Vacuum Insulated Panels for Aircraft Cargo Containers
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Solution Overview
Problem
Current thermally insulated cargo containers for aircraft, such as Unit Load Devices (ULDs), face challenges with weight and cargo space due to the use of thick foam core panels, which increase unloaded weight and reduce cargo capacity, and require heavy and bulky refrigeration equipment for perishable cargo.
Innovation Solution
The implementation of vacuum insulated composite structural panels with a porous filler material and a vacuum core, which provides higher R-values with reduced thickness and weight, allowing for increased cargo capacity and efficient insulation without the need for bulky refrigeration equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If thick foam core panels are used to achieve suitable R-value, then thermal insulation performance is improved, but unloaded weight and panel thickness increase
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 conductivity parameter. This allows achieving R-15 to R-45 per panel with significantly reduced thickness and weight compared to traditional foam panels while maintaining or improving insulation performance.
Solution Approach 2:
The patent creates a vacuum environment within the panel core, eliminating air and other gases that conduct heat. This inert (vacuum) environment provides superior thermal insulation with minimal material, directly resolving the contradiction between insulation performance and weight/thickness.
2Temperature
If thick foam core panels are used to achieve suitable R-value, then thermal insulation performance is improved, but cargo space within ULD is reduced
Solution Approach 1:
By changing the insulation medium to vacuum, the patent achieves the same or better R-value with 50% to 90% less thickness. This directly increases the cargo space volume within the ULD while maintaining thermal insulation performance.
Solution Approach 2:
The vacuum environment provides high insulation performance in a minimal space, allowing the ULD to maintain required temperature control while maximizing cargo holding volume.
3Temperature
If specialized refrigeration equipment is used to refrigerate ULD, then cooling capability is improved, but weight and cargo space are increased
Solution Approach 1:
The patent extracts the need for heavy specialized refrigeration equipment by using vacuum insulation panels that passively maintain temperature. The vacuum barrier significantly reduces heat transfer, allowing simpler, lighter cooling systems to achieve the same effect, or allowing extended periods without active refrigeration.
Solution Approach 2:
The vacuum insulated panels provide self-service thermal protection, actively resisting heat transfer without requiring power or mechanical components. This passive insulation system reduces or eliminates the need for heavy active refrigeration equipment.
4Temperature
If specialized refrigeration equipment is used to refrigerate ULD, then cooling capability is improved, but cargo space of ULD is reduced
Solution Approach 1:
By extracting the heavy refrigeration equipment and replacing it with thin vacuum insulation panels, the patent frees up significant cargo space while maintaining cooling capability through reduced heat ingress.
Solution Approach 2:
The vacuum insulation creates a thermal barrier that passively maintains cargo temperature, eliminating the need for bulky active refrigeration systems and maximizing cargo space availability.
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 vacuum insulated panels achieve higher R-values with 50% to 90% less thickness than traditional foam core panels, reducing weight and allowing for increased cargo capacity while maintaining panel toughness and stiffness, thus enhancing the efficiency of perishable cargo transport.
Implementation Method 1
a vacuum drawn therein such that the core resists transfer of thermal energy through the panel
Implementation Method 2
The core includes a porous filler material that has a vacuum drawn therein such that the core resists transfer of thermal energy through the panel
Data Source
AI summary
A thermally insulated panel includes a first skin, a second skin spaced apart from the first skin, and a core that is disposed between and bonded to the first skin and the second skin such that the core transfers loads between the first skin and the second skin. The core includes a porous filler material that has a vacuum drawn therein such that the core resists transfer of thermal energy through the panel. A cargo container including thermally insulated panels and a method of manufacturing the thermally insulated panels are also disclosed. In addition, a method of repairing a vacuum insulated panel is disclosed.