3D vacuum panel and a folding approach to create the 3D vacuum panel from a 2D vacuum panel of non-uniform thickness
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Solution Overview
Problem
Existing vacuum-in-place insulation panels manufactured in a flat 2D shape are limited in application to flat surfaces and face mechanical stresses when folded into 3D shapes, leading to potential tears or holes in the gas barrier, which compromise insulation effectiveness.
Innovation Solution
A foldable vacuum insulation panel is created from a 2D panel of non-uniform thickness, where the inner film is longer than the outer film to reduce stretching and prevent tears, allowing for the formation of 3D panels with walls of varying thicknesses, enabling the incorporation of features like door dikes and improved insulation performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a 2D vacuum panel is folded into a 3D shape, then the panel can be applied to non-flat surfaces and create varied wall thicknesses, but the film experiences high mechanical stresses that may create tears or holes in the gas barrier
Solution Approach 1:
The gas barrier is pre-formed with a three-dimensional shape matching the final panel configuration, including varying wall thicknesses and non-planar features, before vacuum sealing. This preliminary shaping eliminates the need for post-manufacturing folding operations that would subject the film to high mechanical stresses and potential failure.
Solution Approach 2:
The patent changes the physical state and geometry of the gas barrier from a flat 2D configuration to a pre-formed 3D configuration with varied thickness parameters. This parameter transformation allows the barrier to accommodate non-flat surfaces and complex geometries while maintaining structural integrity and avoiding stress concentration during assembly.
2Shape
If a 3D core is created and sealed in a film, then varied wall thicknesses can be achieved, but high mechanical stresses in the film may create tears or holes allowing air infiltration
Solution Approach 1:
The three-dimensional core structure with varied wall thicknesses is created and sealed within the gas barrier film before the vacuum sealing process. This preliminary formation of the 3D shape ensures that the film accommodates the complex geometry without experiencing excessive stretching or stress concentration that would lead to tears or holes during subsequent processing.
3Ease of manufacture
If a flat 2D VIP panel is manufactured, then manufacturing is simplified, but the panel is limited to flat wall applications and cannot accommodate non-uniform thickness requirements
Solution Approach 1:
The gas barrier film is pre-formed into the desired three-dimensional shape with varied wall thicknesses before vacuum sealing. This preliminary shaping action maintains manufacturing simplicity while enabling the final product to accommodate non-flat surfaces and complex geometries, thus resolving the contradiction between ease of manufacture and adaptability.
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 solution enables the creation of 3D vacuum insulation panels with non-uniform thicknesses that reduce mechanical stress on the film, preventing air infiltration and enhancing insulation performance, potentially replacing polyurethane foamed doors with better thermal efficiency.
Implementation Method 1
vacuum panel and creating a 3D vacuum panel from a 2D vacuum panel of non-uniform thickness
Data Source
AI summary
A three-dimensional (3D) vacuum insulation panel (VIP) and a folding approach to create the 3D VIP from a two-dimensional (2D) VIP of non-uniform thickness for a refrigerator, a refrigerator freezer or a non-appliance, are disclosed. The folding approach includes placing a VIP main panel and a plurality of VIP wall panels on an outer film, where one or more panels are of a greater thickness than other VIP panels; placing an inner film on top of the VIP main and wall panels and sealing the films together. The inner film is longer than the outer film and this allows the films and the VIP wall panels to be folded into a finished panel, wherein the longer inner film allows for fording without causing tears or micro-cracks in the film that would adversely affect the insulation properties of the three-dimensional (3D) VIP.