Insulation structure for an appliance having a uniformly mixed multi-component insulation material, and a method for even distribution of material combinations therein

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Solution Overview

Problem

Existing insulation materials for household appliances often result in non-uniform distribution of insulating components within the appliance cavity, leading to inefficiencies in thermal and acoustical insulation.

Innovation Solution

A multi-component insulation material is created by dispersing nano/micro-sized particulate fill material and hollow insulating spheres throughout the insulating cavity, utilizing an aeolian suspension method where an insulating gas carrier suspends and deposits the particulate material uniformly, ensuring a substantially uniform insulating material configuration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional insulation materials are used to fill the insulating cavity, then the cavity can be filled with insulating material, but the distribution of insulating components becomes non-uniform, leading to insulation inefficiencies

Engineering Contradiction:

Improveuniformity of insulating component distributionVSAvoidinsulation performance consistency

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent changes the physical state and size parameters of insulating materials by using nano-sized and micro-sized particulate materials instead of traditional bulk materials. This parameter change enables uniform distribution throughout the cavity while maintaining high insulation performance, directly resolving the contradiction between manufacturing precision and reliability

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite insulation system by combining multiple components (nano-particulate material, micro-particulate material, and gas-filled hollow spheres) into a multi-component insulation material. This composite approach ensures uniform distribution and consistent insulation performance, addressing both the uniformity and reliability requirements

Inventive Principle:

Principle #40Composite materials

2Reliability

If hollow insulating spheres are used to maximize cavity filling, then thermal and acoustical insulation is enhanced, but the interstitial spaces between spheres may create non-uniform distribution

Engineering Contradiction:

Improvethermal and acoustical insulation performanceVSAvoiduniformity of material distribution

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent applies the nesting principle by placing nano-sized and micro-sized particulate materials within and between the hollow insulating spheres. The smaller particulate materials fill the interstitial spaces between the larger spheres, creating a nested structure that ensures uniform distribution throughout the cavity while maintaining the insulation performance provided by the hollow spheres

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The patent applies local quality by using different sized particulate materials in different locations within the cavity. The nano-particulate material fills the smallest interstitial spaces, while micro-particulate material fills larger gaps, and hollow spheres provide structure in larger voids. This localized adaptation of material size and type ensures uniform distribution throughout the entire cavity

Inventive Principle:

Principle #3Local quality

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 ensures a uniform distribution of insulating components, enhancing thermal and acoustical insulation properties by minimizing pockets and maximizing the filling of the cavity, thereby improving the overall insulation performance.

Implementation Method 1

utilizing an aeolian suspension method where an insulating gas carrier suspends and deposits the particulate material uniformly

Methodology Applied

Scientific EffectAeolian suspension: Suspension

Implementation Method 2

enhancing thermal and acoustical insulation properties by minimizing pockets and maximizing the filling of the cavity

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 3

enhancing thermal and acoustical insulation properties by minimizing pockets and maximizing the filling of the cavity

Methodology Applied

Scientific EffectAcoustic insulation: Acoustic Absorption

Data Source

PatentUS10422573B2Insulation structure for an appliance having a uniformly mixed multi-component insulation material, and a method for even distribution of material combinations therein

Publication Date: 2019.09.24 WHIRLPOOL CORP

AI summary

An insulation structure for an appliance includes a cabinet having an outer wrapper and an inner liner, with an insulating cavity defined therebetween. Insulating powder material is disposed substantially throughout the insulating cavity. An insulating gas is disposed within the insulating cavity, wherein the insulating powder material is combined with the insulating gas and cooperatively defines a suspended state and a precipitated state. The suspended state is defined by the insulating gas in motion and the insulating powder being in an aeolian suspension within the insulating gas while in motion. The precipitated state is defined by the insulating gas being in a deposition state and the insulating powder being precipitated from the insulating gas and deposited within the insulating cavity.