Vacuum insulated refrigerator structure with three dimensional characteristics
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Solution Overview
Problem
The flat two-dimensional shapes of existing vacuum insulated core panels limit their applications in refrigerator structures, restricting their use in more complex geometries and designs.
Innovation Solution
A method of forming a three-dimensional vacuum insulated refrigerator structure by stacking flexible core materials, such as fiberglass mats, between impermeable barrier sheets and molding them into predefined shapes, creating a sealed envelope that can be positioned between a wrapper and a liner to form a vacuum insulated core with a U-shape cross-section, allowing for more versatile applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If flat two-dimensional core panels are used, then manufacturing is simple, but application versatility is limited
Solution Approach 1:
The patent transitions from two-dimensional flat core panels to three-dimensional shaped core panels by introducing a molding step that forms the core material into predefined 3D shapes conforming to complex geometries such as curved surfaces and non-uniform thickness profiles, thereby enabling application in diverse refrigerator components like doors and cabinets
2Adaptability or versatility
If complex three-dimensional shapes are created, then application versatility improves, but manufacturing complexity increases
Solution Approach 1:
The patent performs preliminary action by pre-forming the core material into the desired three-dimensional shape using a mold before vacuum sealing, which simplifies the subsequent manufacturing steps and enables mass production of complex geometries without increasing overall process complexity
Solution Approach 2:
The patent uses flexible impermeable barrier sheets that can be molded into complex three-dimensional shapes and then vacuum sealed, allowing the core material to be formed into intricate geometries while maintaining manufacturing efficiency through the flexibility and formability of the barrier material
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 approach enables the creation of vacuum insulated structures with complex geometries, enhancing the versatility and application range of refrigerator components like doors and cabinets by maintaining airtight insulation and thermal efficiency.
Implementation Method 1
The core is evacuated, and edge portions of the first and second sheets are sealed together while the core is evacuated to form a three dimensional core having an airtight envelope around the core
Data Source
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AI summary
A method of making a vacuum insulated refrigerator structure includes positioning a core of overlapping stacked sheets of fiberglass mat in an envelope of impermeable barrier material. The core is pressed into a predefined three dimensional shape by pressing first and second mold parts together. The core is evacuated, and the envelope is sealed to form a three dimensional core having an airtight envelope around the core. The three dimensional vacuum core is positioned between a wrapper and a liner, and the wrapper and the liner are interconnected to form a vacuum insulated refrigerator structure.