Method for manufacturing a vacuum insulated structure
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Solution Overview
Problem
Conventional vacuum insulated structures face challenges in maintaining vacuum integrity due to air molecule permeation through porous trim breakers and connectors, leading to reduced insulation efficiency and shorter lifespan.
Innovation Solution
The method involves heating a trim breaker within an evacuation chamber, applying a metallic coating to minimize air permeation, adhering it to panels via an adhesive, and using multiple vacuum pumps and heaters to efficiently evacuate and cure the structure, ensuring a continuous vacuum seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a porous trim breaker is used to define the insulated structure, then the ease of manufacture is improved, but air molecule permeation occurs leading to reduced vacuum integrity
Solution Approach 1:
A metallic coating layer is applied to the porous trim breaker to create a barrier against air molecule permeation. The thin metallic film seals the porous structure while maintaining the trim breaker's structural function, preventing vacuum degradation without requiring a solid non-porous alternative.
Solution Approach 2:
The trim breaker is formed as a composite structure combining a porous base material (for manufacturability and structural integrity) with a metallic coating layer (for vacuum sealing). This composite approach leverages the advantages of both materials: the porous substrate provides ease of manufacturing while the metallic coating provides the required vacuum integrity.
2Productivity
If heating is applied to the insulated structure during evacuation, then the efficiency of the evacuation process is improved through outgassing, but energy consumption increases
Solution Approach 1:
The temperature parameter is increased during the evacuation process to accelerate outgassing from the porous trim breaker and insulation materials. By temporarily raising the temperature, the evacuation efficiency is improved as gas molecules are released more rapidly, allowing the vacuum pump to achieve the target vacuum level faster.
Solution Approach 2:
Heating is applied periodically or in stages during the evacuation process rather than continuously. The heating cycle is synchronized with the evacuation phases, applying heat when outgassing is most beneficial and reducing or stopping heat input once the vacuum is achieved, thereby balancing evacuation efficiency with energy consumption.
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 enhances the vacuum integrity of the insulated structure by minimizing air entry, increasing the efficiency of the evacuation process, and extending the useful life of the insulation by maintaining a high-temperature environment for evacuation and adhesive curing.
Implementation Method 1
The heated trim breaker is outgassed via a first vacuum pump operably coupled to the evacuation chamber to define a vacuum within the evacuation chamber
Implementation Method 2
The insulated structure is evacuated via the first vacuum pump, which is operably coupled to the evacuation chamber, and by a second vacuum pump, which is operably coupled to the insulated structure
Implementation Method 3
A metallic coating is applied to the trim breaker
Implementation Method 4
heat is applied to the insulated structure to cure the adhesive
Data Source
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AI summary
A method for manufacturing a vacuum insulated structure (10) includes adhering a trim breaker (18) to a wrapper and a liner via an adhesive (52) to define an insulated structure (10). The insulated structure (10) is positioned within an evacuation chamber (24) proximate to a first heater and a second heater. The insulated structure (10) and the evacuation chamber (24) are heated via the first heater and the second heater. The evacuation chamber (24) is evacuated via a first vacuum pump (78), and the insulated structure (10) is evacuated via a second vacuum pump (80).