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 structures for appliances lack uniform distribution of multi-component insulation materials, leading to inefficiencies in thermal and acoustical insulation due to pockets of uninsulated sections.
Innovation Solution
A method involving hollow insulating spheres and nano/micro-sized particulate material dispersed within an insulating cavity, utilizing an insulating gas carrier to create an aeolian suspension for uniform distribution, combined with a vacuum process to ensure complete filling and sealing of the cavity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multi-component insulation materials are used in the insulating cavity, then thermal and acoustical insulation properties are improved, but uniform distribution of materials is difficult to achieve leading to pockets of uninsulated sections
Solution Approach 1:
The insulation cavity is divided into multiple zones with different insulation material compositions. The system segments the insulation space to accommodate different material types (organic and inorganic) in specific regions, ensuring each zone achieves optimal insulation performance while maintaining overall uniformity through controlled material placement
Solution Approach 2:
The patent changes the physical parameters of the insulation materials by using different particle sizes, densities, and material compositions (organic vs. inorganic) to achieve proper distribution. By adjusting these parameters, the system ensures that materials distribute uniformly throughout the cavity without forming uninsulated pockets
2Reliability
If hollow insulating spheres are used to define secondary insulating volume, then insulation effectiveness is enhanced, but complete filling of the cavity becomes more complex
Solution Approach 1:
The system employs nested doll principle by placing hollow insulating spheres within the insulating cavity and then filling the interstitial spaces between these spheres with additional insulation materials. This nested arrangement allows complete cavity utilization while maintaining manufacturing simplicity through a systematic filling approach
Solution Approach 2:
The hollow insulating spheres create a porous structure within the cavity that facilitates material distribution. The spaces between spheres act as channels for injecting and distributing additional insulation materials, ensuring complete cavity filling while maintaining ease of manufacture through natural material flow paths
3Manufacturing precision
If nano/micro-sized particulate material is dispersed throughout the secondary insulating volume, then uniform insulating material is achieved, but material distribution complexity increases
Solution Approach 1:
The system uses pneumatic injection methods to distribute nano/micro-sized particulate materials throughout the secondary insulating volume. Gas pressure is applied to force materials through injection ports and distribute them uniformly between the hollow spheres, achieving material uniformity without complex mechanical distribution systems
Solution Approach 2:
The patent introduces an intermediary gas medium to facilitate material distribution. The gas acts as a carrier that transports nano/micro-sized particles through the cavity and distributes them uniformly, simplifying the overall distribution system while achieving the desired material uniformity
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 substantially uniform multi-component insulating material that effectively fills the cavity, enhancing thermal and acoustical insulation properties by minimizing uninsulated areas and maintaining a hermetically sealed vacuum insulated structure.
Implementation Method 1
utilizing an insulating gas carrier to create an aeolian suspension for uniform distribution
Implementation Method 2
combined with a vacuum process to ensure complete filling and sealing of the cavity
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. Insulating powder material is disposed substantially throughout the insulating cavity. An insulating gas is disposed within the insulating cavity, wherein the insulating powder material is combined with the insulating gas and cooperatively defines a suspended state and a precipitated state. The suspended state is defined by the insulating gas in motion and the insulating powder being in an aeolian suspension within the insulating gas while in motion. The precipitated state is defined by the insulating gas being in a deposition state and the insulating powder being precipitated from the insulating gas and deposited within the insulating cavity.