3D Vacuum Insulated Refrigerator Door With Folded Dispensing Cavity
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Solution Overview
Problem
Existing insulated appliance door structures, particularly those with polyurethane foam, face inefficiencies in insulation and design, especially when incorporating dispensing cavities for ice and liquid water, leading to suboptimal performance and energy efficiency.
Innovation Solution
A method involving core material boards folded to form a three-dimensional vacuum insulated structure within an envelope, eliminating the need for insulating foam between the door skin and liner, with a dispensing cavity allowing ice and water to be dispensed without opening the door, utilizing a vacuum-sealed assembly for enhanced insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If polyurethane foam insulation is used in traditional insulated door structures, then the door provides thermal insulation, but the insulation efficiency is suboptimal and energy consumption is higher
Solution Approach 1:
The patent changes the physical state of the insulation medium from solid foam to vacuum (gas phase with near-zero pressure), fundamentally altering the thermal conduction parameter to achieve superior insulation efficiency and reduced energy consumption
Solution Approach 2:
The patent creates a vacuum environment within the door structure, eliminating air and other gases that conduct heat, thereby providing an inert thermal environment that significantly reduces heat transfer and improves insulation performance
2Ease of operation
If a dispensing cavity is incorporated into the insulated door structure, then ice and water can be dispensed without opening the door, but the structural complexity increases
Solution Approach 1:
The patent divides the door structure into multiple separable core material boards that can be independently formed and then assembled, allowing the dispensing cavity to be integrated without requiring a completely complex monolithic structure
Solution Approach 2:
The patent nests the dispensing cavity within the door structure by positioning it between the outer door skin and inner door liner, with the cavity formed by the folded core material boards, creating a nested configuration that integrates multiple functions within the door assembly
3Reliability
If core material boards are folded to form a three-dimensional vacuum insulated structure, then vacuum insulation is achieved with improved thermal performance, but the manufacturing process becomes more complex
Solution Approach 1:
The patent segments the insulation structure into multiple flat core material boards that are easier to manufacture individually, which are then folded and assembled into the three-dimensional vacuum structure, simplifying the manufacturing of individual components while achieving complex overall performance
Solution Approach 2:
The patent performs preliminary folding of the core material boards into the desired three-dimensional configuration before applying the vacuum seal, which simplifies the manufacturing process by preparing the structure in stages rather than requiring complex simultaneous operations
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 solution provides improved insulation efficiency and energy savings by creating a vacuum-sealed, three-dimensional structure that maintains temperature while allowing for convenient dispensing of ice and water, enhancing the operational performance of appliance doors.
Implementation Method 1
The generally flat subassembly is positioned in a vacuum chamber, and a vacuum is formed in the vacuum chamber
Implementation Method 2
The folded core material boards form a three dimensional vacuum insulated structure having a dispensing cavity
Data Source
AI summary
An appliance door includes a vacuum insulated structure having a plurality of core sections that are folded to form an ice and/or water dispensing cavity on an outer side of the appliance door. The vacuum insulated door structure may be positioned between an outer door member and a door liner.