Multi-Layer Thermoplastic Barrier for Vacuum Insulated Structures
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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 is thermoformed to create non-planar components with a central portion and sidewalls, secured together to form an interior space filled with porous filler material, which is then evacuated to create a vacuum insulated structure with enhanced gas barrier properties.
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 vacuum degradation
Solution Approach 1:
The patent applies composite materials by constructing a multi-layer barrier material comprising a first layer and a second layer with different material compositions. The first layer provides primary gas barrier properties while the second layer complements it with additional barrier characteristics, creating a synergistic composite structure that achieves superior overall gas barrier performance compared to single-layer materials.
Solution Approach 2:
The barrier material is segmented into multiple distinct layers, each potentially serving different functional purposes. This segmentation allows each layer to be optimized for specific gas barrier requirements, and the combined multi-layer structure provides enhanced protection against gas permeation compared to a single homogeneous layer.
2Temperature
If vacuum insulated structures are used for superior insulation, then thermal performance is improved, but maintaining consistent vacuum is difficult leading to reduced insulation efficiency
Solution Approach 1:
The multi-layer composite barrier material provides enhanced and more consistent gas barrier properties compared to single-layer materials. This consistency in barrier performance ensures more reliable vacuum maintenance over time, directly addressing the vacuum consistency issue while preserving the superior thermal insulation performance that vacuum structures provide.
3Reliability
If multi-layer barrier materials are implemented, then gas barrier properties are enhanced, but manufacturing complexity increases
Solution Approach 1:
The patent employs parameter changes by carefully selecting and optimizing the thickness, material composition, and structural parameters of each layer in the multi-layer barrier material. By adjusting these parameters, the design achieves enhanced gas barrier properties while managing manufacturing complexity through optimized parameter selection rather than excessive layer multiplication.
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 improves insulation efficiency by using thermoplastic polymers or elastomeric materials to form a robust gas barrier, enhancing the thermal performance of vacuum insulated structures in various applications.
Implementation Method 1
The multi-layer sheet of material is thermoformed or vacuum formed to form a non-planar first component
Implementation Method 2
Porous filler material is positioned in the interior space, and a vacuum is formed in the interior space
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.