Insulated structures and methods of making the same
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Solution Overview
Problem
Existing insulated structures face challenges in achieving optimal thermal insulation performance and pressure management due to the presence of fine particles that can impede the manufacturing process and reduce efficiency.
Innovation Solution
A method involving compaction, crushing, granulation, and filtration of raw materials to produce a core material with controlled particle sizes and densities, followed by evacuation and sealing to create a low-pressure insulated structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing materials and processes are used for producing insulated structures, then the production process is simpler, but the thermal insulation performance and pressure management are insufficient
Solution Approach 1:
The patent applies parameter changes by precisely controlling particle size (80-1600 μm) and density (350-600 kg/m3) of the core material to achieve optimal thermal insulation performance. The multi-step processing method changes physical parameters of the raw material through compaction, crushing, and granulation to produce the desired particle characteristics that improve thermal insulation while maintaining manageable production complexity
Solution Approach 2:
The patent uses composite materials by creating a core material from processed raw material that combines specific particle size distribution and density characteristics. This composite core material is then disposed within the cavity between walls to achieve superior thermal insulation performance compared to simple existing materials, resolving the contradiction between reliability and complexity
2Stress or pressure
If existing materials are used, then the material processing is easier, but the pressure regulation within the structure is inadequate
Solution Approach 1:
The patent achieves pressure regulation by controlling the density parameter of the core material within the cavity at 350-600 kg/m3. The compaction process changes the physical state of the raw material to achieve this specific density range, which provides the necessary pressure regulation capability while maintaining reasonable manufacturing ease through a systematic processing approach
3Temperature
If the core material is disposed at higher density, then the thermal conductivity is reduced, but the manufacturing complexity increases
Solution Approach 1:
The patent optimizes thermal conductivity by controlling the density parameter within the range of 350-600 kg/m3. This parameter change achieves reduced thermal conductivity (1-15 mW/mK) while maintaining manageable manufacturing precision through the established compaction and processing methodology described in the patent
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 method results in improved thermal conductivity and reduced pressure within the insulated structure, enhancing its insulation performance and operational efficiency.
Implementation Method 1
compacting the raw material with at least one roller
Implementation Method 2
filtering the core material precursor with a filter member
Data Source
AI summary
An insulated structure includes a plurality of walls and a cavity defined by the plurality of walls. A core material is disposed within the cavity. The core material includes particles with a diameter that is in a range of 80-1600 μm. The core material disposed within the cavity can have a density in a range of greater than 350 kg/m3 to 600 kg/m3. Methods of manufacturing the insulated structure also disclosed.