Vacuum Heat Insulating Panel Resin Edge Joining Under Vacuum
Find Innovative SolutionsGenerate Solutions
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, and they also suffer from decreased heat insulating properties due to deformation and contact issues.
Innovation Solution
A vacuum heat insulating panel design that includes a pair of metal plate members facing each other with a spacer in between, where a first resin material with gas barrier properties is interposed between the outer edge plate portions of the plate members, allowing for joining at a lower temperature than welding, thereby reducing manufacturing costs and improving durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is performed by bringing a welding tool into a vacuum chamber to join metal plate members, 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 structural integrity.
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 adhesive properties of resin to join the metal plates, simplifying the manufacturing process and improving ease of manufacture.
2Stability of the object's composition
If protruding portions are brought into contact with each other to prevent deformation of thin plates, then the structural stability is improved, but the heat insulating property decreases when contact portions are displaced due to aging or external pressure
Solution Approach 1:
A resin material is introduced as an intermediary between the protruding portions of metal plate members. This resin layer prevents direct contact and potential displacement issues while maintaining structural support, thereby preserving heat insulating properties even after aging or under external pressure.
Solution Approach 2:
The invention changes the physical state and properties of the bonding medium from solid-to-solid contact to a resin-based adhesive bond. This parameter change allows for controlled flexibility and stress distribution, preventing displacement of contact portions while maintaining both structural stability and heat insulating performance.
3Reliability
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 be deformed due to pressure difference between internal space and atmospheric pressure
Solution Approach 1:
Protruding portions are formed on the metal plate members before evacuation. These protrusions are designed to make contact and provide structural support against atmospheric pressure before the vacuum is created, preventing deformation of the surface materials during and after evacuation.
Solution Approach 2:
The protruding portions are formed with curved surfaces that can elastically deform under pressure. This curvature allows the protrusions to flex and maintain contact under atmospheric pressure while supporting the vacuum structure, preventing flat surface deformation.
4Ease of manufacture
If a resin material with gas barrier property is interposed between outer edge plate portions to enable low-temperature joining, then the manufacturability and cost are improved, but the joining temperature must be controlled to prevent vacuum chamber contamination
Solution Approach 1:
The joining process uses low-temperature curing of resin material instead of high-temperature welding. By controlling the temperature parameter to remain below the vacuum chamber's contamination threshold, the invention achieves easy manufacture without compromising vacuum integrity.
Solution Approach 2:
The resin material selection and curing process are designed to not release harmful vapors or contaminants in the vacuum environment. The resin acts as an inert bonding agent that maintains vacuum chamber cleanliness while enabling low-temperature joining of metal plates.
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
The proposed solution enhances manufacturability by reducing costs and time in joining metal plate members in a vacuum chamber, while also improving the heat insulating properties and durability of the panel by minimizing contact and deformation issues.
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 obtained by evacuating the internal space
Data Source
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.