Vacuum insulation structures with multiple insulators

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Solution Overview

Problem

Refrigerators face inefficiencies in maintaining low temperatures due to inadequate insulation methods, leading to heat ingress and pressure-related distortions that can cause structural issues.

Innovation Solution

A refrigerator cabinet design featuring an inner liner and external wrapper with a gap filled by first and second insulators, maintaining a pressure below 1000 Pa, where the first insulator is positioned near the front flange and the second insulator fills the rest of the gap, using materials like fumed silica and precipitated silica to minimize thermal conductivity and resist pressure differentials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If traditional insulation methods are used in refrigerators, then structural simplicity is maintained, but insulation efficiency is insufficient leading to heat ingress

Engineering Contradiction:

Improveheat ingressVSAvoidinsulation structure

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The insulation system is divided into multiple discrete insulator components (first insulator, second insulator, third insulator) positioned in different locations within the gap. Each insulator can be independently selected and positioned to optimize thermal performance in specific areas, thereby improving overall insulation efficiency while maintaining manageable structural complexity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs multiple different insulator materials with varying thermal conductivity properties. By selecting materials based on their specific thermal performance characteristics and positioning them strategically within the gap, the system achieves superior composite insulation效果 that reduces heat ingress more effectively than single-material solutions

Inventive Principle:

Principle #40Composite materials

2Loss of energy

If vacuum insulation is implemented, then insulation efficiency is improved, but pressure differentials cause structural distortions

Engineering Contradiction:

Improveinsulation efficiencyVSAvoidstructural integrity

Core Design Contradiction:

Loss of energyVSStrength

Solution Approach 1:

Insulators are strategically positioned at specific locations within the gap, particularly near the front flange and in areas most susceptible to pressure-induced distortion. This localized placement provides structural support exactly where needed to counteract the effects of pressure differentials, maintaining structural integrity while preserving vacuum insulation efficiency

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The insulators act as counterbalancing elements that resist the inward force exerted by atmospheric pressure on the vacuum-insulated gap. By positioning insulators at strategic locations, the system creates internal structural support that counterweights the external pressure load, preventing collapse and maintaining the vacuum seal

Inventive Principle:

Principle #8Anti-weight (Counterweight)

3Loss of energy

If multiple insulators are positioned in the gap, then thermal bridging is reduced, but manufacturing complexity increases

Engineering Contradiction:

Improvethermal bridgingVSAvoidassembly process

Core Design Contradiction:

Loss of energyVSEase of manufacture

Solution Approach 1:

The insulation system is divided into multiple discrete insulator components that can be independently manufactured and positioned. This segmentation allows each insulator to be optimized for its specific location and function, reducing thermal bridging at critical interfaces while enabling modular assembly that simplifies the overall manufacturing process

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Insulators are pre-positioned within the gap during the manufacturing process, with specific placement near the front flange and other critical areas established beforehand. This preliminary positioning ensures optimal thermal performance is achieved before the structure is sealed and put into service, reducing thermal bridging while streamlining the assembly process

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 design enhances insulation efficiency, reduces thermal bridging, and maintains structural integrity by resisting pressure-induced distortions, while allowing for a more compact and cost-effective construction of vacuum-insulated refrigerators.

Implementation Method 1

A first insulator is positioned within the gap, and a second insulator is positioned within the gap

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

A pressure within the gap is below about 1000 Pa

Methodology Applied

Scientific EffectVacuum insulation: Vacuum

Data Source

PatentUS10808987B2Vacuum insulation structures with multiple insulators

Publication Date: 2020.10.20 WHIRLPOOL CORP

AI summary

A refrigerator cabinet is provided. The refrigerator cabinet includes an inner liner and an external wrapper. The inner liner is positioned within the external wrapper such that a gap is defined between the external wrapper and inner liner. A first insulator is positioned within the gap, and a second insulator is positioned within the gap. A pressure within the gap is below about 1000 Pa.