Vacuum Insulation Member Core Structure for Uniform Thickness
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Solution Overview
Problem
The existing vacuum insulation members using glass fiber cores face challenges in handling, require costly preprocessing, result in non-uniform thickness, and are prone to creases leading to defective attachments due to the expansion of foaming agents in gaps.
Innovation Solution
A vacuum insulation member with a core having a box-like shape and cover, supported by ribs and through portions, which simplifies the preprocessing, ensures uniform thickness, and reduces creases, thereby facilitating cost-effective fabrication and preventing defective bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If glass fiber core is used, then initial performance is excellent and cost is low, but preprocessing process is required and productivity is degraded
Solution Approach 1:
The patent changes the physical state of the core material from loose glass fiber to a rigid hollow spherical structure. This parameter change eliminates the need for preprocessing while maintaining insulation performance, as the spherical core can be directly placed in the envelope without hot pressing or needle punching.
Solution Approach 2:
The patent uses a simple hollow spherical core structure that can be mass-produced through injection molding, replacing the complex glass fiber processing. This disposable-like approach allows for rapid production and eliminates the need for expensive preprocessing equipment and time-consuming operations.
2Quantity of substance
If glass fiber core is used, then cost is low, but preprocessing process increases cost and time
Solution Approach 1:
The hollow spherical core is pre-formed through injection molding with the exact shape and size needed, eliminating the need for post-processing operations like hot pressing or needle punching. This preliminary action is performed during mass production, reducing both time and cost at the manufacturing stage.
3Reliability
If vacuum insulation member is fabricated with glass fiber core, then insulation function is provided, but thickness deviation is large and uniformity is poor
Solution Approach 1:
The patent changes the core from compressible glass fiber to a rigid hollow sphere with fixed dimensions. This parameter change ensures that the core maintains its shape and volume under vacuum, providing uniform thickness and eliminating the thickness deviation problems associated with glass fiber compression.
4Reliability
If glass fiber core is used, then insulation performance is achieved, but envelope surface becomes creased and attachment quality deteriorates
Solution Approach 1:
The patent uses a spherical core shape that distributes vacuum pressure uniformly in all directions, preventing the envelope from developing creases or deformations. The curved spherical surface naturally distributes stress evenly, unlike flat or irregular glass fiber structures that cause localized pressure points and surface defects.
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 solution reduces fabrication costs, achieves uniform insulation thickness, minimizes crease generation, and enhances attachment quality by avoiding foaming agent introduction into gaps, thus improving the overall efficiency and reliability of the vacuum insulation member.
Implementation Method 1
a core having a certain shape, having an empty space formed therein, and disposed at an inner side of the envelope to support the envelope
Implementation Method 2
a getter for absorbing an internal gas of the envelope may be provided at the inner side of the envelope
Data Source
AI summary
Disclosed are a vacuum insulation member, a refrigerator having a vacuum insulation member, and a method for fabricating a vacuum insulation member. The vacuum insulation member includes: an envelope having gas impermeability and having a certain decompressed space therein; and a core having a certain shape, having an empty space formed therein, and disposed at an inner side of the envelope to support the envelope. The use of a glass fiber core can be avoided, and thus, employing equipment for preprocessing the glass fiber core and time required therefor can be restrained and fabrication can be facilitated.