Vacuum Insulation Core Material With Filled Glass-Sphere Voids
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Solution Overview
Problem
Existing vacuum insulated structures for appliances face challenges in achieving high insulating performance and resistance to compressibility due to thermal transmission and vacuum bow issues, which are not adequately addressed by current insulating materials.
Innovation Solution
A method involving the use of glass spheres within a rotating drum, where binder materials and insulating materials are mixed to occupy interstitial spaces, forming a super-insulating core material with a homogeneous coating that reduces inter-particle void spacing, thereby enhancing thermal resistance and compressibility resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional insulating materials are used in vacuum insulated structures, then the structure can be manufactured with standard materials, but the thermal transmission is high and compressibility resistance is insufficient
Solution Approach 1:
The patent uses a composite material system consisting of glass spheres as core particles, binder material for adhesion, and insulating materials (such as aerogel or vacuum-deposited layers) to create a multi-layer composite structure. This composite approach combines the mechanical stability of glass spheres with the superior insulating properties of advanced materials, achieving both high insulating performance and structural integrity
Solution Approach 2:
The patent utilizes porous insulating materials including aerogel with extremely low density and high porosity to fill interstitial spaces between glass spheres. The porous structure provides exceptional thermal insulation while maintaining low thermal transmission, directly addressing the insulating performance requirement
2Reliability
If interstitial spaces between glass spheres are not filled, then the manufacturing process is simpler, but thermal transmission increases and insulating performance decreases
Solution Approach 1:
The patent applies binder material to glass spheres in advance to create a coating layer before adding insulating materials. This preliminary action ensures proper adhesion and prevents agglomeration, facilitating the subsequent filling of interstitial spaces with insulating materials while maintaining manufacturing feasibility
Solution Approach 2:
The patent divides the insulating structure into discrete components: glass spheres as structural units, binder material as adhesive medium, and insulating materials as thermal barrier layers. This segmentation allows each component to be optimized independently and combined through controlled mixing processes
3Reliability
If a vacuum is created within the structure, then thermal transmission is reduced, but vacuum bow occurs due to external atmospheric pressure
Solution Approach 1:
The patent changes the physical and mechanical parameters of the core material by using glass spheres with specific size distributions, wall thicknesses, and mechanical strengths. These parameter optimizations enable the material to withstand external atmospheric pressure while maintaining vacuum conditions, preventing vacuum bow
Solution Approach 2:
The patent creates a composite structure where glass spheres form a rigid framework that provides mechanical strength to resist vacuum bow, while insulating materials fill the interstitial spaces to maintain thermal insulation. This composite approach simultaneously addresses both structural integrity and thermal insulation requirements
4Strength
If glass spheres are used as core material, then the structure provides mechanical stability, but interstitial spaces create thermal transmission pathways
Solution Approach 1:
The patent uses porous insulating materials such as aerogel to fill the interstitial spaces between glass spheres. The porous structure of aerogel provides exceptional thermal insulation by trapping gas molecules and reducing heat conduction, effectively blocking thermal transmission pathways while maintaining the mechanical stability provided by glass spheres
Solution Approach 2:
The patent introduces insulating materials as an intermediary substance between glass spheres to block thermal transmission pathways. The binder material serves as another intermediary that adheres glass spheres together while the insulating materials fill remaining voids, creating a multi-layer intermediary system that addresses both mechanical and thermal requirements
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 method results in a super-insulating core material that significantly reduces thermal transmission and minimizes vacuum bow, providing improved insulating performance and structural integrity within vacuum insulated structures.
Implementation Method 1
The at least one binder material, the first insulating material and the glass spheres are mixed to define an insulating base... wherein the first and second insulating materials occupy substantially all of an interstitial volume defined by 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.