3D Vacuum Insulated Refrigerator Structure Using Molded Porous Core

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Solution Overview

Problem

Existing methods for forming vacuum insulated refrigerator structures face limitations, such as inefficiencies in shaping and maintaining a vacuum, which affect the insulation performance and durability of the structures.

Innovation Solution

A method involving the use of a female and male mold to deform porous filler material into a 3D shape, with barrier films sealing a vacuum between them, creating a vacuum insulated core that can be integrated between a liner and a wrapper to form insulated components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If porous filler material is used for vacuum insulation, then insulation performance is improved, but maintaining consistent vacuum and preventing material deformation is difficult

Engineering Contradiction:

Improveinsulation performanceVSAvoidvacuum consistency

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The porous filler material is positioned and pre-formed within the mold cavity before the vacuum sealing process. The male and female molds are brought into contact to deform the material into the desired 3D shape while the vacuum is simultaneously established, ensuring the material maintains its shaped configuration throughout the vacuum formation process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Barrier films are used to seal the vacuum space while allowing the porous filler material to be deformed into complex 3D shapes. The flexible nature of the barrier films enables them to conform to the deformed porous material while maintaining the vacuum seal, resolving the contradiction between material deformation and vacuum consistency.

Inventive Principle:

Principle #30Flexible shells and thin films

2Strength

If porous filler material is deformed into 3D shape, then structural integrity is improved, but maintaining vacuum seal during deformation is challenging

Engineering Contradiction:

Improvestructural integrityVSAvoidvacuum seal

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The deformation process and vacuum sealing process are merged into a single simultaneous operation. The male and female molds are brought into contact to deform the porous filler material into the desired 3D shape while the barrier films are simultaneously sealed to create the vacuum environment, ensuring both structural integrity and vacuum seal are achieved together.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The barrier films serve as flexible seals that can accommodate the deformation of the porous filler material into complex 3D shapes while maintaining the vacuum integrity. The flexibility of these films allows them to conform to the changing geometry of the porous material during the deformation process.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If complex 3D shaping is achieved, then insulation efficiency is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveinsulation efficiencyVSAvoidmolding process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The manufacturing process is segmented into distinct functional components: the female mold cavity for positioning, the male mold for deformation, and the barrier films for sealing. This segmentation allows each component to perform its specific function efficiently, reducing overall process complexity while achieving complex 3D shapes.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The male and female molds serve multiple functions: they position the porous filler material, deform it into the desired 3D shape, and simultaneously establish the vacuum seal when brought into contact. This multi-functionality reduces the need for separate operations, simplifying the manufacturing process while achieving complex geometries.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach effectively forms a high-performance vacuum insulated core that enhances the insulation efficiency and structural integrity of refrigerator components by maintaining a consistent vacuum and ensuring effective sealing.

Implementation Method 1

A vacuum is formed between the first and second barrier films

Methodology Applied

Scientific EffectVacuum insulation: Vacuum

Implementation Method 2

vacuum insulated core having porous filler material disposed in a vacuum

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS11752669B2Method of fabricating 3D vacuum insulated refrigerator structure having core material

Publication Date: 2023.09.12 WHIRLPOOL CORP

AI summary

A method of fabricating a vacuum insulated refrigerator structure includes positioning a first barrier film in a female mold cavity. Porous filler material is positioned on the barrier film, and a second barrier film is positioned over the porous filler material. A male mold is brought into contact with the second barrier film to deform and compress the porous filler material into a 3D shape. A vacuum is formed between the first and second barrier films, and the first and second peripheral edge portions are sealed together to form a vacuum insulated core. The vacuum insulated core may be positioned between a liner and a wrapper to form an insulated refrigerator cabinet, door, or other vacuum insulated component.