Method of Manufacturing Vacuum Insulation Panels

• US 20160305598A1
• Filed: 02/24/2015
• Published: 10/20/2016
• Est. Priority Date: 02/26/2014
• Status: Abandoned Application

• Current Assignee: Sonoco Development Inc (Sonoco Products Company)
• Original Assignee: Sonoco Development Inc (Sonoco Products Company)
• Inventors: Ranade, Ajit
• Application Number:
  US15/038,498
• Publication Number:
  US 20160305598A1
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B29C 66/00145 Vacuum, e.g. partial vacuum
• CPC Class Codes: B29K 2105/04 cellular or porous
• CPC Class Codes: B29L 2031/7162 Boxes, cartons, cases
• CPC Class Codes: B32B 15/08 of synthetic resin
• CPC Class Codes: B32B 15/20 comprising aluminium or copper B32B15/016 and B32B15/017 take precedence
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2264/102 Oxide or hydroxide
• CPC Class Codes: B32B 2307/304 Insulating
• CPC Class Codes: B32B 2307/7242 Non-permeable
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/281 comprising polyimides
• CPC Class Codes: B32B 27/302 comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 27/365 comprising polycarbonates
• CPC Class Codes: B32B 3/04 characterised by at least one layer folded at the edge, e.g. over another layer ; characterised by at least one layer enveloping or enclosing a material
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: F16L 59/029 layered
• CPC Class Codes: F16L 59/065 using vacuum F16L59/075 takes precedence

Abstract

A method is provided of manufacturing a vacuum insulation panel using three-dimensional printing technology. Individual layers of core material are built up to produce a rectilinear core having a very small internal wall thickness and numerable hollow areas, thus creating a core having a highly porous surface. The highly engineered porous core is then encapsulated in a plastic, aluminum or composite envelope and a vacuum is applied. Once all or most of the gas molecules are removed, the engineered VIP delivers a high level of insulation.

Claims

1. A method for manufacturing a vacuum insulation panel comprising the steps of:

(a) Providing a porous core material;

(b) Dispensing the core material from a three-dimensional printing device to produce a core comprising multiple layers of core material;

(c) Encapsulating the core in an envelope to produce an encapsulated core;

(d) Applying a vacuum to the envelope to remove gas molecules within the envelope; and

(e) Sealing the envelope to produce the vacuum insulation panel.

2. The method of claim 1 wherein:

the core material is selected from the group consisting of nylon, acrylonitrile butadiene styrene, polycarbonate and polyetherimide.

3. The method of claim 1 wherein:

step (b) includes producing a core having a highly porous, rectilinear structure.

4. The method of claim 1 wherein:

in step (b) each layer of core material has a highly porous surface.

5. The method of claim 1 wherein:

in step (b) the core comprises internal walls having a thickness between about 90 microns and about 130 microns.

6. The method of claim 1 wherein:

in step (c) the envelope is made of a material selected from the group consisting of plastic, aluminum and composite material.

7. A vacuum insulation panel comprising:

a core comprising a tray defining one or more pockets, and one or more core members nested within the pockets such that the core is a three-dimensional structure with six substantially flat sides and sharp edges; and

an envelope encapsulating the core.

8. The vacuum insulation panel of claim 7 wherein:

the tray comprises multiple layers of highly porous core material.

9. The vacuum insulation panel of claim 8 wherein:

the core members are made of an insulating material.

10. The vacuum insulation panel of claim 9 wherein:

the insulating material is selected from the group consisting of fumed silica and glass fiber.

11. The vacuum insulation panel of claim 9 wherein:

the core members are rectilinear.

12. A vacuum insulation panel comprising:

a core comprising a plurality of layers stacked in a vertically aligned arrangement to form a three-dimensional structure having six flat sides and sharp edges; and

an envelope encapsulating the core.

13. The vacuum insulation panel of claim 12 wherein:

the core 32 comprises at least one 3D layer comprising multiple layers of printed core material and at least one non-3D layer made of insulating material.

14. The vacuum insulation panel of claim 12 wherein:

the insulating material is selected from the group consisting of fumed silica and glass fiber.

15. The vacuum insulation panel of claim 13 comprising:

at least one 3D layer is located between non-3D layers.

16. The vacuum insulation panel of claim 15 wherein:

the 3D layer and non-3D layers are rectilinear.