Vacuum-Insulated Refrigerator Structure With Layered Polymer Barriers
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Solution Overview
Problem
Existing methods for fabricating vacuum insulated refrigerator structures face challenges in achieving effective gas and water vapor barriers while maintaining structural integrity and cost-effectiveness.
Innovation Solution
A multistep injection molding process is used to form a vacuum insulated structure with multiple layers of polymer materials, including a first layer, a thin layer of Ethylene Vinyl Alcohol (EVOH) for gas barrier properties, and a third layer with structural reinforcement features like ribs and screw bosses, which are then assembled to create a vacuum cavity filled with a porous material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple layers of polymer materials are used to achieve effective gas and water vapor barriers, then the barrier performance is improved, but the structural integrity and manufacturing complexity deteriorate
Solution Approach 1:
The patent combines multiple polymer layers with different functions (gas barrier, water vapor barrier, structural support) into a single integrated vacuum insulated structure. The layers are bonded together to form a unified component that maintains both barrier performance and structural integrity while simplifying the manufacturing process compared to separate assembly of multiple components
Solution Approach 2:
The patent uses composite material structures where different polymer materials are layered together to achieve properties that individual materials cannot provide alone. The composite structure combines the gas barrier properties of certain polymers with the structural strength of others, creating a multi-functional material system
2Strength
If structural reinforcement features are added during injection molding, then the structural integrity is improved, but the manufacturing process complexity increases
Solution Approach 1:
The patent merges the structural reinforcement features directly into the injection molding process itself, rather than adding them as separate post-processing steps. Rib and gusset features are formed integrally with the polymer layers during molding, combining structural strengthening with the base manufacturing process
Solution Approach 2:
The patent incorporates structural reinforcement features during the initial injection molding process, performing the structural strengthening action beforehand rather than requiring subsequent reinforcement steps. The ribs and gussets are formed as integral parts of the molded structure
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 method effectively forms a vacuum insulated structure with improved gas and water vapor barriers, enhanced structural integrity, and cost-effective production, maintaining a sealed vacuum environment for efficient insulation.
Implementation Method 1
The vacuum cavity is evacuated to form a vacuum
Implementation Method 2
vacuum insulated structure
Data Source
AI summary
A method of fabricating a vacuum insulated refrigerator structure includes injection molding a first layer of a first polymer material. A second layer of a second polymer material is injection molded over at least a portion of the first layer, and a third layer of a third polymer material is injection molded over at least a portion of the second layer to form a first component. At least one of the layers is impervious to one or more gasses. A second component is secured to the first component to form a vacuum cavity therebetween. The vacuum cavity is filled with a porous material, and the vacuum cavity is evacuated to form a vacuum. At least one of the first and third layers includes a structural reinforcement such as a rib or screw boss of increased thickness that is formed during the injection molding process.