Folded Vacuum-Insulated Cabinet Structure With Heat-Sealed Panels
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Solution Overview
Problem
Existing refrigerator cabinet structures suffer from inefficiencies in insulation, leading to higher thermal conductivity and energy loss, as they rely on conventional insulation materials like polyurethane foam which may not maintain vacuum conditions effectively.
Innovation Solution
A method for fabricating a vacuum insulated cabinet structure using a sheet metal blank with fold lines, where pouches containing porous filler material are sealed between a heat sealable polymer layer and a gas and water vapor barrier layer, forming an air-tight space that is evacuated to create a vacuum insulated panel, which is then folded to form upright side walls and a transverse wall, with components like compressors mounted in an exterior space to maintain insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional insulation materials like polyurethane foam are used, then the cabinet structure is simple to manufacture, but thermal conductivity is high leading to energy loss
Solution Approach 1:
The patent changes the physical state parameter of the insulation medium from solid foam to vacuum (gas phase with near-zero pressure), dramatically reducing thermal conductivity. The vacuum insulated panels achieve thermal conductivity values an order of magnitude lower than conventional foam insulation, directly addressing the energy loss problem.
Solution Approach 2:
The patent employs composite construction by combining multiple materials and structures: vacuum sealed between metal or polymer skins, with corner reinforcements and sealing layers. This composite approach achieves superior insulation performance while maintaining structural integrity, resolving the contradiction between performance and manufacturing complexity.
2Loss of energy
If vacuum insulated panels are used, then thermal conductivity is reduced significantly, but the manufacturing process becomes more complex
Solution Approach 1:
The patent divides the cabinet into modular vacuum insulated panels that can be manufactured separately and assembled. Each panel is a self-contained unit with vacuum-sealed construction, allowing for standardized production and simplified assembly, thus reducing overall system complexity while maintaining high energy efficiency.
Solution Approach 2:
The patent uses thin vacuum-sealed membranes or foils to create the vacuum barrier, which are then encapsulated between structural skins. This approach creates an effective vacuum insulation layer with minimal thickness, reducing structural complexity compared to thick foam insulation while achieving superior thermal performance.
3Duration of action of stationary object
If vacuum insulation is implemented, then insulation efficiency is maintained for at least 10 years, but the manufacturing process requires additional steps
Solution Approach 1:
The patent performs vacuum sealing and insulation creation during the initial manufacturing stage, before the cabinet is assembled and put into service. The vacuum panels are pre-fabricated with sealed edges and corner reinforcements, ensuring long-term durability from the outset. This preliminary action prevents future degradation and maintains insulation efficiency for the required 10-year period.
Solution Approach 2:
The patent incorporates reinforcement elements, sealing layers, and protective skins during manufacturing to preemptively protect the vacuum insulation from potential damage during assembly and service. These protective measures are built in beforehand to prevent punctures, leaks, or structural failure that would compromise the 10-year durability requirement.
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 vacuum insulated cabinet structure significantly reduces thermal conductivity, maintaining efficiency for at least 10 years, and allows for the mounting of refrigeration system components outside the insulated interior, enhancing energy efficiency and durability.
Implementation Method 1
providing a barrier layer that forms a barrier with respect to gasses and water vapor sufficient to maintain a vacuum
Implementation Method 2
The pouches are sealed to the polymer material around the pouches utilizing a heat seal process
Implementation Method 3
forming an air-tight space that is evacuated to create a vacuum insulated panel
Data Source
AI summary
A vacuum insulated cabinet structure includes panels having sheet metal outer side walls and polymer inner side walls. The polymer inner side walls are heat-sealed to a layer of polymer material laminated to a flat sheet metal blank to form vacuum cavities. The blank is then bent along fold lines to form a cabinet structure.