Processes for making a super-insulating core material for a vacuum insulated structure
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Solution Overview
Problem
Existing vacuum insulated structures for appliances face challenges in achieving high insulating performance and resistance to compressive forces due to gaps between glass spheres, leading to thermal transmission issues and vacuum bow during gas expulsion.
Innovation Solution
A method involving a rotating drum process where glass spheres are coated with binder materials and mixed with insulating materials to fill interstitial spaces, creating a dense, homogeneous super-insulating core material that minimizes voids and enhances compressibility resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If glass spheres are used as insulating material in vacuum insulated structures, then thermal insulation performance is improved, but interstitial spaces between spheres create thermal transmission pathways and reduce compressibility resistance
Solution Approach 1:
The invention utilizes the natural porous structure created by interstitial spaces between glass spheres, but transforms it from a weakness into a feature by filling these spaces with additional insulating materials. The porous structure allows for effective thermal insulation while the filled spaces provide mechanical support and compressibility resistance.
Solution Approach 2:
The invention creates a composite insulating structure by combining glass spheres with additional insulating materials (such as aerogel particles, vacuum insulation particles, or other suitable materials). This composite approach allows the material to simultaneously achieve excellent thermal insulation properties and enhanced mechanical strength to resist compression.
2Loss of energy
If glass spheres are used in vacuum insulated structures, then thermal insulation is enhanced, but gaps between spheres lead to thermal transmission and vacuum bow during gas expulsion
Solution Approach 1:
The invention accepts and utilizes the porous structure formed by glass sphere arrangements, filling the interstitial spaces with additional insulating materials that maintain thermal performance while providing structural support during vacuum formation and gas expulsion processes.
Solution Approach 2:
By creating a composite material system combining glass spheres with secondary insulating materials, the invention achieves both reduced thermal transmission through the interstitial spaces and enhanced structural integrity to prevent vacuum bow during gas expulsion operations.
3Temperature
If multiple mixing stages are implemented to fill interstitial spaces completely, then insulating performance is maximized, but manufacturing complexity and processing time increase
Solution Approach 1:
The invention divides the mixing process into distinct stages: first mixing the binder material with glass spheres, then adding and mixing additional insulating materials. This segmentation allows for controlled, progressive filling of interstitial spaces while maintaining manufacturing efficiency and avoiding excessive complexity.
Solution Approach 2:
The binder material is applied to glass spheres in advance to create a coating that facilitates subsequent mixing and filling of interstitial spaces. This preliminary action ensures proper material distribution and adhesion before the final insulating materials are added and mixed.
4Strength
If binder material is used to coat glass spheres, then compressibility resistance is improved, but manufacturing process complexity increases
Solution Approach 1:
The binder material is applied to glass spheres as a preliminary step before adding additional insulating materials. This pre-coating approach simplifies the overall process by preparing the glass spheres for optimal mixing and bonding, while the binder itself contributes to compressibility resistance.
Solution Approach 2:
The binder material creates a composite structure between glass spheres and additional insulating materials, enhancing compressibility resistance through the binding effect while the combination of materials provides both mechanical strength and thermal insulation properties.
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 process results in a super-insulating core material that reduces thermal conductivity and resists compressive forces, maintaining structural integrity and insulating performance even after gas expulsion, thereby improving the efficiency of vacuum insulated structures.
Implementation Method 1
The glass spheres and the at least one binder material are rotated within the rotating drum, wherein the at least one binder material is mixed during a first mixing stage with the glass spheres
Implementation Method 2
the at least one binder material is mixed during a first mixing stage with the glass spheres to partially occupy the interstitial spaces
Data Source
AI summary
A method for forming a super-insulating material for a vacuum insulated structure includes disposing glass spheres within a rotating drum. A plurality of interstitial spaces are defined between the glass spheres. A binder material is disposed within the rotating drum. The glass spheres and the at least one binder material are rotated within the rotating drum, wherein the binder material is mixed during a first mixing stage with the glass spheres. A first insulating material is disposed within the rotating drum. The binder material, the first insulating material and the glass spheres are mixed to define an insulating base. A second insulating material is disposed within the rotating drum. The secondary insulating material is mixed with the insulating base to define a homogenous form of the super-insulating material, wherein the first and second insulating materials occupy substantially all of the interstitial spaces.