Vacuum insulation structures with multiple insulators
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Solution Overview
Problem
Conventional refrigerator insulation methods fail to effectively maintain low temperatures and prevent heat ingress, leading to inefficiencies in refrigeration systems.
Innovation Solution
A vacuum insulated structure is created by positioning an inner liner within an external wrapper, defining a gap, drawing a vacuum, and injecting a first and second insulator into the gap, with a filter placed between them to prevent insulator mixing and enhance thermal insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If conventional insulation methods are used in refrigerators, then the insulation thickness can be reduced, but the thermal insulation effectiveness deteriorates
Solution Approach 1:
The insulation system is segmented into multiple distinct layers: a first insulator material and a second insulator material with different thermal conductivity properties. This segmentation allows each layer to contribute differently to the overall insulation performance, enabling reduced thickness while maintaining effectiveness.
Solution Approach 2:
Different regions of the insulation structure are assigned different materials with specific local qualities. The first insulator and second insulator have different thermal conductivities, and their placement is optimized for specific locations to maximize insulation effectiveness while minimizing overall thickness.
2Loss of energy
If a vacuum is drawn to seal the gap between inner liner and external wrapper, then the thermal insulation is enhanced, but the structural stability under pressure differentials deteriorates
Solution Approach 1:
The insulation structure uses a composite arrangement of first insulator material and second insulator material within the vacuum gap. This composite structure provides both thermal insulation and mechanical strength to resist deformation from pressure differentials, as the multiple materials work together to maintain structural integrity.
Solution Approach 2:
The filter positioned within the gap acts as an intermediary element between the insulator materials and the vacuum environment. It helps maintain the vacuum seal while allowing the insulator materials to provide structural support against pressure differentials.
3Loss of energy
If a filter is positioned between the first and second insulators, then the insulation performance is enhanced by preventing mixing, but the device complexity increases
Solution Approach 1:
A filter is introduced as an intermediary component between the first insulator and second insulator. This filter prevents mixing of the different insulator materials while maintaining the vacuum seal, ensuring that each material remains in its designated position for optimal thermal performance.
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 method provides enhanced thermal insulation, reduces the thickness of insulation by up to 70%, and resists deformation due to pressure differentials, leading to improved refrigeration efficiency and cost savings through strategic use of high and low thermal conductivity insulators.
Implementation Method 1
positioning an inner liner within an external wrapper to define a gap between the external wrapper and the inner liner, and drawing a vacuum within the gap
Implementation Method 2
injecting an insulator into the gap, wherein the insulator comprises a first insulator and a second insulator
Data Source
AI summary
A method for manufacturing a vacuum insulated structure includes positioning an inner liner within an external wrapper and defining a gap between the inner liner and the external wrapper, drawing a vacuum to seal the gap, and injecting a first insulator into the gap. The method further includes positioning a filter proximate to the first insulator within the gap and injecting a second insulator into the gap proximate to the filter.