Construction method for vacuum insulated door
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Solution Overview
Problem
Existing vacuum insulated door panels face challenges in maintaining a sealed vacuum cavity and efficiently integrating bin assemblies, which affects insulation efficiency and user customization.
Innovation Solution
A trim breaker with molded-in features interconnects the outer and inner panels, forming a vacuum cavity with inner and outer channels, and includes engagement features for bin assemblies, ensuring a sealed vacuum and easy reconfiguration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a vacuum insulated door panel uses a traditional sealing structure, then the manufacturing process is simpler, but the vacuum cavity sealing reliability is insufficient
Solution Approach 1:
The trim breaker structure employs nested channels where an inner channel is positioned within an outer channel, creating multiple sealing zones. The inner panel is received in the inner channel while the outer panel is received in the outer channel, forming a nested configuration that enhances vacuum cavity sealing reliability through multiple barriers.
Solution Approach 2:
The trim breaker is divided into distinct functional segments including upright members, cross members, inner channels, and outer channels. Each segment performs a specific function in maintaining the vacuum seal, allowing for modular manufacturing and assembly while achieving complex sealing performance.
2Adaptability or versatility
If bin assemblies are integrated into the door panel, then the appliance functionality is enhanced, but the vacuum cavity sealing may be compromised
Solution Approach 1:
The trim breaker structure serves multiple functions simultaneously: it maintains the vacuum seal, provides structural support, and enables bin assembly integration through engagement features. The upright members include molded-in engagement features that can interface with various bin assembly configurations, making the door panel adaptable while preserving vacuum integrity.
Solution Approach 2:
The trim breaker acts as an intermediary structure between the vacuum cavity and bin assemblies. The engagement features on the upright members provide a controlled interface point, allowing bin assemblies to be integrated without directly compromising the vacuum seal between the inner and outer panels.
3Ease of manufacture
If the trim breaker uses separate components for inner and outer channels, then manufacturing flexibility is improved, but assembly complexity increases
Solution Approach 1:
The trim breaker combines the inner channel and outer channel into a single integrated structure formed from one piece of material. This merging of functions into a unitary component simplifies assembly while maintaining the manufacturing flexibility to create complex nested channel geometries through molding processes.
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 solution maintains a high vacuum pressure, enhances insulation efficiency, and allows for customizable bin assembly configurations, improving user experience and appliance performance.
Implementation Method 1
A trim breaker interconnects the outer panel and the inner panel to form a vacuum cavity therebetween
Data Source
AI summary
A door panel includes an outer panel having a generally planar body portion with inner and outer surfaces and a sidewall with a front edge. An inner panel includes a generally planar body portion with inner and outer surfaces and a sidewall with a front edge. A trim breaker interconnects the outer panel and the inner panel to form a vacuum cavity therebetween. The trim breaker includes first and second upright members interconnected by upper and lower cross members. The trim breaker further includes an inner channel and an outer channel spaced-apart from one another around the trim breaker. The outer channel is outwardly disposed around the inner channel. The front edge of the inner panel is received in the inner channel of the trim breaker, and the front edge of the outer panel is received in the outer channel of the trim breaker.