Leached Microsphere Insulation for Vacuum-Insulated Appliances
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Solution Overview
Problem
Existing insulating materials for appliances do not effectively address the need for high thermal insulation while maintaining structural integrity and reducing weight, particularly in vacuum-insulated structures.
Innovation Solution
A microsphere-based insulating system using leached microspheres with holes and a binder to create microsphere aggregates, combined with a partial vacuum and insulating gas, which enhances thermal insulation and structural support within the insulating cavity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional insulating materials are used in vacuum-insulated structures, then thermal insulation is provided, but weight reduction and structural integrity are not effectively addressed
Solution Approach 1:
The patent uses composite microspheres comprising a hollow core and a porous shell layer, creating a composite material structure that provides both lightweight properties and structural integrity. The hollow core reduces weight while the porous shell maintains strength and provides insulation, resolving the contradiction between weight reduction and structural integrity.
Solution Approach 2:
The porous shell layer of the microspheres provides thermal insulation while maintaining structural integrity. The porous structure reduces density and weight compared to solid materials, while still providing sufficient strength to maintain structural integrity in vacuum-insulated structures.
2Loss of energy
If microsphere aggregates with leached openings are used, then thermal insulation is improved, but manufacturing complexity increases
Solution Approach 1:
The leached openings are pre-formed in the microspheres during manufacturing, allowing vacuum to be applied more effectively later. This preliminary action of creating openings before vacuum application simplifies the overall process by preparing the structure in advance for vacuum evacuation, reducing the complexity of the vacuum application step.
Solution Approach 2:
The leaching process changes the physical parameters of the microsphere structure by creating controlled openings in the shell. This parameter change enables better vacuum penetration and thermal insulation performance, while the leaching process itself can be integrated into existing manufacturing workflows, managing the complexity increase.
3Loss of energy
If a partial vacuum is applied within the insulating cavity, then thermal insulation is enhanced, but structural deformation may occur
Solution Approach 1:
The composite microsphere structure with hollow cores and porous shells provides both lightweight properties and structural strength. The composite nature allows the material to resist deformation under vacuum pressure while maintaining thermal insulation, resolving the contradiction between enhanced insulation and structural stability.
Solution Approach 2:
The porous shell layer provides localized structural support at the microsphere level, distributing vacuum pressure evenly across the structure. This local quality enhancement prevents structural deformation while maintaining the vacuum environment for improved thermal insulation.
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 system provides improved thermal insulation, reduces weight, and maintains structural integrity by resisting deformation under vacuum pressure, while minimizing resource use and transportation costs through a streamlined manufacturing process.
Implementation Method 1
The binder and the outer wall define a substantially air-tight seal around the insulating space
Implementation Method 2
An at least partial vacuum is defined within the insulating cavity
Implementation Method 3
The interior volume of each leached microsphere defines an insulating space that includes an insulating gas
Data Source
AI summary
A low-density insulating material for use in a vacuum insulated structure for an appliance includes a plurality of microspheres that includes a plurality of leached microspheres. Each leached microsphere has an outer wall and an interior volume. The outer wall has a hole that extends through the outer wall and to the interior volume. A binder engages outer surfaces of the plurality of leached microspheres, wherein the binder cooperates with the plurality of leached microspheres to form at least one microsphere aggregate. The interior volume of each leached microsphere defines an insulating space that includes an insulating gas. The insulating space of each leached microsphere is at least partially defined by the binder.