Structural insulating component for a multi-layer insulation system of a vacuum insulated structure
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Solution Overview
Problem
Conventional vacuum insulated cabinets experience inward deflection due to the compressive force generated by the vacuum, leading to undesirable aesthetic changes in the outer surface.
Innovation Solution
A multi-layer insulation system comprising an outer wrapper, an inner liner, and a core insulating material, with first and second insulating structural layers made of glass spheres that resist deflection by maintaining the cabinet's shape through an interstitial insulating space and adhesive or static charge adhesion, while defining an insulating cavity with a partial vacuum.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a vacuum is created in the insulating cavity to improve thermal insulation, then thermal insulation performance is improved, but the outer wrapper and inner liner experience inward deflection due to compressive force
Solution Approach 1:
The patent applies different functional properties to different parts of the insulation system. The glass sphere layers are positioned specifically at the inner surfaces of the outer wrapper and inner liner where structural support is needed, while the foam core material fills the remaining space. This local differentiation allows the system to provide both vacuum insulation and structural reinforcement where needed.
Solution Approach 2:
The patent uses a composite insulation structure combining multiple materials: glass spheres (hollow or solid), foam core material, and adhesive binder. This composite approach allows the system to achieve both excellent thermal insulation properties and structural strength to resist vacuum-induced deflection, resolving the contradiction between insulation performance and shape stability.
2Strength
If glass sphere layers are added to reinforce the cabinet structure and resist deflection, then structural strength is improved, but the complexity of the insulation system increases
Solution Approach 1:
The patent merges multiple functions into a single integrated structure. The glass sphere layers serve dual purposes: they provide structural reinforcement to resist vacuum deflection and simultaneously contribute to thermal insulation. The adhesive binder both holds the glass spheres in place and fills gaps to maintain the vacuum seal, combining structural and sealing functions in one component.
Solution Approach 2:
Each component in the insulation system performs multiple functions. The glass sphere layers provide both structural support and thermal insulation. The foam core material fills space, provides insulation, and distributes vacuum pressure. The adhesive system both bonds components and maintains vacuum integrity. This multi-functionality reduces overall system complexity despite the presence of multiple materials.
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 system effectively maintains the cabinet's shape and aesthetic by reinforcing the outer wrapper and inner liner, preventing inward deflection and ensuring consistent thermal insulation.
Implementation Method 1
the insulating cavity defines an at least partial vacuum
Implementation Method 2
A core insulating material is disposed between the first and second insulating structural layers
Implementation Method 3
adhesive or static charge adhesion
Implementation Method 4
adhesive or static charge adhesion
Data Source
AI summary
A structural cabinet for an appliance includes an outer wrapper and an inner liner defining an insulating cavity therebetween. A first insulating structural layer is disposed against an inner surface of the outer wrapper. A second insulating structural layer is disposed against the inward surface of the inner liner. A core insulating material is disposed between the first and second structural insulating layers, wherein the first and second insulating structural layers reinforce the outer wrapper and inner liner, respectively, and resist deflection when the core insulating material is in a compressed state within the insulating cavity.