Spherical Support Structures for Vacuum Insulated Appliance Cavities

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Solution Overview

Problem

Existing vacuum insulated appliances face challenges in maintaining structural integrity and efficient insulation due to pressure differentials within the insulation cavity.

Innovation Solution

The use of a plurality of supports with a substantially spherical structure disposed within the insulation cavity, which are in fluid communication with the cavity through apertures, to support the outer wrapper and liner assembly against pressure differentials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If a vacuum is created within the insulation cavity, then insulation efficiency is improved, but structural integrity deteriorates due to pressure differential

Engineering Contradiction:

Improveinsulation efficiencyVSAvoidstructural integrity

Core Design Contradiction:

Loss of energyVSStrength

Solution Approach 1:

The support structures are strategically positioned at specific locations within the insulation cavity where pressure differential forces are most significant. This localized placement provides structural reinforcement exactly where needed to counteract the vacuum pressure, rather than requiring uniform reinforcement throughout the entire structure.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The support structures utilize composite construction combining materials with different properties - rigid frameworks for structural strength and low thermal conductivity materials for insulation. This composite approach allows the supports to simultaneously maintain structural integrity against pressure differentials while minimizing heat transfer pathways.

Inventive Principle:

Principle #40Composite materials

2Strength

If support structures are added to maintain structural integrity, then strength is improved, but heat transfer increases

Engineering Contradiction:

Improvestructural integrityVSAvoidheat transfer

Core Design Contradiction:

StrengthVSLoss of energy

Solution Approach 1:

The support structures incorporate porous or cellular material designs that provide structural strength through their geometric framework while maintaining low thermal conductivity. The porous nature of these materials creates tortuous heat paths and reduces solid-to-solid thermal contact, allowing the supports to bear mechanical loads without becoming significant heat transfer bridges.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The support structures utilize curved and spherical geometric forms rather than straight rigid elements. These curved geometries naturally distribute stress more effectively to maintain structural integrity while also creating longer, more tortuous heat transfer paths compared to linear configurations, thereby reducing thermal conduction.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Loss of energy

If the insulation cavity is sealed to maintain vacuum, then insulation efficiency is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveinsulation efficiencyVSAvoidmanufacturing complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The support structures are pre-positioned and secured to either the inner or outer wrapper before the vacuum sealing process. This preliminary placement ensures that supports are correctly positioned to counteract vacuum pressures without requiring complex real-time adjustment mechanisms during sealing, simplifying the overall manufacturing process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The support structures serve multiple functions simultaneously: providing structural reinforcement against vacuum pressure, maintaining spacing between wrappers, and acting as mounting points for sealing components. This multi-functionality reduces the number of separate components needed, thereby simplifying the sealing mechanism and manufacturing process.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 configuration enhances the structural support and insulation efficiency by resisting pressure biases and minimizing heat transfer through tortuous paths and reduced surface areas.

Implementation Method 1

An at least partial vacuum is defined within the insulation cavity biasing the outer wrapper and the liner assembly towards the insulation cavity

Methodology Applied

Scientific EffectPressure differential: Pressure Gradient

Implementation Method 2

A hollow internal volume of each support is in fluid communication with the insulation cavity through a plurality of apertures defined by each support

Methodology Applied

Scientific EffectFluid communication:

Data Source

PatentUS20250137715A1Internal supports for vacuum insulated structure

Publication Date: 2025.05.01 WHIRLPOOL CORP

AI summary

A vacuum insulated appliance includes a cabinet defining at least one compartment. The cabinet includes an outer wrapper having an inner surface and a liner assembly having an inner surface. The liner assembly is coupled to the outer wrapper and defines an insulation cavity therebetween. An at least partial vacuum is defined within the insulation cavity biasing the outer wrapper and the liner assembly towards the insulation cavity. A plurality of supports having a substantially spherical structure are disposed in the insulation cavity. A hollow internal volume of each support is in fluid communication with the insulation cavity through a plurality of apertures defined by each support. The plurality of supports is configured to support the outer wrapper and the liner assembly.