Vacuum Insulated Appliance Structure With Pre-Densified Powder Core

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Solution Overview

Problem

Existing methods for forming insulated structures in appliances are inefficient in creating a vacuum-sealed environment using insulating materials, as they often rely on barrier films or porous bags that separate the insulating material from the enclosure, leading to suboptimal thermal performance.

Innovation Solution

A method involving the formation of a structural enclosure with an outer wrapper and inner liner, where an insulating powder material is compacted to form a pre-densified core material, which is then disposed within the insulating cavity and sealed to create a hermetically sealed vacuum insulated structure, eliminating the need for barrier films by using compaction and gas expression to achieve a dense, uniform distribution of insulating material.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If barrier films or porous bags are used to separate insulating material from the enclosure, then the insulating material is contained within the structure, but thermal performance deteriorates due to suboptimal insulation efficiency

Engineering Contradiction:

Improvecontainment of insulating materialVSAvoidthermal performance

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The invention removes the barrier film or porous bag from the system entirely. Instead of using a separating layer to contain the insulating material, the material itself is compacted to form a dense core that maintains its shape and position without requiring an intermediate containment layer, thus eliminating the thermal resistance introduced by the barrier film

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The insulating material undergoes a change in density parameter through compaction. By compressing the loose insulating material into a densely packed core, the material achieves optimal thermal insulation properties and structural integrity without requiring a barrier film for containment

Inventive Principle:

Principle #35Parameter changes

2Loss of energy

If insulating powder material is compacted to form pre-densified core material, then thermal performance improves through dense uniform distribution, but manufacturing complexity increases

Engineering Contradiction:

Improvethermal performanceVSAvoidmanufacturing process

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The insulating material is pre-compacted into a dense core before being placed into the final assembly. This preliminary compaction action simplifies the overall manufacturing process by eliminating the need for complex in-situ compaction mechanisms, while still achieving the desired dense uniform distribution for optimal thermal performance

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The pre-densified core material acts as an intermediary form between loose powder and final installed insulation. This intermediate state allows the material to be easily handled and positioned while maintaining the density required for high thermal performance, bridging the gap between manufacturing convenience and insulation efficiency

Inventive Principle:

Principle #24Intermediary (Mediator)

3Loss of energy

If gas is expressed from the insulating cavity to create vacuum sealed structure, then insulation efficiency improves, but manufacturing difficulty increases

Engineering Contradiction:

Improveinsulation efficiencyVSAvoidmanufacturing difficulty

Core Design Contradiction:

Loss of energyVSEase of manufacture

Solution Approach 1:

Gas expression is performed as a preliminary step before final sealing of the insulating cavity. By removing gas beforehand, the structure is prepared for vacuum sealing, improving insulation efficiency while organizing the manufacturing process into manageable sequential steps that reduce overall complexity

Inventive Principle:

Principle #10Preliminary action

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 enhances thermal performance by ensuring a tight, uniform distribution of insulating material between the outer wrapper and inner liner, effectively forming a vacuum insulated structure that improves the insulation efficiency of appliances without the use of barrier films.

Implementation Method 1

An insulating powder material is compacted to form a pre-densified core material

Methodology Applied

Scientific EffectCompaction: Compression

Implementation Method 2

At least a portion of the gas contained within the insulating cavity is expressed

Methodology Applied

Scientific EffectGas expression: Depressurisation

Data Source

PatentUS10041724B2Methods for dispensing and compacting insulation materials into a vacuum sealed structure

Publication Date: 2018.08.07 WHIRLPOOL CORP

AI summary

A method of forming an insulated structure for an appliance includes forming a structural enclosure having an outer wrapper and an inner liner and an insulating cavity defined therebetween, forming an insulating powder material, compacting the insulating powder material to form a pre-densified core material, disposing the pre-densified core material within an insulating cavity, wherein the insulating cavity is defined between the outer wrapper and the inner liner and expressing at least a portion of the gas contained within the insulating cavity, wherein the insulating cavity is hermetically sealed to define a vacuum insulated structure.