Sensor assembly for vacuum insulated structure
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Solution Overview
Problem
Vacuum insulated structures, such as refrigerators, face challenges in maintaining a consistent partial vacuum due to gas infiltration, which affects insulation efficiency and longevity, and existing solutions lack effective monitoring and maintenance tools.
Innovation Solution
A sensor assembly is coupled to the structural wrapper of vacuum insulated structures, featuring a connector with a base and housing in fluid communication with the insulating cavity, equipped with a microelectromechanical pressure sensor and sealing plates to monitor and maintain the pressure within the cavity without breaking the vacuum seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor assembly is installed to monitor pressure within the insulating cavity, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The pressure sensor is nested within the sensor assembly housing, which is coupled to the structural wrapper. The connector interior is nested within the housing, creating a compact hierarchical structure that integrates multiple components (sensor, housing, connector, base) into a unified assembly without increasing overall system complexity
Solution Approach 2:
The sensor assembly serves multiple functions: it provides structural support through the base and housing, creates fluid communication pathways via the connector, and performs pressure sensing through the pressure sensor. This multi-functionality reduces the need for separate components, thereby improving measurement precision without proportionally increasing device complexity
2Strength
If the structural wrapper is made more robust to maintain vacuum, then strength is improved, but weight increases
Solution Approach 1:
The structural wrapper is constructed from composite materials that provide high strength-to-weight ratio, enabling robust vacuum maintenance without excessive weight gain. The connector and housing also utilize composite or optimized materials to balance structural integrity with weight constraints
3Ease of operation
If the sensor assembly is made compact for ease of installation, then ease of operation is improved, but manufacturing precision requirements increase
Solution Approach 1:
The base, housing, and connector are pre-assembled into a integrated sensor assembly unit before installation on the structural wrapper. This preliminary assembly ensures precise alignment and sealing relationships are established during manufacturing rather than during field installation, maintaining manufacturing precision while achieving compact, easy-to-install configuration
Solution Approach 2:
The nested structure of the pressure sensor within the housing, and the connector interior within the housing, creates a compact integrated assembly that is easy to handle and install as a single unit, while the precise relationships between nested components are established during controlled manufacturing processes
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 sensor assembly effectively senses and maintains the pressure within the insulating cavity, enhancing the longevity of the vacuum insulation and allowing for continuous monitoring without compromising the vacuum seal, using a compact and efficient design suitable for various insulation configurations.
Implementation Method 1
A pressure sensor is disposed within the housing. The pressure sensor is configured to sense a pressure within the insulating cavity.
Implementation Method 2
The connector defines an interior in fluid communication with the insulating cavity.
Data Source
AI summary
A door assembly includes a structural wrapper defining an insulating cavity. The structural wrapper defines a sensor port. A sensor assembly is coupled to an outer surface of the structural wrapper proximate to the sensor port. The sensor assembly includes a connector having a base coupled to a housing. The base is coupled to the structural wrapper. The connector defines an interior in fluid communication with the insulating cavity. A pressure sensor is disposed within the housing. The pressure sensor is configured to sense a pressure within the insulating cavity. At least one plate is disposed at an open end of the housing. The pressure sensor includes sensor pins that extend through the at least one plate.