Vacuum Insulation Panel Foil Folding to Prevent Thermal Bridging
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Solution Overview
Problem
Typical methods for packaging vacuum insulation panels result in a level difference (step) between folded planes on the upper and lower surfaces of the core, leading to thermal bridging and poor insulation performance when panels are connected.
Innovation Solution
A method involving wrapping a core in airtight foil, forming side folding lines using a jig guided along the core's side surfaces, bringing the surfaces into contact with a step member, folding and pressing the foil onto the step member, and sealing with a thermal bonding member to prevent steps and gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the airtight foil is folded over the upper and lower surfaces of the core using conventional methods, then the packaging process is simple, but a level difference (step) is formed between folded planes, causing thermal bridging and poor insulation performance
Solution Approach 1:
A step member is introduced as an intermediary tool during the folding process. The step member is positioned between the folded airtight foil and the core surface, allowing the foil to be folded without creating a step on the core. This mediator enables the folding operation to proceed while maintaining a flush surface, eliminating thermal bridging paths.
Solution Approach 2:
The step member is positioned in advance at the location where the folding will occur. By pre-positioning this tool, the folding operation can be performed correctly from the start, preventing step formation before it happens. This preliminary arrangement ensures that subsequent folding actions produce the desired flush surface without requiring post-processing corrections.
2Ease of operation
If the airtight foil is folded without using a step member, then the packaging operation is straightforward, but folding lines cannot be formed at regular locations, leading to construction misalignment
Solution Approach 1:
The step member serves as a positioning intermediary that defines the exact location where folding lines should be formed. By placing the step member at predetermined positions, the folding operation automatically occurs at regular, accurate locations. This mediator translates the requirement for precise folding line positioning into a simple operational procedure.
Solution Approach 2:
Instead of using complex mechanical positioning systems or measurement tools to locate folding lines, the invention replaces these with a simple step member that physically defines the folding location. The step member's geometry and position directly determine the folding line location, eliminating the need for complex mechanical positioning mechanisms.
3Productivity
If conventional folding methods are used, then the packaging process is quick, but gaps are formed at junctions between panels, causing thermal bridging and energy loss
Solution Approach 1:
The step member acts as a mediator that prevents gap formation at panel junctions during the folding process. By maintaining a flush surface between the folded foil and the core, it ensures that when multiple panels are assembled, their junctions align properly without gaps. This eliminates thermal bridging paths that would otherwise cause energy loss in the insulation wall.
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 method prevents the formation of steps on the core surfaces, reduces thermal bridging, and enhances the insulation performance of the assembled panels, allowing for accurate energy prediction and construction alignment.
Implementation Method 1
sealing the folding planes using a thermal bonding member
Data Source
Figure 1~3(b)
Figure 4(a)~5
Figure 6~8
AI summary
A method of packing a vacuum insulation material is provided. In one embodiment, the method includes: (a) wrapping a core in an airtight foil such that upper and lower surfaces of the core are open; (b) forming a side folding line and two corresponding folding planes with reference to the side folding line by pushing remaining airtight foil over the upper and lower surfaces of the core wrapped in the airtight foil inwardly of the upper and lower surfaces of the core from both sides of the core; (c) bringing the upper and lower surfaces of the core into close contact with a step member; (d) folding and pressing the folding planes of the airtight foil protruding between the step member and the upper and lower surfaces of the core onto the step member; and (e) sealing the folding planes using a thermal bonding member.