3D Vacuum Insulation Panel Folding to Protect Gas Barrier Integrity
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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 formed 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 with sections of different thicknesses, allowing for a 3D shape with varying wall thicknesses, where the inner film is longer than the outer film to minimize stretching and prevent tears or micro-cracks during folding, enabling the formation of a 3D VIP insulated door panel from a 2D flat panel of non-uniform thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a 3D core is made and sealed in a film having a gas barrier, then a three-dimensional shape with varying wall thicknesses is achieved, but high mechanical stresses in the film may create tears or holes in the gas barrier which allow air or water vapor to enter the vacuum panel
Solution Approach 1:
The vacuum panel is divided into multiple separate flat 2D VIP panels that are assembled together to form a 3D structure. Each panel maintains its own sealed gas barrier, avoiding the need to stretch a single film over a 3D core. This segmentation preserves the integrity of the gas barrier while achieving the desired three-dimensional shape with varying wall thicknesses.
Solution Approach 2:
The invention transitions from creating a 3D shape by stretching a 2D film over a core to assembling multiple flat 2D panels in a three-dimensional configuration. This dimensional approach allows the gas barrier to remain in its original flat state without mechanical stress, while the overall structure achieves the required 3D form through spatial arrangement of multiple panels.
2Ease of manufacture
If vacuum-in-place insulation panels are manufactured in a flat 2D shape and folded, then manufacturing is simplified, but the application is limited to flat walls and it is difficult to use on surfaces that are not flat
Solution Approach 1:
The vacuum insulation system is segmented into multiple flat 2D VIP panels that can be independently manufactured and then assembled into various three-dimensional configurations. This allows each panel to be manufactured simply in a flat state while the assembled structure can adapt to non-flat surfaces and complex geometries.
Solution Approach 2:
The system transitions from a static flat panel to a dynamic three-dimensional structure through the assembly of multiple flat panels. The modular nature allows the insulation system to adapt to different wall configurations and surface geometries while maintaining the manufacturing simplicity of flat panel production.
3Reliability
If the inner film is made longer than the outer film, then stretching during folding is reduced and tears or micro-cracks are prevented, but the film arrangement becomes more complex
Solution Approach 1:
Instead of using a single complex film arrangement, the system segments the vacuum barrier into multiple separate flat panels, each with its own simple film structure. This eliminates the need for complex stretched film arrangements while maintaining film integrity during assembly.
Solution Approach 2:
The solution moves from a two-dimensional stretched film approach to a three-dimensional assembly of multiple flat panels. Each panel maintains its simple flat film structure, and the overall complexity is managed through spatial arrangement rather than film stretching, thereby preserving film integrity.
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 allows for the creation of 3D vacuum insulation panels with non-uniform thicknesses that can replace polyurethane foamed doors, providing better insulation performance and reducing the risk of air infiltration, thus enhancing the insulation properties and manufacturing ease.
Implementation Method 1
vacuum-in-place (VIP) insulation panels
Implementation Method 2
insulation performance
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.