Leached Microsphere Insulation for Lightweight Vacuum Structures
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Solution Overview
Problem
Existing insulating materials for vacuum insulated structures are heavy and inefficient in maintaining thermal insulation and structural integrity under partial vacuum conditions.
Innovation Solution
A low-density insulating material composed of leached microspheres with through holes and a binder, forming microsphere aggregates within a vacuum-insulated cavity, combined with secondary insulating materials and gases, to create a sealed and lightweight thermal barrier.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional insulating materials are used in vacuum insulated structures, then thermal insulation is provided, but the structure becomes heavy and loses structural integrity under vacuum pressure
Solution Approach 1:
The patent uses hollow microspheres with porous or leached outer walls that contain insulating gas or vacuum in their interior volumes. This porous structure provides thermal insulation while significantly reducing the weight of the insulating material compared to conventional solid materials.
Solution Approach 2:
The patent creates a composite insulating system combining hollow microspheres (glass or ceramic), binder material, and insulating gas or vacuum. This composite structure achieves both lightweight properties and thermal insulation performance, resolving the contradiction between weight reduction and thermal insulation maintenance.
2Temperature
If conventional insulating materials are used in vacuum insulated structures, then thermal insulation is provided, but the material deforms under vacuum pressure
Solution Approach 1:
The patent applies a structural reinforcement layer (such as a reflective barrier or structural mesh) that counteracts the external vacuum pressure. This reinforcement prevents the hollow microspheres from collapsing while maintaining the thermal insulation function, thus preserving structural integrity under vacuum conditions.
Solution Approach 2:
The patent changes the physical state of the insulating medium from solid/conventional material to hollow microspheres containing gas or vacuum. This parameter change allows the material to better withstand vacuum pressure while maintaining insulation performance, as the hollow structure is more resistant to external pressure differential.
3Weight of moving object
If hollow microspheres are used to reduce weight, then appliance weight is reduced, but the microspheres collapse under vacuum pressure
Solution Approach 1:
The patent combines hollow microspheres with a binder material to form a composite structure. The binder provides structural support that prevents individual microspheres from collapsing under vacuum pressure, while the overall composite remains lightweight. This composite approach resolves the contradiction between maintaining sphere integrity and reducing weight.
Solution Approach 2:
The patent uses thin-walled hollow microspheres that are flexible yet resistant to collapse. These microspheres may be made of glass or ceramic with controlled wall thickness that provides sufficient strength against vacuum pressure while minimizing weight. The flexible nature allows slight deformation without catastrophic failure.
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 solution provides enhanced thermal insulation and structural support, resisting deformation under vacuum pressure while reducing overall appliance weight and maintaining consistent dimensions.
Implementation Method 1
The binder is disposed within a portion of the leached opening and at least partially defines the interior volume. The binder and the outer wall define a substantially air-tight seal around the insulating space.
Implementation Method 2
The interior volume of each leached microsphere defines an insulating space that includes an insulating gas. Each insulating space is maintained at a pressure less than atmospheric pressure.
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.