Five-Sided Vacuum Panel Insulation for Refrigerator Corners
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Solution Overview
Problem
Existing refrigeration appliance insulation technologies, including vacuum panels, fail to effectively insulate corners of the cabinet, leading to temperature gradients and heat leaks due to the absence of panel extension into these areas.
Innovation Solution
A five-sided, box-like vacuum panel is integrated into the refrigeration appliance structure, combined with a dual foaming process where foam is injected between the vacuum panel and both the case and the liner to attach and insulate, ensuring coverage of corners and enhanced thermal insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional vacuum panels are used in refrigeration appliances, then thermal insulation properties are enhanced, but corners of the cabinet remain uninsulated causing heat leaks and temperature gradients
Solution Approach 1:
The vacuum panel is extended from a traditional four-sided rectangular structure into a five-sided configuration by adding a triangular panel that reaches into the corner region. This dimensional modification allows the insulation to cover the corner area that was previously inaccessible, eliminating heat leaks and temperature gradients while maintaining the vacuum insulation benefits.
2Loss of energy
If vacuum panels are positioned between case and liner, then thermal insulation is improved, but structural attachment and sealing become complex requiring standoffs and additional components
Solution Approach 1:
The five-sided vacuum panel is directly integrated with both the case and the liner, eliminating the need for separate standoff components and complex attachment mechanisms. The extended corner geometry allows the panel to naturally interface with both structures, simplifying the overall assembly while maintaining structural integrity and thermal insulation performance.
3Reliability
If five-sided vacuum panel is integrated with dual foaming process, then corner coverage and structural integrity are improved, but manufacturing process time increases
Solution Approach 1:
The five-sided vacuum panel is pre-formed with the extended corner geometry before installation, allowing the complex shape to be manufactured separately and then easily integrated into the assembly. This preliminary formation of the panel geometry enables subsequent rapid attachment to both case and liner using the dual foaming process, reducing overall manufacturing time while maintaining structural integrity.
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 reduces heat leaks at corners and provides structural integrity, improving thermal insulation and simplifying manufacturing by eliminating the need for vacuum panel standoffs and reducing production time.
Implementation Method 1
The particular type of insulation utilized can actually vary. In refrigerators, for example, it is known to inject a foam insulation into a cavity formed between an outer case of the refrigerator and a liner that defines one or more internal food storage compartments.
Implementation Method 2
Another type of thermal insulation that has been used in appliances and other cabinet structures are insulation panels.
Implementation Method 3
Once the foamed insulation cures, a solid insulation barrier is provided which not only thermally insulates each internal compartment but also adds structural integrity to the overall cabinet assembly.
Data Source
AI summary
A method of insulating a refrigeration appliance. The refrigeration appliance includes a case, a liner, and a five-sided, box like vacuum panel. The liner is formed to be inserted into the case forming a chamber between the liner and the case. The five sides of the vacuum panel define a cavity. The method includes in one embodiment, positioning the five-sided vacuum panel in the chamber between the case and the liner, injecting foam into the chamber, and curing the foam to attach the five sided vacuum panel to the case and the liner.