Method for improved insulation and filler materials
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Solution Overview
Problem
Conventional methods for manufacturing vacuum insulated panels face issues with inconsistent dispersion and packing of filler materials due to differences in density and particle size, leading to non-homogeneous mixing and reduced insulation effectiveness.
Innovation Solution
The method involves altering the surface charge of filler material components, such as glass spheres and fumed silica, by applying a coating to create opposite surface charges, ensuring consistent and homogeneous mixing and distribution within the vacuum cavity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If filler materials with different density and particle size are mixed using conventional methods, then the filling process is simple, but the dispersion and packing become inconsistent leading to non-homogeneous mixing
Solution Approach 1:
The invention changes the surface charge parameter of filler materials by applying coatings with opposite charges. This parameter modification causes electrostatic attraction between differently charged particles, enabling homogeneous mixing of materials with different densities and particle sizes without complex mixing equipment
Solution Approach 2:
The invention uses charged coatings as intermediary layers on filler particle surfaces. These coatings act as mediators that create electrostatic interactions between particles, facilitating uniform distribution and packing of diverse filler materials through electrostatic attraction rather than mechanical mixing
2Reliability
If filler materials are mixed without surface charge treatment, then the process is straightforward, but porosity remains high reducing insulation performance
Solution Approach 1:
The invention modifies the surface charge parameter of filler particles through coating application. This change enables electrostatic attraction that promotes tight particle packing and reduces void spaces, thereby decreasing porosity and improving insulation performance
Solution Approach 2:
The invention replaces mechanical mixing and packing methods with electrostatic interaction mechanisms. By substituting physical force-based mixing with electrostatic attraction, the system achieves superior particle distribution and packing density with simplified process control
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 improved mixing consistency and reduced porosity, enhancing the insulation performance of vacuum insulated panels by ensuring uniform packing and distribution of filler materials.
Implementation Method 1
A coating is applied to the surface of the first part with a chemical having a first charge. The coating forms a first surface charge on the surface of the first part.
Implementation Method 2
The second part includes a material having a second surface charge opposite the first surface charge. The first part and second part are mixed forming the filler material.
Data Source
AI summary
A method for preparing a vacuum insulated panel includes forming an internal cavity between a liner and a wrapper and preparing a filler material to be disposed in the internal cavity. The filler material includes a first part and a second part and is prepared by treating a surface of the first part. A coating is applied to the surface of the first part with a chemical having a first charge. The coating forms a first surface charge on the surface of the first part. The method further includes mixing the first part with the second part forming the filler material. The second part includes a material having a second surface charge opposite the first surface charge.