Explore the vacuum evacuation process of thermos cups

Explore the vacuum evacuation process of thermos cups: technology, advantages and applications

In today's global thermos cup market, the vacuum evacuation process is one of the key factors that determine the performance of thermos cups. For international wholesale buyers, a deep understanding of this process is essential for selecting high-quality products and expanding business. This article will explore all aspects of the vacuum evacuation process ofthermos cupsand present you with a detailed technical analysis.

1. Overview of the vacuum evacuation process of thermos cups
The thermos cup usually adopts a double-layer structure, with an inner and outer layer forming an interlayer. The vacuum evacuation process is to process this interlayer. By vacuuming, the heat conduction and convection conduction of the gas in the interlayer can be greatly reduced, thereby significantly improving the insulation performance of the thermos cup.
The early vacuum evacuation process of thermos cups was mainly tail vacuum evacuation. That is, the vacuum nozzle at the bottom of the cup is connected to the vacuum pump to extract the air in the interlayer. When a certain vacuum degree is reached, the vacuum nozzle is sealed by pressure sealing technology, but a tail will be left at the bottom of the cup, which is the vacuum tail. However, this exhaust tail is relatively fragile and can be easily damaged during transportation or use, resulting in a decrease in thermal insulation performance.
With the continuous advancement of technology, the tailless vacuum pumping process has emerged and gradually become the mainstream of the industry. This process uses computers to accurately control the exhaust, sealing, cooling and other links in a vacuum environment. During sealing, the melting and sealing technology is used to melt the solder at high temperature and seal the exhaust hole, without leaving the exhaust tail, which effectively prevents the leakage problem caused by the tail damage and greatly enhances the reliability and service life of the product.

2. Technical details of the tailless vacuum pumping process
(I) Equipment requirements
The tailless vacuum pumping process needs to be carried out under high vacuum conditions, and usually uses professional equipment such as vacuum furnaces. These equipment can accurately control key parameters such as internal vacuum, temperature and time, providing a stable and reliable environment for the entire process.
(II) Sealing materials
The industry generally uses glass substrates as brazing materials, or selects metal welding balls of the same material as the cup body. Glass substrate brazing materials will melt at high temperatures and fuse with the vacuum holes to achieve sealing. The metal welding ball is melted into the cup body through laser welding and other methods. This sealing method has higher welding strength and stability for the same metal, and the color after sealing is consistent with the cup body, which is conducive to subsequent spraying processing.
(III) Process Flow
Pre-vacuuming: First, place the thermos cup in a vacuum furnace, start the vacuum system, and pump the vacuum degree in the furnace to a certain level, such as about 4×10²Pa. In this process, the furnace may also be preheated to improve the efficiency and quality of subsequent processes.
High temperature and high extraction and getter activation: Continue high vacuum extraction, and at the same time increase the temperature in the furnace to about 450 degrees. When the vacuum degree reaches 1×10⁻³Pa, keep it warm at this temperature for a certain time, such as 20 minutes, to activate the getter. The getter can absorb residual gas and further increase the vacuum degree of the interlayer, which plays a key role in maintaining the thermal insulation performance of the thermos cup for a long time.
Sealing welding: Under the condition of maintaining high vacuum and high temperature, the vacuum hole is sealed by brazing or laser welding. For example, a laser welding gun is used to weld the welding ball and the vacuum hole according to preset parameters to ensure the firmness and sealing of the sealing.
Cooling: After the sealing is completed, the thermos cup needs to be slowly cooled in a vacuum furnace. When the temperature drops to a certain level, air or nitrogen is filled into the furnace to balance the pressure inside the furnace with the outside to complete the entire vacuum process.

3. Advantages of tailless vacuuming process
(I) Excellent insulation performance
The tailless vacuuming process performs vacuuming and sealing welding at a high temperature of nearly 1000℃. When the product returns to room temperature, its vacuum degree will be much higher than that of tailed vacuum products. A higher vacuum degree means that the heat conduction and convection of the gas molecules in the interlayer are weaker, which significantly extends the insulation time of the thermos cup, enabling it to maintain the temperature of the beverage for a longer period of time and meet consumers' high expectations for insulation effect.
(ii) Larger effective capacity
The vacuum flask with a tail needs to retain the exhaust tail and the "tail storage room" that matches it, which occupies the space inside the cup body to a certain extent. The tailless vacuum flask removes the exhaust tail and does not need to set up a "tail storage room", so that the space inside the cup body is fully released. Under the same appearance volume, the effective volume of the tailless vacuum flask is larger, which can provide consumers with more beverage capacity and improve the practicality of the product.
(iii) Longer service life
The pressure sealing technology of the tail vacuum flask is difficult to achieve complete sealing at the microscopic level. After long-term use or certain external force impact, it is easy to leak. In contrast, the melting sealing technology of the tailless vacuum flask allows the solder to fully melt at high temperature and fuse with the cup body, forming a tighter and firmer sealing structure, which can maintain a non-degassing and non-leaking state for a long time, thereby extending the service life of the thermos flask and reducing the replacement frequency of consumers. At the same time, it also provides a more reliable long-term supply guarantee for wholesale buyers.
(IV) Good appearance texture
The tailless vacuuming process avoids the existence of exhaust tails, making the appearance of the thermos cup more concise and beautiful. In addition, the use of welding materials that are the same as the cup body and have been finely processed, the color of the sealing part is consistent with the cup body, and the overall appearance is more coordinated and unified, which improves the grade and attractiveness of the product, has more advantages in market competition, and helps wholesale buyers meet the needs of different consumers for product appearance.
(V) Higher production efficiency and lower energy consumption
The traditional tail vacuuming process is relatively cumbersome, and has high requirements for the adaptability of equipment and operating environment, resulting in low production efficiency. The tailless vacuuming process can achieve more efficient production with the help of advanced equipment and automation technology. At the same time, by optimizing the process flow and parameters, such as using more energy-saving methods such as laser welding, energy consumption is reduced, and production costs are reduced, so that wholesale buyers can obtain more competitive price advantages while ensuring product quality.

4. The current situation and limitations of the tail vacuuming process
Although the tailless vacuuming process has obvious advantages, the tail vacuuming process has not completely withdrawn from the market. In some specific scenarios, such as some large-volume cup and pot products, the tail vacuum process may still be adopted due to factors such as equipment cost and process compatibility. However, its inherent limitations limit its development in the high-end thermos cup market.
Due to the existence of the exhaust tail, the tail vacuum process is not only easily damaged during transportation and use, resulting in an increase in product scrap rate, but also difficult to compete with the tailless vacuum process in terms of thermal insulation performance and service life. With the continuous improvement of consumer requirements for product quality and performance, as well as the continuous maturity of tailless vacuum process technology and the gradual reduction of costs, the market share of the tail vacuum process is expected to continue to shrink.

5. Challenges and solutions faced by tailless vacuum process

(I) Equipment and technical threshold

The tailless vacuum process has extremely high requirements for the accuracy and performance of production equipment, such as vacuum control of vacuum furnaces, temperature uniformity, and positioning accuracy of welding equipment. Enterprises need to invest a lot of money to purchase advanced equipment, and need professional technicians to operate and maintain it.

Solution:
Governments and industry organizations can provide relevant equipment purchase subsidies and technical training programs to help small and medium-sized enterprises improve their technical level. At the same time, equipment suppliers should also continuously optimize product design, reduce equipment costs, and improve the ease of use and reliability of equipment to promote the application of tailless vacuum pumping technology in more enterprises.
(II) Process stability and quality control
The tailless vacuum pumping process involves multiple complex links, and deviations in any link may affect the quality stability of the product. For example, performance fluctuations of brazing materials and slight changes in welding parameters may lead to problems such as loose sealing and air leakage.
Solution:
Enterprises should establish a strict quality management system to monitor every link from raw material procurement to production process control to finished product inspection. At the same time, strengthen technical training and quality awareness education for production personnel to improve their operating skills and sense of responsibility. In addition, use advanced testing equipment and technologies, such as helium mass spectrometer leak detectors, to conduct quality inspections on products, timely discover and solve quality problems, and ensure the stability and consistency of product quality.
(III) Cost and market competition
Although the tailless vacuum pumping process has advantages in product quality and performance, its production cost is relatively high, which to a certain extent affects its promotion in the mid- and low-end markets. In the fierce market competition, enterprises need to ensure product quality while striving to reduce production costs to improve the cost-effectiveness of products.
Solution:
Enterprises can reduce costs by optimizing production processes, improving production efficiency, and reducing the waste of raw materials. For example, adopting automated production technology, reducing manual operation links, and improving production efficiency; establishing long-term and stable cooperative relationships with suppliers to reduce the cost of raw material procurement; strengthening the recycling and reuse of waste materials in the production process to reduce production costs, etc. At the same time, enterprises can also seek higher profit margins in the high-end market by innovating product design and increasing product added value to balance the relationship between production costs and market prices.

6. Development trend of tailless vacuuming process
(I) Intelligent and automated production
With the continuous development of industrial automation and intelligent manufacturing technology, the vacuuming process of thermos cups will move towards a more intelligent and automated direction. The vacuuming equipment of the future will have a higher degree of automation, and can realize the full process of automated production from loading, vacuuming, sealing and welding to unloading. At the same time, with the help of advanced sensor technology, artificial intelligence algorithms and big data analysis, the equipment will be able to monitor various parameters in the production process in real time, automatically adjust process parameters, ensure the stability and consistency of product quality, and be able to predict and warn equipment failures, thereby improving the operating efficiency and reliability of the equipment.
(II) Green environmental protection and sustainable development
Against the background of increasing global attention to environmental protection, the vacuum evacuation process of thermos cups will also pay more attention to green environmental protection and sustainable development. On the one hand, in the process of equipment research and development and production, more energy-saving, low-carbon and environmentally friendly materials and technologies will be used to reduce energy consumption and pollutant emissions. For example, efficient vacuum pumps and heating systems will be used to improve energy utilization efficiency; non-toxic, harmless and degradable brazing materials will be used to reduce environmental pollution. On the other hand, enterprises will strengthen the treatment and recycling of production waste, realize the recycling of resources, and reduce resource waste in the production process.
(III) Integration and innovation with other technologies
The tailless vacuum evacuation process will continue to integrate and innovate with other thermos cup manufacturing technologies to jointly promote the improvement of thermos cup product performance and quality. For example, combined with the research and development of new insulation materials, thermos cup products with higher insulation performance are developed; combined with intelligent temperature control technology, intelligent reminder technology, etc., to provide consumers with a more intelligent and personalized use experience; combined with fashion design, cultural creativity and other elements, to create thermos cup products with unique charm and brand value to meet the increasingly diverse needs of consumers.

7. Market prospects of tailless vacuum flask
With the improvement of people's living standards and the change of consumption concepts, the demand for high-quality thermos cups continues to increase. Tailless vacuum flasks have broad prospects in the global market with their excellent insulation performance, larger effective capacity, longer service life and more beautiful appearance.
In the international market, consumers in developed countries such as Europe and the United States have high requirements for the quality and performance of thermos cups, and have a high acceptance and demand for tailless vacuum flasks. At the same time, in emerging market countries, with the development of the economy and the improvement of consumption capacity, the demand for high-quality thermos cups is also showing a rapid growth trend. For international wholesale buyers, choosing to cooperate with thermos cup manufacturers with advanced tailless vacuuming technology can meet the needs of customers in different markets, expand business scope and enhance market competitiveness.

VIII. How to choose a high-quality thermos cup supplier with tailless vacuuming technology
(I) Evaluate the technical strength of the supplier
Understand the supplier's R&D investment, equipment technology level and process innovation ability in tailless vacuuming technology. Visit its production workshop to inspect the advanced level of equipment, the standardization and automation level of production process, etc. At the same time, ask the supplier about the technical details and quality control measures of the process, and evaluate whether its technical strength can guarantee the stability and reliability of product quality.
(II) Inspect product quality and certification
Require the supplier to provide product quality inspection reports and relevant certification certificates, such as ISO quality management system certification, FDA food safety certification, etc. Check whether the product's appearance quality, thermal insulation performance, sealing and other indicators meet the standard requirements. In addition, you can also understand the performance of its product quality in actual use by checkingthe supplier'scustomer evaluation, market reputation, etc.
(III) Compare prices and services
Compare the product prices and services of different suppliers on the premise of ensuring product quality. Choose suppliers with reasonable prices and cost competitiveness, and also consider the service quality of suppliers, such as the accuracy of delivery time, timeliness and professionalism of after-sales service, etc. Good service can solve the worries of wholesale buyers and ensure the smooth development of business.
(IV) Pay attention to the sustainable development capabilities of suppliers
Understand the performance and sustainable development capabilities of suppliers in terms of environmental protection and social responsibility. Choosing suppliers with good environmental awareness and social responsibility will not only help promote the sustainable development of the industry, but also enhance their own brand image and social reputation.

In summary, the development process of the vacuum evacuation process of thermos cups from tail to tailless reflects the important role of scientific and technological progress in improving product performance and quality. The tailless vacuum evacuation process has a dominant position in the thermos cup market with its significant advantages, but it still faces some challenges. In the future, with the continuous innovation and development of technology, the tailless vacuum evacuation process will show a development trend of intelligence, greening and integrated innovation, and the market prospects are broad. For international wholesale buyers, in-depth understanding of this process and selection of high-quality suppliers will help seize opportunities in the fierce market competition and achieve sustainable development of business.