Multi-layer gas barrier materials for vacuum insulated structure
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Solution Overview
Problem
Existing vacuum insulated structures face challenges in maintaining a consistent vacuum and preventing gas and moisture infiltration, which affects their insulation efficiency in applications like refrigerator cabinets.
Innovation Solution
A multi-layer sheet of thermoplastic polymers or elastomeric materials is thermoformed to create a non-planar component with a central portion and sidewalls, secured with another component to form an interior space, where porous filler material is introduced and evacuated to create a vacuum, ensuring a sealed and insulated structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional single-layer materials are used for vacuum insulated structures, then the structure can be simpler to manufacture, but gas and moisture infiltration occurs reducing insulation efficiency
Solution Approach 1:
The patent employs a multi-layer composite material structure consisting of an outer layer, barrier layer, and inner layer. Each layer serves a specific function: the outer layer provides structural support, the barrier layer prevents gas and moisture infiltration, and the inner layer contacts the vacuum space. This composite structure resolves the contradiction by achieving superior vacuum maintenance capability through material composition rather than relying on a single material type.
Solution Approach 2:
The patent applies local quality by assigning different properties to different layers of the material structure. The barrier layer specifically targets gas and moisture permeability with low permeation rates, while the outer and inner layers focus on structural integrity and vacuum space formation. This localized functional differentiation enables the overall structure to maintain vacuum reliability without requiring all layers to be equally complex.
2Reliability
If porous filler material is used in the vacuum space, then insulation properties are enhanced, but the structure becomes more complex to assemble
Solution Approach 1:
The patent applies preliminary action by forming the multi-layer material into a pre-assembled unit where the outer layer, barrier layer, and inner layer are already bonded together before deployment. This pre-assembly includes pre-formed sealing structures and integrated vacuum space configuration, which simplifies the final installation process despite the enhanced insulation functionality. The porous filler material is incorporated into this pre-formed structure, reducing on-site assembly complexity.
Solution Approach 2:
The patent implements the nested doll principle by placing the porous filler material within the vacuum space defined by the multi-layer structure. The inner layer contains the filler material, which is nested within the sealed vacuum chamber formed by the outer and barrier layers. This nested configuration allows the complex insulated vacuum structure to be compactly integrated into the refrigerator cabinet space.
3Reliability
If multi-layer barrier materials are used to prevent gas infiltration, then vacuum consistency is improved, but manufacturing cost increases
Solution Approach 1:
The patent utilizes porous materials, specifically porous filler material placed within the vacuum space, to enhance insulation performance. The porous structure provides high insulation efficiency by trapping gas molecules and reducing heat transfer. This approach maintains vacuum consistency by adding functional insulation material rather than simply increasing the thickness or complexity of the barrier layers, thereby controlling material consumption.
Solution Approach 2:
The patent employs a composite material structure where the barrier layer uses materials with specific low permeation properties for gases and moisture, while the porous filler material provides additional insulation. This composite approach optimizes vacuum consistency by combining materials with complementary functions, avoiding the need to use excessive amounts of any single expensive barrier material throughout the entire structure.
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 method effectively maintains a vacuum within the insulated structure, enhancing insulation properties by preventing gas and moisture infiltration, thereby improving energy efficiency in refrigerator cabinets and other applications.
Implementation Method 1
at least one layer of barrier material that is disposed between first and second outer layers
Implementation Method 2
barrier material...preventing gas and moisture infiltration
Implementation Method 3
a vacuum is formed in the interior space by removing gasses and moisture (water vapor)
Implementation Method 4
Porous filler material is positioned in the interior space...enhancing insulation properties
Data Source
Figure 1
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AI summary
A method of forming a vacuum insulated refrigerator cabinet structure includes providing a multi-layer sheet of material comprising at least one layer of barrier material that is disposed between first and second outer structural layers. The barrier material and the first and second outer layers comprise thermoplastic polymers. The multi-layer sheet of material is thermoformed to form a non-planar first component having a central portion and four sidewalls extending transversely from the central portion. The method further includes securing a second component having a central portion and four sidewalls extending transversely from the central portion to the first component to form an interior space therebetween. Porous filler material is positioned in the interior space, and a vacuum is formed in the interior space. The first and second components are sealed together to form a vacuum insulated refrigerator cabinet structure.