Multi-Component Appliance Panel Design for Hermetic Vacuum Insulation

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Solution Overview

Problem

Existing insulation structures for appliances lack effective sealing and hermeticity, leading to inefficiencies in maintaining a vacuum insulation environment, which affects the thermal performance and energy efficiency of appliances.

Innovation Solution

A multi-component structural panel for appliances is developed, comprising a metallic outer wrapper, an inner liner, corner brackets, and a trim breaker, which together form a perimetrical breaker channel and insulating cavity, using a method that involves stamping and shaping metallic sheets into specific patterns to create a hermetic seal with an insulating material within the cavity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If existing insulation structures are used for appliances, then the structure is simple, but the sealing and hermeticity are insufficient, leading to poor vacuum insulation performance

Engineering Contradiction:

Improvesealing and hermeticityVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The insulation structure is divided into multiple functional components: inner liner, outer wrapper, corner brackets, and trim breaker. Each component serves a specific purpose in achieving hermetic sealing, with the corner brackets providing structural support and the trim breaker ensuring continuous sealing along the periphery.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple components are combined to form an integrated hermetic sealing system. The inner liner, outer wrapper, corner brackets, and trim breaker work together as a unified structure to maintain vacuum integrity, with adhesive bonding and mechanical interlocking creating a continuous seal.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If a hermetic seal is achieved using multiple components, then the thermal insulation performance is improved, but the manufacturing process becomes more complex

Engineering Contradiction:

Improvethermal insulation performanceVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The corner brackets are pre-formed with channel structures that receive the trim breaker, and the inner liner is pre-shaped with peripheral edges that engage with the sealing system. This preliminary preparation of components facilitates easier assembly while maintaining hermetic integrity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Adhesive bonding serves as an intermediary method to join the multiple components (inner liner, outer wrapper, corner brackets, trim breaker) into a unified hermetic structure, simplifying the manufacturing process compared to mechanical fastening while ensuring reliable sealing.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If the insulating cavity is sealed hermetically, then the vacuum insulation environment is maintained, but the device complexity increases

Engineering Contradiction:

Improvevacuum insulation environmentVSAvoidcomponent assembly

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The inner liner acts as a flexible hermetic barrier that can be conformally shaped to fit the insulating cavity, providing continuous sealing along complex geometries. The thin film structure of the liner allows for effective sealing without adding significant structural complexity.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The corner brackets are formed with curved channel structures that smoothly receive the trim breaker, creating continuous curved sealing paths around the periphery of the insulating cavity. This curvature allows for effective sealing at corners and edges without requiring additional complex components.

Inventive Principle:

Principle #14Spheroidality (Curvature)

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 achieves a secure and hermetic seal, enhancing the thermal insulation and energy efficiency of appliances by maintaining a vacuum within the insulating cavity, thereby improving the operational performance and reducing energy consumption.

Implementation Method 1

maintaining a vacuum within the insulating cavity

Methodology Applied

Scientific EffectVacuum insulation: Vacuum

Implementation Method 2

enhancing the thermal insulation

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS11065842B2Structural panel for an appliance having stamped components and method therefor

Publication Date: 2021.07.20 WHIRLPOOL CORP

AI summary

An operable panel for an appliance includes a metallic outer wrapper having a perimetrical wrapper edge that partially defines a perimetrical breaker channel, an inner liner and a plurality of corner brackets disposed proximate the perimetrical wrapper edge. Each corner bracket cooperates with the perimetrical wrapper edge to fully define the perimetrical breaker channel. A trim breaker is adhered to the metallic outer wrapper and the corner brackets at the perimetrical breaker channel and having a liner channel that receives a portion of the inner liner. The trim breaker extends between the inner liner and the outer wrapper. An insulation material is disposed within an insulating cavity defined between the inner liner and the outer wrapper.