Folded Vacuum-Insulated Door with Integrated Dispenser Cavity
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Solution Overview
Problem
Existing insulated appliance door structures, such as those in refrigerators, often rely on polyurethane foam or other insulating materials, which may not provide sufficient insulation efficiency and can be cumbersome in design, particularly when incorporating dispensing cavities for ice and liquid water.
Innovation Solution
A method involving a series of core material boards forming a three-dimensional vacuum insulated structure, where the boards are folded to create a dispensing cavity within an envelope made of impermeable barrier material, eliminating the need for foam insulation by utilizing a vacuum to enhance insulation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If polyurethane foam or traditional insulating materials are used in insulated appliance door structures, then the door structure can be simply constructed, but the insulation efficiency is insufficient and the design becomes cumbersome when incorporating dispensing cavities
Solution Approach 1:
The vacuum insulation system is segmented into multiple flat panels that can be independently manufactured and then assembled through folding to form three-dimensional door structures with integrated dispensing cavities, eliminating the need for complex foam molding processes
Solution Approach 2:
The invention changes the physical state of the insulation medium from solid foam to vacuum (gas removal), achieving superior insulation efficiency while allowing for simpler panel-based construction that can be folded into complex shapes
2Adaptability or versatility
If vacuum insulation panels are used to create three-dimensional door structures with dispensing cavities, then insulation efficiency is enhanced and design flexibility is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The vacuum insulation panels are pre-manufactured as flat panels with vacuum already evacuated and sealed, allowing these ready-to-use components to be easily assembled into various door configurations through folding, thereby simplifying the overall manufacturing process
Solution Approach 2:
The invention transitions from two-dimensional flat vacuum insulation panels to three-dimensional door structures with dispensing cavities by folding the panels along predetermined lines, enabling complex geometries to be created from simple flat components
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 results in a more efficient and compact insulation system that maintains temperature while allowing for the dispensing of ice and liquid water without the need for foam, enhancing both insulation and structural design.
Implementation Method 1
The generally flat subassembly is positioned in a vacuum chamber, and a vacuum is formed in the vacuum chamber. The opening of the envelope is sealed while the flat subassembly is in the vacuum chamber to thereby form a vacuum inside the envelope.
Implementation Method 2
The folded core material boards form a three dimensional vacuum insulated structure having a dispensing cavity defined by the second, third, fourth, fifth, and sixth core material boards
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
An appliance door (32) includes a vacuum insulated structure (52) having a plurality of core sections (1, 2, 3, 4, 5, 6, 7) that are folded to form an ice and/or water dispensing cavity (38) on an outer side of the appliance door (32). The vacuum insulated door structure (52) may be positioned between an outer door member (54) and a door liner (56).