Deep-Drawn Machine Compartment for Vacuum Insulated Refrigerator

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Solution Overview

Problem

Existing refrigerator designs face challenges in maintaining insulative efficiency due to the formation of compartments, which can compromise the vacuum insulation and lead to heat transfer.

Innovation Solution

A method of forming a refrigerator cabinet that involves providing an external wrapper, deep-drawing it to create a machine compartment and a foot, and positioning an inner liner within the wrapper to create a gap, which is then evacuated to enhance insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If traditional compartment formation methods are used in refrigerators, then structural support and accessibility are improved, but insulative ability deteriorates due to heat transfer through walls and welds

Engineering Contradiction:

Improveaccessibility to refrigerator componentsVSAvoidheat transfer through compartment walls

Core Design Contradiction:

Ease of operationVSLoss of energy

Solution Approach 1:

The patent implements nesting by placing the inner liner inside the external wrapper, creating a vacuum-sealed gap between them. This nested configuration allows the vacuum insulation to envelop the refrigerator components while maintaining structural integrity and accessibility, thereby reducing heat transfer without compromising operational access to refrigerator parts.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The patent creates a vacuum environment within the gap between the inner liner and external wrapper. This vacuum (inert atmosphere) eliminates air molecules that would otherwise conduct heat, thereby significantly reducing thermal transfer through the compartment walls while maintaining the structural framework and component accessibility.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

2Strength

If traditional insulation methods are used, then structural support is maintained, but insulation thickness increases by up to 70%

Engineering Contradiction:

Improvestructural support of refrigeratorVSAvoidinsulation thickness

Core Design Contradiction:

StrengthVSLength of stationary object

Solution Approach 1:

The patent fundamentally changes the physical parameter of the insulation medium by transitioning from solid foam insulation to a vacuum environment. This parameter change (from material-based insulation to vacuum insulation) achieves superior thermal performance with dramatically reduced thickness while the external wrapper and inner liner structure maintain the required structural support.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs thin-walled external wrapper and inner liner structures that form a vacuum-sealed envelope. These flexible shells maintain structural integrity while enabling the vacuum insulation layer to be extremely thin compared to traditional foam insulation, thus reducing overall insulation thickness by up to 70% while preserving structural support.

Inventive Principle:

Principle #30Flexible shells and thin films

3Strength

If multiple welds and support mechanisms are used in compartment formation, then structural integrity is improved, but manufacturing complexity and costs increase

Engineering Contradiction:

Improvestructural integrity of compartmentVSAvoidnumber of welds and support mechanisms

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent merges the functions of multiple separate components (wrapper, liner, insulation layer, support structures) into a integrated vacuum insulation assembly. The external wrapper and inner liner are positioned to form a vacuum-sealed gap that simultaneously provides insulation and structural support, eliminating the need for multiple welds and separate support mechanisms while maintaining structural integrity.

Inventive Principle:

Principle #5Merging (Combining)

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 approach reduces air leaks, enhances insulative properties, and potentially lowers manufacturing costs by eliminating the need for multiple welds and support mechanisms, while also reducing the thickness of the insulation by up to 70%.

Implementation Method 1

A vacuum is drawn within the gap

Methodology Applied

Scientific EffectVacuum insulation: Vacuum

Data Source

PatentUS12275050B2Machine compartment for a vacuum insulated structure

Publication Date: 2025.04.15 WHIRLPOOL CORP

AI summary

A method of forming a refrigerator cabinet includes a step where an external wrapper that defines a rear surface is provided. The rear surface of the external wrapper is deep-drawn to form a machine compartment that defines a top wall, a bottom wall, and an interior wall. An inner liner is positioned within the external wrapper such that a gap is defined between the inner liner and the interior wall of the machine compartment. A vacuum is drawn within the gap.