Vacuum Insulation Filling with Pre-Degassed Powder Loading
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Solution Overview
Problem
Current vacuum insulation technologies in refrigerators face challenges in achieving optimal energy efficiency due to residual adsorbed gases and moisture content in vacuum insulation materials, leading to increased pressure and reduced performance over time.
Innovation Solution
A powder processor system is used to heat and degas vacuum insulation materials, reducing moisture content to less than 2 wt% and evacuating them to a pressure below 1.01325 kPa, which are then filled into a vacuum insulated structure using a gas permeable feature to maintain a low pressure and prevent gas adsorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If vacuum insulation material is loaded directly without pre-treatment, then the loading process is simple, but the moisture content remains high and residual gases increase pressure over time
Solution Approach 1:
The vacuum insulation material undergoes pre-treatment in a powder processor before being loaded into the vacuum insulated structure. This preliminary action includes heating to reduce moisture content and applying vacuum to remove residual gases, ensuring the material is ready for long-term vacuum maintenance before actual loading occurs.
Solution Approach 2:
A powder processor serves as an intermediary device between the vacuum insulation material and the vacuum insulated structure. This intermediary performs essential pre-treatment functions (heating, drying, degassing) on the material before it enters the final vacuum environment, bridging the gap between atmospheric conditions and vacuum requirements.
2Reliability
If heating is applied to reduce moisture content, then moisture content decreases to less than 2 wt%, but energy consumption increases
Solution Approach 1:
The heating process is optimized by controlling temperature and time parameters to achieve the required moisture content reduction (to less than 2 wt%) while minimizing energy consumption. The vacuum condition is also utilized to facilitate moisture removal at lower temperatures, reducing the overall energy requirement for the drying process.
Solution Approach 2:
The vacuum environment, which is essential for the final application, is also utilized during the drying process to facilitate moisture removal. The same vacuum condition that is needed for the final product performance is used beneficially during manufacturing to reduce moisture content, turning a requirement into a helpful condition during processing.
3Reliability
If vacuum is applied to remove residual gases, then pressure decreases below 1.01325 kPa, but the loading time increases
Solution Approach 1:
Vacuum is applied to the vacuum insulation material in the powder processor before loading, removing residual gases in advance. This preliminary vacuum treatment ensures that when the material is loaded into the vacuum insulated structure, the vacuum level is already optimized, reducing the time needed for final vacuum establishment.
Solution Approach 2:
The vacuum condition is maintained continuously throughout the process - during the degassing phase in the powder processor and during loading into the vacuum insulated structure. This continuous vacuum application eliminates the need to break and re-establish vacuum, saving time while maintaining pressure control.
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 enhances the efficiency of vacuum insulation by minimizing residual gases and moisture, allowing for better vacuum maintenance and improved energy performance in refrigerators by ensuring a more efficient and rapid loading process.
Implementation Method 1
applying heat and a first vacuum to the vacuum insulation material to form a dry and degassed vacuum insulation material
Implementation Method 2
applying heat and a first vacuum to the vacuum insulation material to form a dry and degassed vacuum insulation material
Implementation Method 3
applying a second vacuum to the vacuum insulated structure using the gas permeable feature
Data Source
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AI summary
A filling system for a vacuum insulated structure is provided having a powder processor including a hopper having an inner hopper wall and an outer hopper wall. The filling system also includes a vacuum insulated structure having a liner positioned inside a wrapper, a trim breaker coupling an outer liner edge and an outer wrapper edge to form a shell defining an internal cavity with at least one gas permeable feature positioned in the internal cavity configured to help apply a vacuum. A loading port is positioned on a surface of the shell. The powder processor loads the shell with a heated and at least partially degassed vacuum insulation material through the loading port while a vacuum is applied to the shell through the at least one gas permeable feature.