Multi-Layer Gas Barrier Thermoformed Panels for Vacuum Insulation
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Solution Overview
Problem
Existing vacuum insulated structures face challenges in maintaining a consistent vacuum and effective gas barrier properties, leading to reduced insulation efficiency in applications such as refrigerator cabinets and ovens.
Innovation Solution
A multi-layer sheet comprising thermoplastic polymers or elastomeric materials with a barrier layer between outer layers, thermoformed to create non-planar components that form an interior space filled with porous filler material, which is then evacuated to create a vacuum insulated structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional single-layer materials are used for vacuum insulated structures, then manufacturing is simpler, but gas barrier properties are insufficient leading to reduced 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 and inner layers provide structural integrity while the barrier layer (comprising materials like PVdC, nylon, or liquid crystal polymer) provides superior gas barrier properties. This composite structure resolves the contradiction by achieving enhanced gas barrier performance through material composition rather than relying on a single material, thus improving insulation efficiency while maintaining manufacturability.
Solution Approach 2:
The barrier layer is nested between the outer and inner layers, creating a sandwich structure where the gas-impermeable barrier is protected within the structural layers. This nesting arrangement ensures that the barrier material is shielded from mechanical damage while maintaining its gas barrier function, effectively preventing gas transmission into the vacuum space without requiring the entire structure to be complex.
2Reliability
If vacuum insulated structures are used, then insulation efficiency is improved, but maintaining consistent vacuum becomes difficult
Solution Approach 1:
The multi-layer composite structure with a dedicated barrier layer provides consistent gas barrier properties that prevent gas transmission into the vacuum space. This consistent barrier function maintains vacuum integrity over time, resolving the issue of vacuum consistency while preserving the high insulation efficiency that vacuum structures provide.
Solution Approach 2:
The patent specifies particular materials for the barrier layer (PVdC, nylon, liquid crystal polymer) with known low gas permeability parameters. By selecting materials with specific gas transmission rate parameters, the invention ensures consistent vacuum maintenance. The barrier layer's material properties are chosen to minimize gas transmission, thereby stabilizing the vacuum condition within the insulated structure.
3Reliability
If barrier layers are added to prevent gas transmission, then vacuum maintenance is improved, but manufacturing complexity increases
Solution Approach 1:
The barrier layer is nested between the outer and inner layers in a sandwich configuration, which simplifies the manufacturing process. The layers can be bonded together using conventional lamination or co-extrusion techniques, and the nested structure allows for integrated fabrication rather than separate assembly steps. This nesting approach maintains vacuum maintenance capability while avoiding excessive manufacturing complexity.
4Reliability
If porous filler material is used in the vacuum space, then insulation performance is enhanced, but gas transmission risk increases
Solution Approach 1:
The multi-layer composite structure with the gas-impermeable barrier layer positioned between the porous filler material and the external environment prevents gas transmission. The barrier layer acts as a protective shield that blocks gas molecules from reaching the porous filler, thereby allowing the use of high-performance porous insulation materials without compromising vacuum integrity or increasing gas transmission risk.
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 effectively maintains a vacuum and enhances insulation efficiency by using gas-impermeable materials to prevent gas transmission, thereby improving thermal insulation in various applications.
Implementation Method 1
at least one layer of barrier material that is disposed between first and second outer layers... gas-impermeable materials to prevent gas transmission
Implementation Method 2
Porous filler material is positioned in the interior space... filled with porous filler material, which is then evacuated to create a vacuum
Implementation Method 3
The multi-layer sheet of material is thermoformed or vacuum formed to form a non-planar first component
Implementation Method 4
a vacuum is formed in the interior space... effectively maintains a vacuum and enhances insulation efficiency
Implementation Method 5
enhances insulation efficiency by using gas-impermeable materials to prevent gas transmission, thereby improving thermal insulation
Data Source
AI summary
A vacuum insulated structure includes a multi-layer sheet of material comprising at least one layer of barrier material that is disposed between first and second outer layers. The barrier material and the first and second outer layers comprise thermoplastic polymers or elastomeric or hybrid material systems. The multi-layer sheet of material is thermoformed or vacuum formed to form a non-planar first component having a central portion and four sidewalls extending transversely from the central portion. A second component having a central portion and four sidewalls extending transversely from the central portion is secured 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 by removing gasses and moisture (water vapor). The first and second components are sealed together to form a vacuum insulated structure.