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 hollow insulating spheres and nano/micro-sized particulate material throughout the insulating cavity, using an insulating gas carrier to form an aeolian suspension that uniformly deposits the particulate material, ensuring a consistent and efficient filling of the cavity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional insulation materials are used to fill the insulating cavity, then the cavity can be filled with insulation material, but the distribution of insulating components becomes non-uniform, leading to insulation inefficiencies
Solution Approach 1:
The patent changes the physical state and size parameters of insulation materials by using hollow spheres with specific size ranges (0.1-5mm) combined with fine particulate materials (0.01-0.1mm). This parameter variation enables the materials to fill the cavity more uniformly, with larger spheres providing structural framework and finer particles filling interstitial spaces, thereby improving distribution uniformity and insulation performance consistency
Solution Approach 2:
The patent employs a composite insulation system combining hollow insulating spheres with nano/micro-sized particulate insulation materials. This composite approach allows the two different material types to work synergistically - the hollow spheres provide bulk insulation and structural support, while the fine particulate material fills gaps and enhances thermal barrier properties, resulting in improved uniformity and reliability of insulation performance throughout the cavity
2Area of stationary object
If insulation material is disposed in the insulating cavity, then the cavity is filled, but pockets and incomplete coverage occur, reducing insulation effectiveness
Solution Approach 1:
The patent segments the insulation material into two distinct size categories: hollow spheres (0.1-5mm) and fine particulate materials (0.01-0.1mm). This segmentation allows the larger spheres to be distributed throughout the cavity providing broad coverage, while the finer particles settle into interstitial spaces, eliminating pockets and ensuring complete coverage of the entire cavity surface area with uniform distribution
Solution Approach 2:
The patent implements a nested structure where fine particulate insulation materials are positioned within and around the hollow spheres. The smaller particles nest in the spaces between and around the larger hollow spheres, creating a multi-level filling structure that maximizes cavity coverage and eliminates empty pockets, thereby achieving both complete area coverage and uniform material distribution
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 results in a uniformly distributed insulation material that enhances both thermal and acoustical insulation properties by minimizing pockets and ensuring comprehensive coverage of the insulating cavity, thereby improving the overall performance of the appliance.
Implementation Method 1
using an insulating gas carrier to form an aeolian suspension that uniformly deposits the particulate material
Data Source
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. A plurality of hollow insulating organic/inorganic spheres is disposed within the insulating cavity, wherein a secondary insulating volume is defined between the plurality of hollow insulating organic/inorganic spheres and an interior surface of the cabinet. The interior surface of the cabinet defines the insulating cavity. An insulating fill material is disposed within the secondary insulating volume, wherein the insulating fill material and the plurality of hollow insulating organic/inorganic spheres define a substantially uniform insulating material.