Vacuum Insulation Panel Laser Sealing for Smaller Evacuation Chambers
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Solution Overview
Problem
Existing vacuum insulation panel manufacturing methods are costly and result in reduced heat insulating performance due to chamber size requirements, brazing needs, and evacuation issues leading to recess and flatness deterioration, which hinder high-vacuum achievement.
Innovation Solution
A method involving stacking a core member between metal plates with an evacuation port, seam welding the edges, evacuating the inner area, and laser welding a sealing member to seal the evacuation port, allowing for a compact manufacturing device and maintaining a vacuum state without heating units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If evacuation and brazing are performed in the chamber, then vacuum insulation panel can be manufactured, but the chamber size increases and manufacturing costs increase
Solution Approach 1:
The manufacturing process is segmented into two separate stages: (1) evacuation performed in a large chamber, and (2) brazing performed in a small chamber after the panel is removed from the large chamber. This segmentation allows each chamber to be optimized for its specific function, reducing the overall equipment size and cost while maintaining vacuum insulation quality.
Solution Approach 2:
Evacuation is performed as a preliminary action before brazing. The panel is evacuated in a large chamber to remove air and contaminants, then removed and brazed in a smaller chamber. This preliminary evacuation ensures the vacuum environment is established before the final sealing process, allowing the brazing chamber to be smaller since it only needs to maintain rather than create the vacuum.
2Reliability
If heating unit is used for brazing in the chamber, then sealing can be achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The heating unit required for brazing is replaced by performing brazing in a separate, smaller chamber after evacuation. The mechanical heating system is eliminated from the main evacuation chamber, reducing device complexity. The brazing process uses localized heating only in the small chamber where it is performed, rather than requiring a heating unit in the large evacuation chamber.
3Speed
If thin-walled region is compressed during evacuation, then evacuation can proceed, but evacuation passage becomes blocked and high vacuum cannot be achieved
Solution Approach 1:
Evacuation is performed as a preliminary action before the panel is removed from the chamber. During this preliminary evacuation, the thin-walled region can compress slightly to allow air removal, but the panel is then removed and brazed while maintaining the vacuum. This timing of the preliminary evacuation prevents the evacuation passage from becoming blocked, as the panel structure is stabilized before final sealing.
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 enables the production of low-cost, high-performance vacuum insulation panels with improved heat insulation by reducing chamber size, preventing evacuation passage blockage, and ensuring efficient sealing without heating, thus maintaining thermal conductivity within 2.5 to 3.0 mW/m·K.
Implementation Method 1
an evacuating step for applying a vacuum in an inner area which is held between the first metal plate and the second metal plate
Implementation Method 2
a laser welding step in which, in a state in which the inner area is made into a vacuum by the evacuating step, the evacuation port is sealed by means of a sealing member and the sealing member, the second metal plate and the backing member are laser welded
Data Source
AI summary
A vacuum insulation panel manufacturing method that makes it possible to manufacture low-cost, high-performance vacuum insulation panels, and a vacuum insulation panel are provided. This method of manufacturing a vacuum insulation panel (1) involves: a stacking step in which a first metal plate (20) is stacked on one side of an insulating core material (10), and in which a backing member (50) having an opening (51) and a second metal plate (30) having an evacuation port (32) are stacked, with the opening (51) and the evacuation port (32) stacking, on the other surface of the core member (10) in the order of backing member (50) and second metal plate (30) from the core member (10) side; a first welding step for welding outwards of where the core member (10) is arranged in the first metal plate (20) and the second metal plate (30); an evacuating step from the evacuation port (32) to create a vacuum in an inner area which is held between the first metal plate (20) and the second metal plate (30) and in which the core member (10) is arranged; and a laser welding step in which, in a state in which the inner area is made into a vacuum by the evacuating step, the evacuation port (32) is sealed by means of a sealing material (60) and the sealing material (60), the second metal plate (30) and the backing member (50) are laser welded.