Main content:
Second-generation vacuum insulation
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Innovation 1: Vacuum insulation panel with stepped profiles along the edges. This enables the panels to be installed with lapped joints
© va-Q-tec AG
Vacuums enable very good thermal protection within a small space. During recent years there have been various pilot projects using vacuum panels in building facades. The panels consist of plate-shaped, micro-porous silicon dioxide that is packed in a gas- and water vapour-tight film under vacuum. Although these panels have excellent thermal insulation, their manufacture is very expensive. In addition, thermal leaks occur at the joints between the panels. In a research project, a production process for a new type of vacuum panel has been developed. Loose silica powder can now be directly processed to form vacuum insulation panels. This enables special shapes to be realised such as vacuum panels with continuously stepped profiles or cylindrical, curved vacuum elements. The new vacuum insulation panels have already been successfully tested in practice in various buildings.
Technology summary
| Term of project | 01.04. 2006 bis 31.01.2010 |
|---|---|
| Technology status |  Pilot Project |
| Key aspects |
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Project description
Vacuum insulation panels were previously manufactured from compressed silica powder. The support pillars that are manufactured in an upstream process are then packed under vacuum in the high-barrier film and sealed. It was previously not possible to process loose powder fillings. This would have several advantages, however, since it would also enable cheaper materials to be used as supporting cores, special shapes could be manufactured and the overall production process would be simpler.
Therefore one of the aims of the research project was to develop a new manufacturing process that also enables powdery materials to be directly processed to form vacuum insulation panels. At the same time it was also intended to reduce and simplify the manufacturing process to a few steps while enabling vacuum shapes with complex geometries.
Focus
The project is essentially concerned with the integration of injected loose powder fillings in a new production process for manufacturing vacuum insulation panels. It shall also be used for manufacturing special vacuum shapes that will also be developed in the project. Because increased demands are made in terms of the robustness and air-tightness of the barrier films –particularly when using cheap loose powder – improved envelope designs are also being investigated.
Successes
A simplified manufacturing process for vacuum insulation panels has been developed, which, because of its reduced complexity, enables considerably reduced costs. A pilot production plant has been established for processing powdery fillings and manufacturing special elements. A demonstration building has already been equipped with the new powder-filled vacuum insulation panels. It has also been possible to lower the thermal conductivity of vacuum insulation panels with silica powder fillings relative to existing products. An interesting aspect is the ability to create indentations to restructure the surface of the powder-filled panels. For example, cylindrical and curved vacuum insulation panels or panels with continuously stepped profiles can now be manufactured.
Milestones
On completion of the research project, the production technology will be further developed and made ready for series production.
Application
The new product is available from va-Q-tec AG under the name “va-Q-plus B” for building applications and under the name “va-Q-plus” for further applications such as freezers and refrigeration units.
