Coated Vacuum Insulation Core Without Film Envelope Defects
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Solution Overview
Problem
Existing vacuum insulation members using glass fiber cores face issues with durability, preprocessing complexity, non-uniform thickness, and crease-induced defects, leading to increased costs and reduced productivity.
Innovation Solution
A vacuum insulation member is developed without a glass fiber core, featuring a core with a gas barrier layer formed by coating metal or inorganic materials on its surface, along with a filler and getter, to maintain a vacuum state and prevent creases, thereby ensuring uniform thickness and improved reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a film envelope is used to maintain vacuum, then vacuum impermeability is improved, but the envelope may be damaged by external force, reducing reliability
Solution Approach 1:
The invention removes the film envelope entirely from the vacuum insulation member structure. Instead of using a separate envelope to maintain vacuum, the core itself is designed to maintain the vacuum state through its intrinsic properties, eliminating the weakness of film-based vacuum containment
Solution Approach 2:
The invention changes the fundamental parameter of vacuum maintenance from external film containment to internal core stability. The core material and structure are designed to inherently maintain vacuum without requiring a separate protective envelope, transforming the approach from containment to intrinsic stability
2Reliability
If glass fiber core is used, then initial performance is improved, but preprocessing is required, increasing complexity and reducing productivity
Solution Approach 1:
The invention extracts the problematic preprocessing requirement from the core material system. By using a foam core that inherently maintains its structure without hot pressing or needle punching, the complex preprocessing steps are eliminated while preserving the insulation performance
Solution Approach 2:
The invention adopts a core material that is simpler and more straightforward to process, accepting that the core may have shorter operational life in exchange for dramatically reduced processing complexity and cost, aligning with the disposable or replaceable nature of insulation components
3Reliability
If glass fiber core is used, then insulation performance is improved, but thickness deviation increases, reducing manufacturing precision
Solution Approach 1:
The invention changes the core material from glass fiber to foam material, which fundamentally alters the thickness control characteristics. The foam core can be manufactured with precise thickness control through molding processes, eliminating the thickness deviation problems inherent in glass fiber compression
4Reliability
If glass fiber core is used, then insulation performance is improved, but creases form on envelope surface, reducing ease of operation
Solution Approach 1:
The invention removes the envelope component that develops creases. By using a foam core that maintains its own structural integrity without requiring a separate envelope, the creasing problem is eliminated, making the component easier to handle and attach
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 enhances the reliability and uniformity of the vacuum insulation member, reducing fabrication costs and preventing defective bonding, while maintaining a low internal vacuum degree without the need for complex preprocessing or external envelopes.
Implementation Method 1
a gas barrier layer formed by coating a certain material on a surface of the core to have impermeability
Implementation Method 2
a core having a certain shape and having a decompressed space therein
Implementation Method 3
use the characteristics of low thermal conductivity of vacuum
Implementation Method 4
a getter for absorbing an internal gas of the envelope may be provided at the inner side of the envelope
Data Source
AI summary
Disclosed are a vacuum insulation member, a refrigerator having the vacuum insulation member, and a method for fabricating the vacuum insulation member. The vacuum insulation member includes: a core having a certain shape and having a decompressed space therein; and a gas barrier layer formed by coating a certain material on a surface of the core to have impermeability. Accordingly, the use of an envelope (film) can be avoided to obtain reliability, and the use of a glass fiber core which must undergo a preprocessing process for which much equipment and time are required can be avoided.