Multi-Layer Vacuum Insulation Structure for Gas and Moisture Barrier
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Solution Overview
Problem
Existing vacuum insulated structures face challenges in maintaining a consistent vacuum and preventing gas and moisture infiltration, which affects their insulation efficiency and durability.
Innovation Solution
A multi-layer sheet comprising thermoplastic polymers or elastomeric materials with barrier layers is thermoformed to create a non-planar component, which is sealed with another component to form an interior space filled with porous filler material, and then evacuated to create a vacuum insulated structure, ensuring an airtight seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a vacuum insulated structure is created using conventional single-layer materials, then the structure can be formed, but gas and moisture infiltration occurs which compromises insulation efficiency
Solution Approach 1:
The patent employs a multi-layer composite barrier material comprising alternating layers of polymer materials with different gas barrier properties. Specifically, it uses layers of polyvinylidene chloride (PVdC) which provides excellent moisture vapor transmission barrier, alternating with layers of nylon or other polymers that provide gas barrier properties. This composite structure creates a material that simultaneously resists both gas penetration and moisture infiltration, resolving the contradiction between maintaining vacuum and blocking harmful factors.
2Reliability
If barrier layers are added to prevent gas and moisture infiltration, then insulation efficiency improves, but the complexity of the material structure increases
Solution Approach 1:
The patent applies local quality by assigning different functional properties to different layers of the composite material. Each layer is specifically selected for its particular barrier property - PVdC layers for moisture barrier, nylon layers for gas barrier. This localized functional differentiation allows the material as a whole to achieve superior dual barrier performance without requiring a monolithic complex structure, as each layer performs its specialized function efficiently.
Solution Approach 2:
The multi-layer composite structure combines materials with complementary barrier properties in a systematic alternating pattern. This composite approach achieves superior overall performance by leveraging the strengths of each individual material layer, preventing both gas and moisture infiltration simultaneously while maintaining a manageable structural complexity through regular alternation of layer types.
3Reliability
If porous filler material is used in the vacuum space, then insulation performance improves, but the difficulty of maintaining consistent vacuum increases
Solution Approach 1:
The patent incorporates porous filler material into the vacuum space before final sealing of the structure. This preliminary placement ensures that the filler is properly positioned and the vacuum space is optimized for insulation performance before the vacuum is created and sealed. By preparing the interior space with filler material in advance, the system achieves both improved insulation performance and consistent vacuum maintenance, as the filler provides structural support and prevents vacuum collapse while the multi-layer barrier prevents contamination.
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 effectively maintains a vacuum and enhances insulation efficiency by preventing gas and moisture infiltration, thereby improving the structural integrity and performance of vacuum insulated structures.
Implementation Method 1
at least one layer of barrier material that is disposed between first and second outer layers... preventing gas and moisture infiltration
Implementation Method 2
Porous filler material is positioned in the interior space... preventing gas and moisture infiltration
Data Source
AI summary
A method of forming a vacuum insulated refrigerator cabinet structure includes providing a multi-layer sheet of material comprising at least one layer of barrier material that is disposed between first and second outer structural layers. The barrier material and the first and second outer layers comprise thermoplastic polymers. The multi-layer sheet of material is thermoformed to form a non-planar first component having a central portion and four sidewalls extending transversely from the central portion. The method further includes securing a second component having a central portion and four sidewalls extending transversely from the central portion to the first component to form an interior space therebetween. Porous filler material is positioned in the interior space, and a vacuum is formed in the interior space. The first and second components are sealed together to form a vacuum insulated refrigerator cabinet structure.