Robust vacuum insulation panel with mechanical supports

A punch out structure for a robust vacuum insulation panel, the punch out structure forming at least one mechanical support for the vacuum insulation panel, comprising;

• a sheet of foil of a predetermined material, the sheet of foil having a punch out structure, the punch out structure having at least one tensile element;
• the at least one tensile element configured to support at least the atmospheric load applied to the vacuum insulation panel, the at least one tensile element connecting at least two compressive elements;
• the at least two compressive elements comprising an outer and an inner compressive element, each compressive element having a top and a bottom portion;
• the at least one tensile element extending between and connecting the top portion of the outer compressive element to the bottom portion of the second compressive element;
• the at least one tensile element and the at least two compressive elements transforming from a first flat form to a second constructed form upon changing the configuration of the at least one tensile element and the at least two compressive elements.

A method to produce a mechanical support structure for a robust vacuum insulation panel comprising;

• selecting a punch out structure;
• placing the punch out structure on a device that can implement a predetermined punch out force;
• selecting a foil of a predetermined material to become the mechanical support structure;
• punching out the mechanical support structure from a utilized portion of the predetermined foil material;
• removing an unutilized punched out foil excess;
• folding the utilized punch out foil along predetermined fold lines indicated on the punch out structure;
• and
• attaching weld tabs to the mechanical support structure.

A robust vacuum insulation panel with mechanical support structures comprising:

• a core comprised of a three-dimensional array of mechanical support structures constructed from at least one sheet of a foil material, the three-dimensional array of mechanical support structures configured to support at least an atmospheric load upon the vacuum insulation panel, the three-dimensional array of mechanical support structures comprising at least one mechanical support structure constructed from the at least one sheet of foil material;
• the at least one mechanical support structure having N number of compressive elements and N−1 number of tensile elements, the N number of compressive elements and the N−1 number of tensile elements configured to minimize heat transfer through the at least one mechanical support structure;
• a top foil disposed above the core and a bottom foil disposed below the core;
• and
• a side edge foil attached to the top and bottom foils, the side edge foil hermetically enclosing the sides of the core.

A robust vacuum insulation panel, comprising:

• a top foil and a bottom foil spaced apart a predetermined distance,
• a core extending between and in contact with a lower surface of the top foil and an upper surface of the bottom foil;
• the core comprising an array of spaced apart hollow mechanical supports;
• the array of hollow mechanical supports defining a heat conductivity path between the top foil and the bottom foil;
• and
• at least one black body radiation shield extending among the spaced apart hollow mechanical supports.

A robust vacuum insulation panel comprising:

• a ceramic layer and a bottom foil spaced apart a predetermined distance;
• a core extending between a lower surface of the ceramic layer and an upper surface of the bottom foil;
• the core comprising an array of mechanical supports, the mechanical supports defining a heat conductivity path between the ceramic layer and the bottom foil;
• the array of mechanical supports comprising a plurality of individual mechanical supports;
• each individual mechanical support comprising a pair of nested compressive elements and a tensile element, the tensile element in contact with and extending between the nested compressive elements.

A robust vacuum insulation panel, comprising:

• a top transparent glass pane and a bottom transparent glass pane spaced apart a predetermined distance;
• a core extending between and in contact with a lower surface of the top glass pane and an upper surface of the lower glass panel;
• the core comprising an array of mechanical supports, the mechanical supports defining a heat conductivity path between the top glass pane and the bottom glass pane;
• the array of mechanical supports comprising a plurality of individual mechanical supports;
• each individual mechanical support comprising at least a pair of nested compressive elements and at least one tensile element, the at least one tensile element in contact with and extending between the at least a pair of nested compressive elements.

A method for forming a support element for a vacuum insulation panel from a flat foil material, comprising:

• severing a predetermined amount of foil from the flat foil material, the predetermined amount of material including weld tabs;
• placing a conducting rod of a predetermined cross section over the predetermined amount of foil;
• wrapping, using a first actuator initially located below the predetermined amount of foil, the predetermined amount of foil around a lower portion of the conducting rod;
• pinching together, using a second actuator, a top part of the predetermined amount of foil over the conducting rod;
• attaching together, using one of spot welding and brazing, the weld tabs;
• removing the conducting rod.