Vacuum Insulation Core Filling to Minimize Gaseous Pores
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Solution Overview
Problem
Existing methods for creating super-insulating materials for vacuum insulated structures face challenges in minimizing gaseous pores and ensuring the structural integrity of the insulating core, leading to inefficiencies in thermal insulation and resistance to pressure differentials.
Innovation Solution
The method involves using hollow glass spheres and a silica-based material, where an anchor or coating material is mixed with the glass spheres to occupy interstitial spaces, and the silica-based material is entrapped or adheres to the spheres, reducing gaseous pores to less than one micron and enhancing the structural density of the insulating core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If hollow glass spheres are used as the base material for vacuum insulated structures, then the insulating performance is improved, but gaseous pores remain between the spheres reducing insulation efficiency
Solution Approach 1:
The patent applies porous materials by introducing a silica-based material that fills the interstitial spaces between hollow glass spheres. The silica-based material creates a controlled porous structure where pores are reduced to less than one micron in size, transforming the harmful gaseous pores into beneficial micro-porous insulation that reduces gaseous conductivity while maintaining thermal insulation performance.
Solution Approach 2:
The patent creates a composite material structure by combining hollow glass spheres with silica-based material. This composite approach integrates two different materials with complementary properties: the hollow glass spheres provide structural framework and vacuum insulation, while the silica-based material fills interstitial spaces and reduces gaseous conductivity, achieving superior overall insulation performance.
2Device complexity
If interstitial spaces between glass spheres are left empty to maintain sphere integrity, then structural simplicity is maintained, but insulation efficiency decreases due to gaseous pores
Solution Approach 1:
The patent applies local quality by selectively filling only the interstitial spaces between hollow glass spheres with silica-based material, while leaving the interior of the glass spheres themselves empty to maintain vacuum. This localized modification optimizes insulation efficiency in the critical interstitial regions without compromising the structural integrity and vacuum insulation function of the glass spheres.
3Object-affected harmful factors
If silica-based material is added to fill interstitial spaces, then gaseous conductivity is reduced, but the manufacturing process becomes more complex
Solution Approach 1:
The patent employs pneumatic principles by using a fluidized bed process where air flow fluidizes the hollow glass spheres, allowing silica-based material to be uniformly distributed and settled into interstitial spaces. This pneumatic approach simplifies the manufacturing process compared to traditional methods by enabling automatic, uniform filling of interstitial spaces through fluidization and controlled settling.
4Strength
If the insulating core structure is made denser to resist pressure differentials, then structural integrity is improved, but manufacturing difficulty increases
Solution Approach 1:
The patent applies self-service principles through the fluidized bed manufacturing process, where the hollow glass spheres self-arrange and self-fill with silica-based material during fluidization and settling. The process leverages the natural behavior of granular materials under fluid flow to achieve uniform distribution and dense packing, eliminating the need for complex external compaction or arrangement mechanisms.
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 results in a super-insulating material with minimal gaseous conductivity and robust structural integrity, effectively resisting compression and maintaining a stable vacuum within the insulated structure.
Implementation Method 1
The hollow glass spheres and the anchor material are rotated within the rotating drum
Implementation Method 2
the silica-based material adheres to the glass spheres via the coating material
Implementation Method 3
the coating material and the silica-based material 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 for an appliance includes disposing hollow glass spheres within a rotating drum, wherein a plurality of interstitial spaces are defined between the hollow glass spheres. An anchor material is disposed within the rotating drum. The hollow glass spheres and the anchor material are rotated within the rotating drum, wherein the anchor material is mixed with the hollow glass spheres to partially occupy the interstitial spaces. A silica-based material is disposed within the rotating drum. The silica-based material is mixed with the anchor material and the hollow glass spheres to define a super-insulating material, wherein the silica-based material attaches to the anchor material and is entrapped within the interstitial spaces. The silica-based material and the anchor material occupy substantially all of an interstitial volume defined by the interstitial spaces.