel Structure for Uniform Thickness and Bonding
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Solution Overview
Problem
Existing vacuum insulation members face challenges in maintaining a high internal vacuum degree, achieving uniform insulation thickness, and preventing surface creases, leading to increased costs, reduced productivity, and defective attachments due to the use of glass fiber cores and metal-laminated layers.
Innovation Solution
A vacuum insulation member is developed using laminated mesh members with synthetic resin wires and a filler with micro pores, supported by a core that eliminates the need for glass fiber preprocessing, maintains a lower internal vacuum degree, and reduces creases, allowing for easier fabrication and improved bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If glass fiber is used as the core material, then initial insulation performance is excellent and cost is low, but preprocessing is required and durability is weak
Solution Approach 1:
The patent changes the physical state and form of the core material from fibrous glass to spherical beads (expanded perlite or glass beads). This parameter change eliminates the need for preprocessing while maintaining insulation performance and improving durability through a more robust structural form that doesn't require hot pressing or needle punching.
Solution Approach 2:
The patent uses inexpensive spherical bead materials (expanded perlite or glass beads) that can be directly filled into the envelope without preprocessing. These materials provide durable, long-lasting insulation without requiring the complex treatment needed for glass fiber, effectively replacing the need for disposable preprocessing steps.
2Reliability
If glass fiber is used as the core, then a relatively high vacuum degree must be maintained, but this requires much equipment, time and efforts
Solution Approach 1:
The patent changes the core material from glass fiber to spherical beads with smooth surfaces and closed-cell structure. This parameter change reduces the material's reactivity with residual gases and its ability to outgas, allowing the vacuum system to operate at lower vacuum degrees with simpler equipment while maintaining effective insulation performance.
3Reliability
If a metal-laminated layer is used to maintain high vacuum degree, then vacuum maintenance is improved, but heat transmission is generated and performance is degraded
Solution Approach 1:
The patent changes the core material properties to spherical beads that require lower vacuum maintenance. This parameter change eliminates the need for metal-laminated layers, thereby preventing heat transmission through the envelope while maintaining effective insulation through the vacuum environment.
4Reliability
If the envelope is fabricated to maintain high internal vacuum degree, then vacuum maintenance is improved, but fabrication cost and efforts increase
Solution Approach 1:
The patent changes the core material to spherical beads that are compatible with lower vacuum degrees. This parameter change allows the envelope to be fabricated with simpler, less expensive materials and processes while maintaining effective insulation, thereby reducing fabrication cost and efforts.
5Ease of manufacture
If the vacuum insulation member has non-uniform thickness, then fabrication is simpler, but uniform insulation thickness cannot be obtained and overall thickness increases
Solution Approach 1:
The patent uses a flexible envelope structure that can be easily formed into uniform thickness configurations. The spherical bead core material can be evenly distributed within this flexible envelope, allowing for simple fabrication processes that naturally produce uniform insulation thickness without requiring complex molding or assembly steps.
6Ease of operation
If the envelope surface is creased after fabrication, then packaging or handling is easier, but defective attachment occurs when bonded to objects
Solution Approach 1:
The patent uses a flexible envelope that can be handled and installed without creating creases. The smooth, continuous surface of the flexible envelope maintains good bonding contact with attached objects, preventing defective attachment while still allowing for easy handling and installation processes.
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 solution simplifies the fabrication process, reduces costs, maintains a stable internal vacuum, ensures uniform insulation thickness, and prevents defective bonding by using laminated mesh members and a filler with micro pores, enhancing the insulation performance and lifespan of the vacuum insulation member.
Implementation Method 1
an envelope having gas impermeability and having a certain decompressed space therein; and a core including a plurality of laminated mesh members to support the envelope at an outer side of the envelope
Implementation Method 2
a filler with micro pores
Data Source
AI summary
Disclosed is a vacuum insulation member having a uniform insulation thickness, a refrigerator having a vacuum insulation member, and a method for fabricating a vacuum insulation member. The vacuum insulation member includes: an envelope having gas impermeability and having a certain decompressed space therein; and a core including a plurality of laminated mesh members to support the envelope at an outer side of the envelope.