Vacuum Insulated Appliance Structure With Pressed Fill Density Control
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Solution Overview
Problem
Existing mechanisms for forming vacuum insulated structures lack efficient methods to deliver and compress insulating materials uniformly, leading to suboptimal thermal insulation and structural integrity.
Innovation Solution
An insulation delivery apparatus with a hopper, delivery mechanism, and pressing mechanism that selectively delivers insulating material into an insulated structure, compresses it to a target density, and creates a hermetic seal using an outer and inner support system, along with a vacuum pump to enhance insulation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If insulating material is delivered into the insulated structure, then the insulation density increases, but the structural integrity may be compromised due to outward deflection of the outer wrapper and inner liner
Solution Approach 1:
The outer support is positioned against the outer wrapper before insulation material is delivered into the insulated structure. This preliminary positioning of the support prevents outward deflection of the outer wrapper and inner liner during the insulation filling process, thereby maintaining structural integrity while achieving uniform insulation density
Solution Approach 2:
The outer support acts as an intermediary element between the insulation material delivery system and the insulated structure. It provides temporary structural reinforcement to the outer wrapper and inner liner during the insulation filling process, preventing deflection without becoming part of the final product
2Reliability
If the pressing mechanism compresses the insulation material to achieve target density, then the thermal insulation performance improves, but the structural stability may be compromised due to outward deflection
Solution Approach 1:
The outer support is positioned against the outer wrapper before the pressing mechanism compresses the insulation material. This preliminary support prevents outward deflection of the structure during compression, enabling achievement of target density for optimal thermal insulation performance while maintaining structural stability
Solution Approach 2:
The outer support provides beforehand cushioning or reinforcement to the outer wrapper and inner liner structure. This pre-positioned support acts as a protective measure that prevents structural instability during the insulation compression process, allowing the pressing mechanism to achieve the required density for reliable thermal insulation
3Quantity of substance
If the delivery mechanism delivers insulation material into the insulated structure, then the insulation coverage increases, but the manufacturing complexity increases due to coordination with the pressing mechanism and support system
Solution Approach 1:
The manufacturing system is segmented into distinct functional components: the delivery mechanism for insulation material, the pressing mechanism for compression, and the outer support for structural stability. This segmentation allows each component to perform its specific function independently, facilitating coordinated operation to achieve complete insulation coverage while managing manufacturing complexity through modular design
Solution Approach 2:
The outer support serves multiple functions: it provides structural reinforcement to prevent outward deflection during insulation delivery, maintains structural stability during the pressing operation, and ensures the insulated structure maintains its shape throughout the manufacturing process. This multi-functionality reduces the need for additional specialized components, managing overall device complexity
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 apparatus ensures uniform insulation density, maintains structural integrity, and enhances thermal insulation by compressing insulating material to a target density within the insulated structure, forming a hermetic vacuum insulated structure.
Implementation Method 1
The pressing mechanism is operated during operation of the delivery mechanism to compress the insulating material disposed within the insulating cavity to define a target density
Implementation Method 2
Gas is expressed from the interior cavity to define a vacuum insulated structure
Implementation Method 3
an insulated structure having an outer wrapper and an inner liner that cooperate to define an interior cavity
Data Source
AI summary
An insulation delivery apparatus for forming an insulated appliance structure includes an insulated structure having a wrapper and a liner that define an interior cavity and a hopper having a storage bin and a delivery mechanism. The delivery mechanism delivers an insulating medium from the storage bin, through an insulation conduit and into the interior cavity. The delivery mechanism operates between idle and delivery states. A pressing mechanism is coupled with the insulation conduit and is in selective engagement with the insulated structure. The pressing mechanism operates between rest and compressing states. An inner support is in selective engagement with an outer surface of the inner liner and an operable outer support in selective engagement with the outer wrapper. The inner support and the operable outer support provide structural support to the insulated structure when the pressing mechanism is in the compressing state.