Barrier layer for insulated structures
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Solution Overview
Problem
Vacuum insulated structures face challenges with gas permeation due to the infiltration of gases into the insulating cavity, which compromises the integrity and longevity of the insulation, particularly when using plastic barriers.
Innovation Solution
Incorporating a glass-type barrier between the liner and wrapper of the insulating structure, coupled with an inner and outer gasket assembly, helps maintain a partial vacuum by reducing gas permeation rates and providing protection against compressive forces and abrasive contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a plastic barrier is used in the insulating structure, then the device complexity is reduced and ease of manufacture is improved, but gas permeation increases compromising the integrity and longevity of the insulation
Solution Approach 1:
The patent employs a composite barrier structure consisting of an inner barrier layer (preferably metal or glass) and an outer barrier layer (preferably plastic). This composite approach combines the gas impermeability of metal/glass with the manufacturing advantages and protective qualities of plastic, resolving the contradiction between ease of manufacture and insulation integrity.
Solution Approach 2:
The invention changes the material parameter of the barrier from single-material plastic to a multi-layer composite structure. By modifying the barrier's compositional parameters, the system achieves both low gas permeation (through the metal/glass inner layer) and ease of manufacture (through the plastic outer layer that can be thermally formed).
2Reliability
If a glass-type barrier is used to reduce gas permeation, then the reliability of the insulating structure is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent combines glass (or metal) inner barrier layer with plastic outer barrier layer. The glass provides the required gas impermeability for reliability, while the plastic layer simplifies manufacturing through thermal forming processes and provides protective functions, thus resolving the manufacturing complexity issue.
Solution Approach 2:
The plastic outer barrier layer acts as an intermediary between the glass inner barrier and the external environment. It protects the fragile glass from mechanical damage during manufacturing and use, while the glass layer provides the gas impermeability function. This intermediary structure enables the use of glass without proportionally increasing manufacturing complexity.
3Device complexity
If a single barrier layer is used, then the device complexity is reduced, but the barrier material is susceptible to damage from compressive forces and abrasive contact
Solution Approach 1:
The dual-layer barrier structure provides differentiated protection: the inner layer (glass/metal) provides gas impermeability while the outer plastic layer provides mechanical protection against compressive forces and abrasion. This composite approach maintains relatively simple device architecture while significantly improving strength and damage resistance.
Solution Approach 2:
The plastic outer barrier layer serves as a protective cushion that absorbs mechanical stresses and abrasive contact before they reach the inner glass/metal barrier. This beforehand cushioning protects the more fragile inner layer from damage during installation and operation, maintaining structural integrity without requiring complex reinforcement structures.
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
The use of a glass-type barrier, combined with a gasket assembly, effectively diminishes gas permeation, extending the useful life of the insulating structure by maintaining the partial vacuum and preventing damage to the barrier material.
Implementation Method 1
gas permeation due to the infiltration of gases into the insulating cavity
Implementation Method 2
providing protection against compressive forces and abrasive contact
Implementation Method 3
providing protection against compressive forces and abrasive contact
Data Source
AI summary
An insulating structure for an appliance includes a trim breaker, a wrapper, and a liner. The wrapper and liner coupled to the trim breaker and at least partially defining a structural cabinet. A barrier is positioned between the liner and the wrapper. The barrier is also coupled to the trim breaker. An inner compressible gasket is proximate the liner, and an outer gasket is proximate the wrapper. The inner gasket and the outer compressible gasket are coupled to the barrier.