Insulated structures and method of making the same
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Solution Overview
Problem
Existing methods for producing insulated structures face challenges in achieving optimal density and thermal conductivity of core materials within insulated cavities, leading to inefficiencies in thermal management and potential pump clogging due to fine particles.
Innovation Solution
A method involving compaction, crushing, and granulation of raw materials to produce a core material precursor, followed by filtration to remove fine particles, and subsequent deposition within a cavity to achieve a desired density and diameter range, accompanied by evacuation and sealing to maintain low pressure and enhance thermal insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If raw material is compacted and processed through crusher and granulator to achieve optimal density, then thermal insulation performance is improved, but fine particles are generated causing pump clogging
Solution Approach 1:
The patent extracts and removes fine particles from the processed core material using a classification system that separates particles by size. This eliminates the harmful fine particles that cause pump clogging while retaining the larger particles needed for optimal thermal insulation performance.
Solution Approach 2:
The patent introduces a classification system as an intermediary between the granulator and the deposition process. This intermediary system processes the core material to remove fine particles before deposition, preventing pump clogging while maintaining the density and insulation properties of the larger particles.
2Reliability
If core material is deposited to high density to improve thermal management, then insulation efficiency is enhanced, but manufacturing complexity increases
Solution Approach 1:
The patent performs preliminary classification of core material particles before deposition, removing fine particles in advance. This preliminary action simplifies the deposition process by preventing pump clogging and ensures consistent high-density packing of appropriately sized particles, improving thermal management efficiency without excessive manufacturing complexity.
Solution Approach 2:
The patent changes the particle size parameter of the core material by using classification to remove fine particles. This parameter change optimizes the particle size distribution for high-density deposition, enhancing thermal management efficiency while the systematic approach keeps manufacturing complexity manageable.
3Reliability
If particle size is reduced to increase density, then thermal conductivity is improved, but fine particles are generated causing operational issues
Solution Approach 1:
The patent extracts fine particles that are too small for optimal performance and removes them through classification. This maintains the thermal conductivity benefits of smaller particles while eliminating the operational problems caused by excessively fine particles in the pump system.
Solution Approach 2:
The patent applies different quality requirements to different particle size ranges. Larger particles are retained for optimal thermal conductivity and pump operation, while fine particles are removed. This local quality approach ensures each particle size range serves its optimal function in the insulation structure.
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 method results in an insulated structure with improved thermal conductivity (1-15 mW/mK) and reduced pressure (less than 100 Pascal) within the cavity, preventing pump clogging and enhancing manufacturing efficiency.
Implementation Method 1
compacting the raw material with at least one roller
Implementation Method 2
directing the raw material that has been compacted to a crusher
Implementation Method 3
directing the raw material that has been compacted to a granulator
Implementation Method 4
filtering the core material precursor with a filter member
Implementation Method 5
accompanied by evacuation and sealing to maintain low pressure
Data Source
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AI summary
An insulated structure (10) includes a plurality of walls (14) and a cavity (42) defined by the plurality of walls (14). A core material (46) is disposed within the cavity (42). The core material (46) includes particles (50) with a diameter that is in a range of 80-1600 µm. The core material (46) disposed within the cavity (42) can have a density in a range of greater than 350 kg/m3 to 600 kg/m3. Methods of manufacturing the insulated structure (10) also disclosed.