Powder Processor for Vacuum Insulation Degassing
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Solution Overview
Problem
Current vacuum insulation technologies in refrigerators face challenges in achieving optimal energy efficiency due to issues with gas permeation and moisture content in vacuum insulation materials, leading to inefficiencies in evacuation times and energy consumption.
Innovation Solution
A powder processor system that heats and degasses vacuum insulation material, reducing moisture content to less than 2 wt% and applying a vacuum pressure of less than 0.01 atm, which is then loaded into a vacuum insulated structure using a gas permeable feature to enhance evacuation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If vacuum insulation material is loaded directly without pre-treatment, then the process is simple and fast, but the evacuation time is extended and energy consumption increases due to high moisture content
Solution Approach 1:
The vacuum insulation material undergoes pre-treatment in the powder processor before being loaded into the vacuum cavity. The heater heats the material to evaporate moisture, and the evacuator removes water vapor during the heating process. This preliminary removal of moisture significantly reduces the evacuation time required after loading, resolving the contradiction between process simplicity and evacuation time efficiency.
2Quantity of substance
If vacuum insulation material with high moisture content is used, then material cost is reduced, but energy consumption increases due to extended evacuation time
Solution Approach 1:
The invention converts the harmful effect of high moisture content (which increases evacuation time and energy consumption) into a beneficial process feature. The powder processor's heater and evacuator are designed to efficiently evaporate and remove water vapor during the loading process. By utilizing the moisture content as a driver for the pre-treatment process, the system achieves both cost-effective material selection and energy-efficient processing, as the moisture is removed before the material enters the vacuum cavity.
3Device complexity
If conventional loading methods are used without pre-evacuation, then equipment complexity is minimized, but gas permeation rates increase reducing vacuum insulation performance
Solution Approach 1:
The invention merges the heating function and vacuum evacuation function into a single integrated powder processor unit. The heater heats the vacuum insulation material while the evacuator simultaneously removes water vapor through the air permeable hopper wall. This combination of functions in one device achieves low gas permeation rates without significantly increasing overall system complexity, as the integrated design eliminates the need for separate pre-treatment equipment.
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 significantly reduces the time and energy required to achieve desired vacuum levels in vacuum insulated structures, improving energy efficiency and reducing gas permeation rates, thereby enhancing the overall performance of refrigeration systems.
Implementation Method 1
A heater is positioned in a space defined between the inner hopper wall and the outer hopper wall... applying heat using the heater... to form a dry and degassed vacuum insulation material
Implementation Method 2
At least one evacuator is coupled to the vacuum port of the powder processor. The at least one evacuator is configured to couple to a vacuum port of the vacuum insulated structure and apply a vacuum to the internal cavity of the vacuum insulated structure
Implementation Method 3
The inner hopper wall includes an air permeable surface... reducing moisture content to less than 2 wt%
Data Source
AI summary
A filling system for a vacuum insulated structure includes a powder processor configured to load an internal cavity of the vacuum insulated structure with a heated and at least partially degassed vacuum insulation material. The powder processor includes a hopper with inner and outer hopper walls. The inner hopper wall includes an air permeable surface. A heater is positioned in a space defined between the inner and outer hopper walls. A feed screw is positioned along an inside edge of the inner hopper wall. A vacuum port is positioned on the outer hopper wall. An aperture exit is positioned at a bottom of the hopper. At least one evacuator is coupled to the vacuum port of the powder processor. The at least one evacuator is configured to couple to a vacuum port of the vacuum insulated structure and apply a vacuum to the internal cavity of the vacuum insulated structure.