Vacuum Insulating Panel Edge Sealing Without Vacuum Welding
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Solution Overview
Problem
Existing vacuum heat insulating panels face challenges in manufacturability due to high manufacturing costs and low manufacturability, especially when welding is performed in a vacuum chamber. Additionally, these panels often experience a decrease in heat insulating properties due to deformation of surface materials caused by pressure differences and contact between surface materials.
Innovation Solution
The proposed solution involves a vacuum heat insulating panel design where a pair of metal plate members face each other with a spacer supporting them from the internal space side. The first plate member includes a standing plate portion formed by a curved surface, and a first resin material with gas barrier properties is interposed between the outer edge plate portions of the two plate members. This allows for joining of the metal plates at a lower temperature than welding, reducing manufacturing costs and time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is performed by bringing a welding tool into a vacuum chamber to join metal plates, then the joining strength and reliability are improved, but the manufacturing cost increases and manufacturability decreases
Solution Approach 1:
A resin material is introduced as an intermediary substance between the metal plate members to achieve joining without direct welding. The resin material fills the space between plates and bonds them together, eliminating the need to bring welding tools into the vacuum chamber while maintaining reliable joining.
Solution Approach 2:
The mechanical welding process is replaced with a chemical bonding process using resin material. Instead of using thermal energy and mechanical pressure from welding tools, the invention uses the adhesive properties of resin to join the metal plates, simplifying the manufacturing process.
2Reliability
If the internal space is evacuated to form a vacuum layer for heat insulation, then the heat insulating property is improved, but the surface material may deform due to pressure difference
Solution Approach 1:
The metal plate members are designed with sufficient flexibility to withstand the pressure difference without rigid deformation. The plates can elastically deform under vacuum pressure and return to their original shape, preventing permanent deformation while maintaining the vacuum seal for heat insulation.
3Stability of the object's composition
If protruding portions are brought into contact to prevent deformation, then the structural stability is improved, but the heat insulating property decreases due to contact between surface materials
Solution Approach 1:
The resin material serves as an intermediary that prevents direct contact between the metal plate members. It fills the gaps and contact points between plates, eliminating thermal conduction paths while maintaining structural stability through adhesive bonding rather than mechanical contact.
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 design improves manufacturability by reducing the need for high-temperature welding in a vacuum chamber, while also enhancing the durability and heat insulating properties of the panel by minimizing contact between the plate members and allowing for easier release of external pressure.
Implementation Method 1
a first resin material having a gas barrier property is interposed between the first outer edge plate portion and a second outer edge plate portion on an outer edge side of the second plate member
Implementation Method 2
a vacuum heat insulating panel in which a pair of plate members face each other in a manner that an internal space is formed between the plate members
Data Source
Figure 1A~1D
Figure 2A~2C
Figure 3A~3D
AI summary
A vacuum heat insulating panel, in which a pair of plate members face each other in a manner that an internal space is formed between the plate members, includes: a first plate member; a second plate member configured to form an internal space between the first plate member and the second plate member; and a spacer configured to support the first plate member and the second plate member. The first plate member includes a first outer edge plate portion, a standing plate portion standing from the first outer edge plate portion and formed by a curved surface, and a main plate portion continuous from the standing plate portion and supported by the spacer. A first resin material having a gas barrier property is interposed between the first outer edge plate portion and a second outer edge plate portion on an outer edge side of the second plate member.