Vacuum Insulation Panel Leveling Layer for Flat Metal Surfaces
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Solution Overview
Problem
Vacuum insulation bodies in refrigerators and freezers often exhibit irregularities due to high pressure causing local density differences, which can lead to visible imperfections on sheet metal walls, failing to meet high optical standards when no additional insulation materials are used.
Innovation Solution
Incorporating a curable or cured material, such as cast resin based on epoxy or polyurethane, between the vacuum film and the protective cover to level out irregularities, which also serves as a protective layer, ensuring a smooth and damage-resistant surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a vacuum insulation body with powder core is used under high pressure (e.g., 10 t/m2), then the insulation body provides effective thermal insulation, but local density differences in the powder core cause irregularities on the film surface that become visible on sheet metal walls
Solution Approach 1:
A liquid injection material is introduced as an intermediary substance between the vacuum insulation body and the sheet metal wall. This material fills irregularities on the film surface and cures to form a leveling layer, preventing transmission of surface defects to the visible sheet metal exterior while maintaining the insulation body's thermal performance
Solution Approach 2:
The injection material undergoes a parameter change from liquid to solid state through curing. In liquid form, it flows to fill irregularities; after curing, it becomes a rigid leveling layer that prevents irregularity transmission, thus resolving the surface flatness issue without compromising insulation reliability
2Strength
If sheet metal wall is used as protective cover to provide good protection against damages, then the protective strength is improved, but irregularities of the vacuum insulation body are transmitted to the sheet metal surface making it visible
Solution Approach 1:
The liquid injection material serves as a mediator between the irregular vacuum insulation body and the rigid sheet metal wall. It absorbs and levels out surface irregularities, preventing their transmission to the sheet metal while allowing the sheet metal to maintain its protective function
Solution Approach 2:
The solution creates a composite structure consisting of the vacuum insulation body, the cured injection material layer, and the sheet metal wall. This multi-layer composite combines the protective strength of sheet metal with the irregularity-leveling properties of the cured injection material, achieving both protection and optical quality
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
Effectively conceals irregularities on the vacuum insulation body, meeting high optical demands by creating a flat surface that prevents deformation and damage, even in the absence of additional insulation materials.
Implementation Method 1
the material preferably is a curable or already cured material
Data Source
AI summary
The present invention relates to a vacuum insulation body with at least one vacuum-tight film which surrounds a vacuum region with at least one supporting material arranged therein. At least one protective cover for protection of the film is provided, and a material leveling out film irregularities is included as well.