Super-Insulating Core Material with Glass Spheres to Reduce Vacuum Bow
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Solution Overview
Problem
Existing insulating materials for vacuum insulated structures in appliances lack sufficient compressibility resistance and thermal insulation efficiency, leading to increased thermal transmission and vacuum bow during gas expression.
Innovation Solution
A method for forming a super-insulating material involving the use of glass spheres, binder materials, and multiple insulating materials within a rotating drum to create a homogeneous coating that reduces inter-particle void spacing, enhancing compressibility resistance and thermal insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing insulating materials are used in vacuum insulated structures, then the structure can be assembled, but thermal transmission increases and compressibility resistance decreases
Solution Approach 1:
The patent uses a composite material system consisting of glass spheres as core particles, binder material for adhesion, and multiple insulating materials (first and second insulating materials) to fill interstitial spaces. This multi-material composite structure simultaneously provides mechanical stability (compressibility resistance) and thermal insulation properties, resolving the contradiction between structural integrity and thermal performance
Solution Approach 2:
The patent utilizes the controlled porous structure created by packing glass spheres with defined interstitial spaces, then filling these spaces with insulating materials. The porous arrangement of glass spheres provides structural framework and compressibility resistance, while the filled interstitial spaces provide thermal insulation, addressing both requirements simultaneously
2Shape
If glass spheres with interstitial spaces are used, then the material structure is formed, but thermal transmission increases due to void spacing
Solution Approach 1:
The patent applies different materials to different locations within the structure: glass spheres form the primary structural framework, binder material occupies specific interstitial spaces for adhesion, and two different insulating materials fill remaining voids. This localized material assignment optimizes both structural integrity and thermal insulation by placing appropriate materials in appropriate locations
Solution Approach 2:
The patent implements a nested structure where glass spheres are nested within the overall material matrix, binder material is nested within interstitial spaces between glass spheres, and insulating materials are nested within remaining voids. This multi-level nesting approach fills void spaces hierarchically to eliminate thermal pathways while maintaining the glass sphere structural framework
3Ease of manufacture
If simple mixing of materials is used, then the process is simple, but homogeneous coating is not achieved and insulating performance is reduced
Solution Approach 1:
The patent segments the mixing process into distinct stages: first mixing glass spheres with binder material to form adhering base material, then mixing with first insulating material to form aggregate material, and finally mixing with second insulating material. This segmented approach ensures homogeneous distribution of each material component while maintaining process simplicity through sequential rather than simultaneous mixing
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 super-insulating material achieves reduced thermal transmission and increased resistance to compressibility, minimizing vacuum bow and enhancing the insulating performance of vacuum insulated structures in appliances.
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 to partially occupy the interstitial spaces
Implementation Method 2
The second 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 an interstitial volume defined by the interstitial spaces
Implementation Method 3
The glass spheres and the at least one binder material are rotated within the rotating drum
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.