Analysis of the Full Installation Process of Vacuum Insulation Panels (VIP) and New Developments in the International Market

I. In-Depth Analysis of the STP Vacuum Insulation Panel Installation Process

1. Pre-Construction Preparation: Precise Pretreatment

① Base Inspection: Scan the wall surface using an infrared thermal imaging camera (such as the FLIR A8000 series). Thermal imaging measures temperature gradients and ensures they are ≤0.5°C/m. Furthermore, a high-precision humidity sensor (accuracy ±0.1% RH) monitors wall humidity, which should be ≤8%. For renovations of existing walls, X-ray fluorescence spectrometry (XRF) is required to measure the heavy metal content of the wall to prevent core material contamination. For example, in a German project, XRF testing revealed excessive lead content in the wall. After special treatment, the VIP vacuum insulation panels are installed to ensure unaffected material performance.

② Material Pre-Cutting: Use a laser water jet cutter (accuracy ±0.1mm) to cut the panels to the designed dimensions, leaving a 3-5mm expansion joint to accommodate thermal expansion and contraction. Immediately after cutting, seal the edges with a nano-grade sealant (such as Henkel's TEROSON® MS 9385). This sealant maintains its elasticity in temperatures ranging from -50°C to 150°C, preventing air infiltration.

③ Tool Upgrade: Equipped with a vacuum pressure sensor (range 0-10 Pa) to monitor the vacuum level of the panels in real time, an electronic torque wrench (accuracy ±2%) is used to control the anchor tightening force (standard value 8-12 N·m). For example, at a construction site in Japan, the electronic torque wrench ensures consistent tightening force for each anchor, preventing deformation of the panels due to uneven local force.

2. Core Installation Process: Modularized Intelligent Construction

① 3D Positioning System: Based on BIM + GPS integrated technology, a Trimble V10 laser scanner is used to create a 3D wall model with an error control of within ±0.3 mm. Construction workers can view the model in real time using AR glasses, guiding the precise splicing of panels to ensure a joint width of ≤1 mm. For example, on a super-high-rise building project in Dubai, the application of this technology increased installation efficiency by 30%. ② Intelligent Bonding Technology: An AI-powered visual recognition robot (such as ABB YuMi) automatically applies graphene-modified bonding mortar (bond strength ≥ 1.2 MPa) and uses an ultrasonic flaw detector to inspect the bond layer for uniformity, with a defect rate of ≤ 0.5%. This mortar contains graphene nanoparticles, which improve thermal conductivity and enhance bonding strength.

③ Dynamic Sealing Process: Shape memory alloy strips (such as NiTi) are embedded in the joint to automatically compensate for thermal expansion and contraction within a temperature range of -50°C to 80°C. Combined with a liquid metal sealant (such as GaInSn), this process achieves nanoscale sealing. For example, in a Norwegian polar project, this process achieved joints without cracking at -40°C, maintaining a stable vacuum level. 3. Acceptance and Operation and Maintenance: Full Lifecycle Management

① Four-Dimensional Inspection System: Vacuum level is measured using a magnetic levitation vacuum gauge (MKS 937B), ≤10Pa; thermal conductivity is tested using the transient plane heat source method (TPS 2500), with a standard value of ≤0.0025 W/(m·K); fire resistance is assessed using a cone calorimeter (ISO 5660), with a peak heat release rate of ≤100kW/m²; and compressive strength is tested using a pressure testing machine (Instron 5982), ≥0.5MPa.

② Intelligent Operation and Maintenance Platform: Deploy an IoT sensor network (such as LoRaWAN) to monitor the vacuum level, temperature field, and stress changes of the panels in real time. When the vacuum level drops to a critical value (e.g., 50Pa), the system automatically triggers a drone inspection (such as the DJI Matrice 350 RTK) to locate and mark the damaged area. For example, a data center in Singapore has achieved fault early warning using this platform, improving operation and maintenance efficiency by 40%.

II. VIP Performance Breakthroughs and Full-Scenario Applications

1. Revolution in Materials Science

① Nano-core Material Innovation: Utilizes a composite structure of mesoporous silica aerogel (pore size 2-50 nanometers) and a carbon fiber skeleton. Using atomic layer deposition (ALD) to coat the core material with an Al₂O₃ nanolayer, the core material's water absorption rate is reduced to ≤0.1%, while its puncture resistance is tripled. For example, VIP core material produced using this technology in a US laboratory maintains structural stability even at -196°C in liquid nitrogen.

② Packaging Technology Upgrade: Developed a multi-layer composite gas barrier film (e.g., a five-layer structure of EVOH/PET/Al/PET) with a water vapor transmission rate of ≤0.001g/(m²·day) and a vacuum-maintaining lifespan of over 30 years. This gas barrier film utilizes nano-scale coating technology to effectively block the permeation of oxygen and water vapor. 2. Extreme Environment Applications

① Polar Research Stations: China's Zhongshan Station in Antarctica uses VIP vacuum insulation panels to cover the building's exterior walls. At -60°C, heat loss from the walls is reduced by 85%, maintaining a stable indoor temperature of 20±2°C. The snowmelt system utilizes vacuum insulated pipes (DN150), which deliver 70°C hot water with a temperature drop of ≤0.5°C/km. The pipes feature a three-layer vacuum structure: an inner stainless steel layer, a middle nanocore material layer, and an outer carbon fiber composite material layer.

② Deep-sea Equipment: The deep-sea methane hydrate pressure-maintaining and thermally insulated sampler developed by Shenzhen University in China utilizes VIP material. This achieves long-term in-situ pressure (14.5 MPa) and temperature (3°C) stability at a depth of 1,385 meters, ensuring 100% fidelity of methane hydrate samples. The sampler is equipped with a pressure sensor and temperature control system, enabling real-time adjustment of the insulation performance.

③ Aerospace: The cryogenic chamber of the Tianzhou-6 cargo spacecraft utilizes VIP material. In environments with temperatures varying from -20°C to 40°C, the insulation time is extended to 120 hours, ensuring the safety of astronauts' food and medicine. The VIP panel features a lightweight carbon fiber shell, only 15 mm thick, making it 60% lighter than traditional insulation materials.

3. Innovations in Industry and Construction

① Cold Chain Logistics: This medical cold chain box utilizes a VIP + phase change material composite structure, maintaining heat for up to 168 hours at -80°C. It is FDA 21 CFR Part 11 certified, meeting the transportation requirements for mRNA vaccines. It is equipped with a temperature recorder for real-time temperature monitoring.

② Industrial High-Temperature Sector: The Redstone Concentrated Solar Power Plant in South Africa uses high-temperature-resistant VIP (800°C resistant) to cover its molten salt storage tanks, reducing CO2 emissions by 66.5 tons annually and increasing system efficiency by 12%. The VIP panel features a ceramic fiber core and a metal insulation layer to withstand extreme temperatures. ③ Ultra-low energy buildings: The Hamburg "HafenCity" project in Germany uses VIP exterior walls (20mm thick) with an overall window K value of ≤0.6 W/(m²·K), resulting in an annual energy consumption of only 15 kWh/(m²·a), meeting the EU's "nearly zero energy building" standard. The building employs a passive design and incorporates a solar photovoltaic system to achieve energy self-sufficiency.

III. International Market Dynamics and Technology Trends

1. Policy and Standard Updates

EU: The Energy Performance of Buildings Directive, implemented in 2025, requires that the thermal conductivity of exterior walls of new buildings must be ≤0.10 W/(m·K), driving the VIP penetration rate to 45%. VA-Q-TEC, a German company, has launched recyclable VIP insulation material, reducing its carbon footprint by 35% and receiving EU CE certification.

US: California's Title 24-2025 standard reduces the thermal conductivity limit for insulation layers in industrial equipment from 0.035 W/(m·K) to 0.025 W/(m·K). Aspen Aerogels has launched VIP material that is resistant to temperatures of 1000°C and has been used in the thermal insulation layer of Boeing 787 engines.

China: The "Passive Ultra-Low Energy Building Technical Standard" (GB/T 51350-2024) lists VIP vacuum insulation panels as a core material. Woqin's 5mm ultra-thin VIP has passed the scientific and technological achievement appraisal of the Ministry of Housing and Urban-Rural Development, increasing installation efficiency by 50%.

2. Technological Breakthrough

Flexible VIP: BASF of Switzerland has launched NanoFlex® flexible nanosheets, with a bending radius of ≤5mm, suitable for complex curved surfaces such as pipelines and ships. Its thermal conductivity is ≤0.003 W/(m·K). This material utilizes a nanofiber matrix and can withstand repeated bending.

Smart VIP: LG Chem of South Korea has developed self-healing VIP. When the vacuum level drops, embedded microcapsules release a sealant to automatically repair damage. This technology has been applied in data center cold aisles. This technology achieves automatic repair by rupturing the microcapsules and releasing the sealant.

Conclusion

Vacuum insulation panels are evolving from traditional insulation materials to become versatile, intelligent, and suitable for extreme environments. With breakthroughs in artificial intelligence construction technology, self-healing materials, ultra-high temperature resistant core materials and other technologies, vacuum insulation panels will drive global construction and industrial energy consumption to reduce by 40% by 2030, becoming a strategic fulcrum for achieving the "dual carbon" goals.