Foil-Wrapped Vacuum Insulation Panel With Powder-Tight Core Envelope
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Solution Overview
Problem
The manufacturing of foil-wrapped vacuum insulation elements faces challenges in retaining particles during evacuation, which can contaminate sealing seams and damage evacuation equipment, and existing solutions like nonwoven fabrics are complex to implement with powdered core materials.
Innovation Solution
Incorporating layers of paper, cardboard, or paperboard between the core and shell to envelop the core in a powder-tight manner, using paper or cardboard materials with specific grammage and properties to enhance tear strength and foldability, and forming these materials into hollow bodies or bags to contain the core particles effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If nonwoven fabric is used to envelop the core, then particles are retained during evacuation, but the manufacturing process becomes complicated and cannot accommodate powdered core material
Solution Approach 1:
The patent changes the material parameter from nonwoven fabric to paper/cardboard/paperboard layers, which have different physical properties (porosity, flexibility, envelopeability) that enable both particle retention and easier manufacturing with powdered core material
Solution Approach 2:
The paper/cardboard layers serve as a disposable protective envelope that is easy to manufacture, use, and dispose of, replacing the more complex nonwoven fabric while achieving the same particle retention function
2Reliability
If the core is evacuated to remove air, then thermal insulation performance is improved, but particles are pulled out and contaminate sealing seams or damage evacuation pumps
Solution Approach 1:
The paper/cardboard/paperboard layers act as an intermediary protective barrier between the core particles and the external environment (sealing seams and evacuation pumps), allowing the core to be evacuated while preventing particle escape
Solution Approach 2:
The envelope layers are applied to the core before evacuation to preemptively prevent particle pull-out and contamination, addressing the harmful effect before it occurs during the evacuation process
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 approach simplifies the manufacturing process, allows for reliable particle retention, and maintains the core's shape without the need for a shaped core material, resulting in improved thermal insulation performance and reduced material density.
Implementation Method 1
within the pores the heat cannot be transported by either thermal conduction or thermal convection
Implementation Method 2
within the pores the heat cannot be transported by either thermal conduction or thermal convection
Data Source
AI summary
A foil-wrapped vacuum insulation panel having a core, and an air-tight envelope in the form of a wrapping foil surrounding the core made of powder or granulate, wherein between the core made of powder or granulate and the air-tight wrapping foil, there is provided at least one intermediate layer of cardboard and/or paperboard, which completely envelopes the core made of powder or granulate in a powder-tight manner and is formed cuboid box which has approximately the same shape as the finished vacuum insulation element, wherein the powder or granulate is filled into the cuboid box in such an amount that the body is completely filled up to its very top, and the shape of the vacuum insulation element is acquired only via the cuboid box and not by the powder or granulate, while the structural integrity of the core is not sufficient to retain the shape of the core on its own without the surrounding cardboard or paperboard box.