EP2778581A2 - Folded vacuum insulated structure - Google Patents
Folded vacuum insulated structure Download PDFInfo
- Publication number
- EP2778581A2 EP2778581A2 EP14158615.6A EP14158615A EP2778581A2 EP 2778581 A2 EP2778581 A2 EP 2778581A2 EP 14158615 A EP14158615 A EP 14158615A EP 2778581 A2 EP2778581 A2 EP 2778581A2
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- EP
- European Patent Office
- Prior art keywords
- blank
- side walls
- edges
- layer
- forming
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25D—REFRIGERATORS; COLD ROOMS; ICE-BOXES; COOLING OR FREEZING APPARATUS NOT OTHERWISE PROVIDED FOR
- F25D23/00—General constructional features
- F25D23/06—Walls
- F25D23/062—Walls defining a cabinet
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25D—REFRIGERATORS; COLD ROOMS; ICE-BOXES; COOLING OR FREEZING APPARATUS NOT OTHERWISE PROVIDED FOR
- F25D2201/00—Insulation
- F25D2201/10—Insulation with respect to heat
- F25D2201/14—Insulation with respect to heat using subatmospheric pressure
Definitions
- the cabinet structure includes a metal outer layer and a polymer inner layer.
- the inner and outer layers are spaced apart to form an insulation space.
- the insulation space is filled with a filler material, and a vacuum is formed in the space.
- a sheet metal layer is cut to form a blank.
- the sheet metal layer includes a layer of heat-sealable polymer material that is laminated to a first side of the sheet.
- a layer of polymer material including an impermeable layer of polymer material such as ethylene vinyl alcohol (EVOH) is heat-sealed to the metal/polymer blank.
- the resulting structure is then folded to form a cabinet structure having an "O" shape or a "U” shape. Additional insulated panels are then secured to the O or U-shaped primary structure to thereby form an insulated space.
- a refrigerator 1 includes an insulated cabinet 2 that generally includes vertical side walls 4A and 4B, a horizontal upper wall 6, and a horizontal lower wall 8. Doors 10A and 10B are moveably mounted to the insulated cabinet 2 in a known manner.
- refrigerator 1 may include an "O" shaped primary structure 20A ( Fig. 2 ), or it may include a U-shaped primary structure 20B ( Fig. 4 ).
- O-shaped primary structure 20A defines enlarged front and rear openings 12 and 14, respectively. Doors 10A and 10B selectively close off the front opening 12, and a rear panel assembly 16 may be utilized to close off rear opening 14.
- Rear panel assembly 16 may include a vertical panel 18, and a horizontal divider 22 and/or a vertical divider 24.
- the divider 22 (or 24) may include a cooling module that cools the insulated space on opposite sides of the divider 22 (or 24). Examples of suitable cooling modules are disclosed in U.S. Patent Application No. 13/108,226 entitled "COOLING SYSTEM INTEGRATION ENABLING PLATFORM ARCHITECTURE" filed on May 16, 2011; U.S. Patent Application No.
- primary structure 20A includes an outer skin 26 and an inner skin 28.
- the outer skin 26 comprises a layer of sheet metal (e.g. low carbon steel) having a layer of heat-sealable polymer material laminated to one side of the layer of metal.
- Inner skin 28 comprises a layer of thermoplastic polymer such as high impact styrene and a barrier layer that may comprise polymer material such as ethylene vinyl alcohol (EVOH).
- EVOH ethylene vinyl alcohol
- the barrier layer forms a barrier with respect to gasses and water vapor.
- the polymer inner skin 28 is sealed to the polymer material of the outer skin 26 to form an insulation space 30 ( Fig. 3 ).
- the polymer inner skin 28 is may be sealed to the polymer material of the outer skin 26 utilizing a heat seal process that softens or partially melts the polymer material of the skin 26 and/or skin 28.
- Heat can be generated using one or more conventional electrical resistance heating elements (not shown), or heat can be generated using ultrasonic processes. Mechanical pressure can also be used to seal the skins 26 and 28 together. Still further, adhesive or other suitable material can also be used to connect/seal skins 26 and 28 together.
- Powdered silica or other filler material 32 is disposed in the insulation space 30, and a vacuum is formed in the insulation space 30 to thereby provide a vacuum insulated structure. Openings or valves 34 and 36 may be utilized to blow the filler material 32 into the space 32 prior to forming a vacuum.
- the primary structure 20A may be placed in a vacuum chamber, and openings or valves 34 and 36 may then be closed to form a vacuum in the insulation space 30.
- the filler material 32 may be positioned in the insulation space 30 prior to interconnection of outer skin 26 and inner skin 28.
- the skins 26 and 28 sealed together in a vacuum chamber to form a vacuum in insulation space 30. If this process is utilized, the openings or valves 34 and 36 are not required.
- a primary cabinet structure 20B is substantially U-shaped, with side walls 4A and 4B extending from a rear wall 38.
- Upper and lower side walls 6A and 8A may comprise separate panels that are secured to the primary structure 20B to form an insulated space 44B.
- the primary structure 20B includes a metal outer skin 26 and a polymer inner skin 28 that are heat sealed together to form a vacuum in substantially the same manner as primary structure 20A.
- the upper side wall 6A or lower side wall 8A may include a cooling module as described above in connection with dividers 22 and 24.
- An outer optional cover 46 having side walls 48A-48D (and optionally 48E) may be utilized to form an outer decorative surface of the refrigerator to cover, for example, the joints between primary structure 20B and upper and lower walls 6A and 6B, respectively.
- the outer cover 46 is optional.
- a refrigerator including the primary structure 20A of Fig. 2 may also include an outer cover 46.
- a polymer liner 50 may also be disposed with the primary structure 20B. Polyurethane foam or the like may be injected into spaces between primary structure 20B and liner 50 to provide support for the polymer liner 50.
- the polymer liner 50 may include various features such as shelf supports 52A-52C that support shelves 54.
- O-shaped primary structure 20A is formed from a subassembly 56 that is folded along lines 58A-58C.
- the inner skin 28 may comprise a composite sheet having a layer of thermoplastic polymer material such as high impact polystyrene that is laminated to a thin barrier layer of polymer material.
- the thin barrier layer may comprise EVOH or other material (e.g. metal foil) capable of maintaining a vacuum in insulation space 30 for the life of the insulated cabinet structure.
- the barrier layer may selected such that the thermal conductivity of the vacuum insulated structure does not exceed 200% of its initial value for at least 10 years.
- the outer skin 26 may comprise a metal sheet 62.
- Metal sheet 62 may comprise low carbon steel or the like having a pre-painted outer surface 66.
- Outer skin 26 includes a layer of heat-sealable polymer material 64 that is laminated to the metal 62.
- the inner skin 28 may be thermoformed to form elongated shaped grooves 70A-70C having angled side walls 72A and 72B.
- the grooves 70 may include a flat side wall portion 74 extending between side walls 72A and 72B.
- the lower surface 76 of flat side wall portion 74 may be spaced apart from surface 78 of heat-sealable plastic 64 to form a gap "G".
- the lower surface 76 may be in contact with surface 78, and a seal may be formed between the surfaces 76 and 78.
- the angled side walls may form a "sharp" V 74A if groove 70 includes a side wall 72C as shown in dashed lines.
- outer skin 26 and inner skin 28 may be interconnected along the opposite side edges 68A and 68B of subassembly 56.
- Inner skin 26 may include an outwardly extending flange 80 that is heat-sealed to the polymer material 64 of outer skin 26 along edge 82 of outer skin 26.
- ends 60A and 60B of subassembly 56 may be angled at a 45 degree angle and joined together at a corner 84.
- the ends of 60A and 60B may be orthogonal, and joined along a center seam 86.
- the ends 60A and 60B may have a configuration that is substantially similar to the configuration of edges 68A and 68B ( Fig. 13 ).
- polyurethane foam 88 Fig. 12
- side wall 90 Fig.
- inner skin 28 may be angled or beveled in a manner similar to the angled side walls 72A and 72B ( Fig. 11 ) along one or both side edges 68A, 68B to provide an angled front edge 92A ( Fig. 7 ) and/or angled rear edge 92B.
- Edges 94 of panel 18 ( Fig. 2 ) may be beveled to fit closely with beveled or angled rear edges 92B of primary structure 20A.
- Polyurethane foam 88 ( Fig. 12 ) may be injected between liner 50 and inner skin 28 to fill gaps at the joints between edge 92B of primary structure 20A and vertical panel 18.
- a sheet of metal/plastic is cut to form a blank 126 having generally rectangular perimeter 96.
- skin 28 comprises a thermoplastic polymer material such a high impact polystyrene that is laminated to a relatively thin layer of EVOH or other suitable barrier material. It will be understood that the skin 28 may comprise multiple layers of material, and the EVOH layer may be sandwiched between adjacent layers of thermoplastic polymer material.
- the polymer material of the inner skin 28 is thermoformed utilizing known processes and tools to form a polymer blank 128 that includes the grooves 70A and 70C and side walls 90 ( Fig. 13 ) and flanges 80.
- the polymer blank 128 is then positioned on the outer blank 126.
- the filler material 32 may be positioned in cavities 30 prior to positioning polymer blank 128 on metal blank 126.
- one or more pouches 33 containing filler material 32 may be placed on metal blank 126.
- the pouches 33 may comprise a single elongated pouch having a generally rectangular perimeter that is positioned adjacent rectangular parameter 96 of outer skin blank 126. Alternately, a plurality of individual pouches 33 having shapes corresponding to individual panel sections 98A-98C may be positioned on the metal blank 126.
- the pouches 33 may comprise an outer layer of paper or other permeable material 35 that permits airflow, but retains filler material 32.
- the pouch may be compressed at the V-grooves 70A-70C such that the regions of the pouch 33 in the vicinity of the gap G ( Fig. 11 ) are thin.
- the polymer blank 128 can be sealed to outer skin blank 126 along the V-grooves 70.
- the metal blank 126 and polymer 128 are then positioned in a vacuum chamber (not shown).
- the polymer blank 128 is sealed to polymer material 64 of outer skin blank 126 along flanges 80 to thereby form an air-tight seal around insulation spaces 30.
- the polymer blank 128 is also sealed to metal blank 126 at V-grooves 70 if necessary for a particular application.
- the entire perimeter 96 of subassembly 56 can be sealed in the vacuum chamber. Alternately, a portion of the rectangular perimeter 96 may be sealed prior to positioning the blanks 126 and 128 in the vacuum chamber, and the remaining portion of the perimeter 96 can be sealed in the vacuum chamber.
- a plurality of the subassemblies 56 can be positioned in a single vacuum chamber in a stacked relationship, and the blanks 126 and 128 of the subassemblies 56 can be sealed in the vacuum chamber.
- the blanks 126 and 128 can be connected/sealed utilizing a heat seal process, mechanical pressure, adhesives, or other suitable processes/materials.
- the subassembly 56 After the subassembly 56 is removed from the vacuum chamber, it can be folded along the V-grooves 70A-70C to form a primary structure 20A ( Fig. 7 ).
- the ends 60A and 60B can be adhesively interconnected or otherwise secured together.
- a forming tool (not shown) can be positioned in the V-grooves 70A-70C during the bending process.
- the blank 56 may optionally be heated in the vicinity of V-grooves 70A-70C to facilitate bending at the grooves 70A-70C.
- the rear panel assembly 16 may then be secured to the primary structure 20A ( Fig. 2 ).
- a polymer liner 50 may optionally be inserted into the primary structure 20A, and polyurethane foam 88 may be injected into the space 89 between inner skin 28 and polymer liner 50.
- the filler material 32 may be positioned between the metal blank 126 and polymer blank 128 prior to the sealing operation as just described. Alternately, the outer metal blank 126 may be sealed to the polymer blank 128 under atmospheric conditions.
- the subassembly 56 can then be folded to form primary structure 20A.
- the filler material 32 can then be blown into the spaces 30 utilizing one or more openings or valves 34 and 36 ( Fig. 2 ).
- a filter (not shown) may be placed over opening 36, and filler material 32 may be blown into the spaces 30 utilizing opening 34. The filter over opening 36 permits air to flow out of the internal space 30, thereby compacting the filler material 32 in spaces 30.
- each panel section 98A-98C may include both an inlet opening 34 and an outlet opening 36 if filler material 32 is blown into spaces 30 after folding blanks 56.
- a U-shaped primary structure 20B may be formed utilizing a metal blank 126A and a polymer blank 128A in substantially the same manner as described above in connection with Figs 5-7 .
- the polymer blank 128 includes three panel sections 98A-98C corresponding to the three side walls 4A, 38 and 4B of U-shaped primary structure 20B ( Fig. 10 ).
- an upper wall 6A and lower wall 8A are secured to the U-shaped primary structure 20B ( Fig. 4 ).
- the side wall 90 ( Fig. 13 ) along side edges 68A and 68B ( Fig.
- inner skin blank 128 may be angled at, for example, a 45 degree angle (i.e. similar to side wall 72B of Fig. 11 ), such that upper edges 5A-5C ( Fig. 10 ) and lower edges 11A-11C of primary structure 20B are beveled or angled.
- side edges 7A-7C of upper wall 6A ( Fig. 4 ) and edges 9A-9C of lower wall 8A may also be beveled.
- Polyurethane foam 88 ( Fig. 12 ) can be utilized to fill any spaces that may exist at the joints formed between upper wall 6A and primary structure 20B, as well as gaps at joints between lower wall 8A and primary structure 20B.
- a vacuum insulated cabinet 102 includes an inner member 104, and an outer member 106.
- Inner member 104 may comprise a one-piece metal structure having including integrally formed side walls 108A-108E
- outer member 106 may comprise a one-piece metal member having side walls 110A-110E.
- inner and outer members 104 and 106 may both be formed from a single piece of sheet metal utilizing a drawing process, or one or both of the inner and outer members 104 and 106 may be thermoformed from a sheet of polymer material. If inner member 104 or outer member 106 is formed of a polymer material, the polymer material preferably includes a barrier layer such as EVOH or metal foil, and one or more layers of thermoplastic material.
- inner member 104 is positioned inside outer member 106, and an elongated edge member 112 is connected to the inner member 104 and outer member 106 along edges 114 and 116 to thereby form a space 118 between inner member 104 and outer member 106.
- the edge member 112 may comprise an extruded polymer material, and preferably includes one or more layers of impermeable material such as EVOH and layers of regions of thermoplastic polymer material.
- the edge member 112 may be sealingly connected to the edges 114 and 116 utilizing adhesive sealant or other suitable material.
- inner member 104 and/or outer member 106 may comprise a metal sheet having a layer of heat-sealable polymer material laminated to a side face of the material, and the edges 114 and 116 may be heat-sealed to edge member 112.
- inner member 104 and/or outer member 106 may comprise a polymer material and the edges 114 and 116 can be heat-sealed to edge member 112. If inner member 104 and outer member 106 comprise sheet metal, the edge member 112 provides a thermal break, thereby reducing or preventing conductive heat transfer between inner member 104 and outer member 106.
- Filler material 120 is disposed in insulating space 118.
- the filler material may comprise silica or other porous material capable of supporting the inner and outer members 104 and 106 when a vacuum is formed in the insulating space 118.
- the inner member 104, outer member 106, and edge member 112 may be positioned in a vacuum chamber, and filler material 120 may be disposed and compacted in space 118.
- the edge member 112 may then be sealingly connected to the inner member 104 and outer member 106, and the cabinet 102 can then be removed from the vacuum chamber.
- one or more openings or valves 34 and 36 can be utilized to blow filler material 120 into insulating space 118, and the openings can then be sealed off before removal of the cabinet 102 from a vacuum chamber
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Combustion & Propulsion (AREA)
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- General Engineering & Computer Science (AREA)
- Refrigerator Housings (AREA)
- Thermal Insulation (AREA)
Abstract
Description
- One aspect of the present invention is a vacuum insulated refrigerator cabinet structure. The cabinet structure includes a metal outer layer and a polymer inner layer. The inner and outer layers are spaced apart to form an insulation space. The insulation space is filled with a filler material, and a vacuum is formed in the space. During fabrication, a sheet metal layer is cut to form a blank. The sheet metal layer includes a layer of heat-sealable polymer material that is laminated to a first side of the sheet. A layer of polymer material including an impermeable layer of polymer material such as ethylene vinyl alcohol (EVOH) is heat-sealed to the metal/polymer blank. The resulting structure is then folded to form a cabinet structure having an "O" shape or a "U" shape. Additional insulated panels are then secured to the O or U-shaped primary structure to thereby form an insulated space.
- These and other features, advantages, and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.
The present invention will be further described by way of example with reference to the accompanying drawings in which:- -
Fig. 1 is an isometric view of a refrigerator having a vacuum insulated cabinet structure according to one aspect of the present invention; -
Fig. 2 is an exploded perspective view of a vacuum insulated cabinet structure having a O-shaped primary structure; -
Fig. 3 is a cross-sectional view of the vacuum insulated cabinet structure ofFig. 2 ; -
Fig. 4 is an exploded perspective view of an insulated cabinet structure having a U-shaped primary component; -
Fig. 5 is an isometric view of a subassembly that is folded to form an O-shaped primary structure; -
Fig. 6 is an elevational view of the subassembly ofFig. 5 ; -
Fig. 7 is an isometric view of a O-shaped vacuum insulated primary structure; -
Fig. 8 is an isometric view of a subassembly used to fabricate a U-shaped primary vacuum insulated structure; -
Fig. 9 is an elevational view of the subassembly ofFig. 8 ; -
Fig. 10 is an isometric view of a U-shaped vacuum insulated primary structure; -
Fig. 11 is a cross-sectional view of a portion of the subassemblies ofFigs. 6 and9 ; -
Fig. 12 is a cross-sectional view of a corner of the vacuum insulated primary structures ofFigs. 2 and4 ; -
Fig. 13 is a partially fragmentary enlarged cross-sectional view of a portion of the subassemblies ofFigs. 6 and9 ; -
Fig. 14 is an isometric view of a vacuum insulated cabinet structure according to another aspect of the present invention; -
Fig. 15 is a cross-sectional view of the vacuum insulated cabinet structure ofFig. 14 ; and -
Fig. 16 is partially fragmentary enlarged view of a portion of the vacuum insulated cabinet structure ofFig. 15 . - For purposes of description herein, the terms "upper," "lower," "right," "left," "rear," "front," "vertical," "horizontal," and derivatives thereof shall relate to the invention as oriented in
Fig. 1 . However, it is to be understood that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise. - With reference to
Fig. 1 , a refrigerator 1 according to one aspect of the present invention includes an insulatedcabinet 2 that generally includesvertical side walls upper wall 6, and a horizontallower wall 8.Doors cabinet 2 in a known manner. As discussed in more detail below, refrigerator 1 may include an "O" shapedprimary structure 20A (Fig. 2 ), or it may include a U-shapedprimary structure 20B (Fig. 4 ). - With reference to
Fig. 2 , O-shapedprimary structure 20A defines enlarged front andrear openings Doors front opening 12, and arear panel assembly 16 may be utilized to close offrear opening 14.Rear panel assembly 16 may include avertical panel 18, and ahorizontal divider 22 and/or avertical divider 24. The divider 22 (or 24) may include a cooling module that cools the insulated space on opposite sides of the divider 22 (or 24). Examples of suitable cooling modules are disclosed inU.S. Patent Application No. 13/108,226 U.S. Patent Application No. 13/108,293 U.S. Patent Application No. 13/108,183 - As discussed in more detail below,
primary structure 20A includes anouter skin 26 and aninner skin 28. Theouter skin 26 comprises a layer of sheet metal (e.g. low carbon steel) having a layer of heat-sealable polymer material laminated to one side of the layer of metal.Inner skin 28 comprises a layer of thermoplastic polymer such as high impact styrene and a barrier layer that may comprise polymer material such as ethylene vinyl alcohol (EVOH). The barrier layer forms a barrier with respect to gasses and water vapor. The polymerinner skin 28 is sealed to the polymer material of theouter skin 26 to form an insulation space 30 (Fig. 3 ). The polymerinner skin 28 is may be sealed to the polymer material of theouter skin 26 utilizing a heat seal process that softens or partially melts the polymer material of theskin 26 and/orskin 28. Heat can be generated using one or more conventional electrical resistance heating elements (not shown), or heat can be generated using ultrasonic processes. Mechanical pressure can also be used to seal theskins skins other filler material 32 is disposed in theinsulation space 30, and a vacuum is formed in theinsulation space 30 to thereby provide a vacuum insulated structure. Openings orvalves filler material 32 into thespace 32 prior to forming a vacuum. Theprimary structure 20A may be placed in a vacuum chamber, and openings orvalves insulation space 30. Alternatively, as discussed in more detail below, thefiller material 32 may be positioned in theinsulation space 30 prior to interconnection ofouter skin 26 andinner skin 28. Theskins insulation space 30. If this process is utilized, the openings orvalves - With further reference to
Fig. 4 , aprimary cabinet structure 20B according to another aspect of a present invention is substantially U-shaped, withside walls rear wall 38. Upper andlower side walls primary structure 20B to form aninsulated space 44B. As discussed in more detail below, theprimary structure 20B includes a metalouter skin 26 and a polymerinner skin 28 that are heat sealed together to form a vacuum in substantially the same manner asprimary structure 20A. Theupper side wall 6A orlower side wall 8A may include a cooling module as described above in connection withdividers optional cover 46 havingside walls 48A-48D (and optionally 48E) may be utilized to form an outer decorative surface of the refrigerator to cover, for example, the joints betweenprimary structure 20B and upper andlower walls 6A and 6B, respectively. Theouter cover 46 is optional. A refrigerator including theprimary structure 20A ofFig. 2 may also include anouter cover 46. Apolymer liner 50 may also be disposed with theprimary structure 20B. Polyurethane foam or the like may be injected into spaces betweenprimary structure 20B andliner 50 to provide support for thepolymer liner 50. Thepolymer liner 50 may include various features such as shelf supports 52A-52C that supportshelves 54. - With further reference to
Figs. 5-7 , O-shapedprimary structure 20A is formed from asubassembly 56 that is folded alonglines 58A-58C. Theinner skin 28 may comprise a composite sheet having a layer of thermoplastic polymer material such as high impact polystyrene that is laminated to a thin barrier layer of polymer material. The thin barrier layer may comprise EVOH or other material (e.g. metal foil) capable of maintaining a vacuum ininsulation space 30 for the life of the insulated cabinet structure. For example, the barrier layer may selected such that the thermal conductivity of the vacuum insulated structure does not exceed 200% of its initial value for at least 10 years. - With further reference to
Fig. 11 , theouter skin 26 may comprise ametal sheet 62.Metal sheet 62 may comprise low carbon steel or the like having a pre-paintedouter surface 66.Outer skin 26 includes a layer of heat-sealable polymer material 64 that is laminated to themetal 62. Theinner skin 28 may be thermoformed to form elongated shapedgrooves 70A-70C having angledside walls grooves 70 may include a flatside wall portion 74 extending betweenside walls lower surface 76 of flatside wall portion 74 may be spaced apart fromsurface 78 of heat-sealable plastic 64 to form a gap "G". Alternately, thelower surface 76 may be in contact withsurface 78, and a seal may be formed between thesurfaces V 74A ifgroove 70 includes aside wall 72C as shown in dashed lines. - With further reference to
Fig. 13 , theouter skin 26 andinner skin 28 may be interconnected along theopposite side edges subassembly 56.Inner skin 26 may include an outwardly extendingflange 80 that is heat-sealed to thepolymer material 64 ofouter skin 26 alongedge 82 ofouter skin 26. - Referring again to
Figs. 6 and 7 , ends 60A and 60B ofsubassembly 56 may be angled at a 45 degree angle and joined together at acorner 84. Alternatively, the ends of 60A and 60B may be orthogonal, and joined along acenter seam 86. If aseam 86 is utilized, theends edges Fig. 13 ). When assembled, polyurethane foam 88 (Fig. 12 ) can be injected to fill gaps betweenpolymer liner 50 andinner skin 28 and betweenends Fig. 13 ) ofinner skin 28 may be angled or beveled in a manner similar to theangled side walls Fig. 11 ) along one or both side edges 68A, 68B to provide an angledfront edge 92A (Fig. 7 ) and/or angledrear edge 92B.Edges 94 of panel 18 (Fig. 2 ) may be beveled to fit closely with beveled or angledrear edges 92B ofprimary structure 20A. Polyurethane foam 88 (Fig. 12 ) may be injected betweenliner 50 andinner skin 28 to fill gaps at the joints betweenedge 92B ofprimary structure 20A andvertical panel 18. - Referring again to
Fig. 5 , during fabrication ofprimary structure 20A, a sheet of metal/plastic is cut to form a blank 126 having generallyrectangular perimeter 96. As discussed above,skin 28 comprises a thermoplastic polymer material such a high impact polystyrene that is laminated to a relatively thin layer of EVOH or other suitable barrier material. It will be understood that theskin 28 may comprise multiple layers of material, and the EVOH layer may be sandwiched between adjacent layers of thermoplastic polymer material. The polymer material of theinner skin 28 is thermoformed utilizing known processes and tools to form a polymer blank 128 that includes thegrooves Fig. 13 ) andflanges 80. Thepolymer blank 128 is then positioned on the outer blank 126. Thefiller material 32 may be positioned incavities 30 prior topositioning polymer blank 128 onmetal blank 126. For example, one ormore pouches 33 containingfiller material 32 may be placed onmetal blank 126. Thepouches 33 may comprise a single elongated pouch having a generally rectangular perimeter that is positioned adjacentrectangular parameter 96 ofouter skin blank 126. Alternately, a plurality ofindividual pouches 33 having shapes corresponding toindividual panel sections 98A-98C may be positioned on themetal blank 126. Thepouches 33 may comprise an outer layer of paper or otherpermeable material 35 that permits airflow, but retainsfiller material 32. If a singleelongated pouch 33 is utilized, the pouch may be compressed at the V-grooves 70A-70C such that the regions of thepouch 33 in the vicinity of the gap G (Fig. 11 ) are thin. Alternately, if a plurality ofindividual pouches 33 are utilized, the polymer blank 128 can be sealed toouter skin blank 126 along the V-grooves 70. - After placing polymer blank 128 over
pouches 33 onmetal blank 126, themetal blank 126 andpolymer 128 are then positioned in a vacuum chamber (not shown). Thepolymer blank 128 is sealed topolymer material 64 ofouter skin blank 126 alongflanges 80 to thereby form an air-tight seal aroundinsulation spaces 30. Thepolymer blank 128 is also sealed to metal blank 126 at V-grooves 70 if necessary for a particular application. Theentire perimeter 96 ofsubassembly 56 can be sealed in the vacuum chamber. Alternately, a portion of therectangular perimeter 96 may be sealed prior to positioning theblanks perimeter 96 can be sealed in the vacuum chamber. Also, a plurality of thesubassemblies 56 can be positioned in a single vacuum chamber in a stacked relationship, and theblanks subassemblies 56 can be sealed in the vacuum chamber. As discussed above, theblanks - After the
subassembly 56 is removed from the vacuum chamber, it can be folded along the V-grooves 70A-70C to form aprimary structure 20A (Fig. 7 ). The ends 60A and 60B can be adhesively interconnected or otherwise secured together. A forming tool (not shown) can be positioned in the V-grooves 70A-70C during the bending process. Also, the blank 56 may optionally be heated in the vicinity of V-grooves 70A-70C to facilitate bending at thegrooves 70A-70C. Therear panel assembly 16 may then be secured to theprimary structure 20A (Fig. 2 ). Apolymer liner 50 may optionally be inserted into theprimary structure 20A, andpolyurethane foam 88 may be injected into thespace 89 betweeninner skin 28 andpolymer liner 50. - The
filler material 32 may be positioned between themetal blank 126 andpolymer blank 128 prior to the sealing operation as just described. Alternately, the outer metal blank 126 may be sealed to thepolymer blank 128 under atmospheric conditions. Thesubassembly 56 can then be folded to formprimary structure 20A. Thefiller material 32 can then be blown into thespaces 30 utilizing one or more openings orvalves 34 and 36 (Fig. 2 ). For example, a filter (not shown) may be placed overopening 36, andfiller material 32 may be blown into thespaces 30 utilizingopening 34. The filter over opening 36 permits air to flow out of theinternal space 30, thereby compacting thefiller material 32 inspaces 30. Theprimary structure 20A can then be placed in a vacuum chamber, and theopenings structure 20A can be moved from the vacuum chamber. It will be understood that eachpanel section 98A-98C (Fig. 5 ) may include both aninlet opening 34 and anoutlet opening 36 iffiller material 32 is blown intospaces 30 after foldingblanks 56. - With further reference to
Figs 8-10 , a U-shapedprimary structure 20B (see alsoFig. 4 ) may be formed utilizing a metal blank 126A and a polymer blank 128A in substantially the same manner as described above in connection withFigs 5-7 . Thepolymer blank 128 includes threepanel sections 98A-98C corresponding to the threeside walls primary structure 20B (Fig. 10 ). After formation ofprimary structure 20B, anupper wall 6A andlower wall 8A are secured to the U-shapedprimary structure 20B (Fig. 4 ). The side wall 90 (Fig. 13 ) alongside edges Fig. 8 ) ofinner skin blank 128 may be angled at, for example, a 45 degree angle (i.e. similar toside wall 72B ofFig. 11 ), such thatupper edges 5A-5C (Fig. 10 ) andlower edges 11A-11C ofprimary structure 20B are beveled or angled. Similarly, side edges 7A-7C ofupper wall 6A (Fig. 4 ) and edges 9A-9C oflower wall 8A may also be beveled. Thus, when assembled, theedges 7A-7C ofupper wall 6A fit closely againstupper edges 5A-5C ofprimary structure 20B, and side edges 9A-9C oflower wall 8A fit closely in side edges 11A-11C of U-shapedprimary structure 20B. Polyurethane foam 88 (Fig. 12 ) can be utilized to fill any spaces that may exist at the joints formed betweenupper wall 6A andprimary structure 20B, as well as gaps at joints betweenlower wall 8A andprimary structure 20B. - With further reference to
Figs 14-16 , a vacuum insulatedcabinet 102 according to another aspect of the present invention includes aninner member 104, and anouter member 106.Inner member 104 may comprise a one-piece metal structure having including integrally formedside walls 108A-108E, andouter member 106 may comprise a one-piece metal member havingside walls 110A-110E. In general, inner andouter members outer members inner member 104 orouter member 106 is formed of a polymer material, the polymer material preferably includes a barrier layer such as EVOH or metal foil, and one or more layers of thermoplastic material. - After
inner member 104 andouter member 106 are formed,inner member 104 is positioned insideouter member 106, and anelongated edge member 112 is connected to theinner member 104 andouter member 106 alongedges space 118 betweeninner member 104 andouter member 106. Theedge member 112 may comprise an extruded polymer material, and preferably includes one or more layers of impermeable material such as EVOH and layers of regions of thermoplastic polymer material. Theedge member 112 may be sealingly connected to theedges inner member 104 and/orouter member 106 may comprise a metal sheet having a layer of heat-sealable polymer material laminated to a side face of the material, and theedges member 112. Alternately,inner member 104 and/orouter member 106 may comprise a polymer material and theedges member 112. Ifinner member 104 andouter member 106 comprise sheet metal, theedge member 112 provides a thermal break, thereby reducing or preventing conductive heat transfer betweeninner member 104 andouter member 106. -
Filler material 120 is disposed in insulatingspace 118. The filler material may comprise silica or other porous material capable of supporting the inner andouter members space 118. - During assembly, the
inner member 104,outer member 106, andedge member 112 may be positioned in a vacuum chamber, andfiller material 120 may be disposed and compacted inspace 118. Theedge member 112 may then be sealingly connected to theinner member 104 andouter member 106, and thecabinet 102 can then be removed from the vacuum chamber. Alternately, one or more openings orvalves 34 and 36 (Fig. 2 ) can be utilized to blowfiller material 120 into insulatingspace 118, and the openings can then be sealed off before removal of thecabinet 102 from a vacuum chamber
Claims (15)
- A method of forming a vacuum insulated cabinet structure, the method comprising:forming a generally rectangular first blank from a sheet of material that includes a metal layer and a thermoplastic polymer layer;forming a generally rectangular second blank from a sheet of material that includes a layer of thermoplastic polymer material and a layer of material that is substantially impermeable, wherein the second blank includes a plurality of shallow pockets that open towards a first side of the second blank, the second blank including at least one groove extending between opposite side edges of the second blank to form a divider between adjacent shallow pockets;positioning the first and second blanks directly adjacent one another such that the first blank substantially closes off the shallow pockets;providing a porous filler material in the pockets;positioning the first and second blanks in a vacuum chamber;sealing the second blank to the thermoplastic layer of the first blank such that the shallow pockets form sealed vacuum spaces;folding the first and second blanks along the groove.
- The method of claim 1, wherein at least one of:(a) the second blank comprises a layer of EVOH material; and(b) the metal layer comprises low carbon steel.
- The method of claim 1 or 2, wherein:the second blank includes a generally rectangular perimeter and an outwardly-extending flange at the perimeter.
- The method of claim 3, including:heat-sealing the flange to the thermoplastic polymer layer of the first blank.
- The method of claim 1, wherein either:(a) the second blank is sealed to the first blank along the groove; or (b) the second blank includes a plurality of generally planar dies wall portions having substantially rectangular perimeters, and optionally the second blank includes edge wall portions extending at approximately 45 degree angles relative to the generally planar side wall portions to define the groove.
- The method according to any one of the preceding claims, wherein:the second blank includes first and second grooves extending between opposite side edges of the second blank;the first and second blanks are folded along the first and second grooves to form a generally U-shaped primary cabinet structure.
- The method of claim 6, wherein:the cabinet structure defines upper and lower U-shaped opposite side edges; and including:securing an upper insulated panel to the upper side edge;securing a lower insulated panel to the lower side edge to thereby define a cabinet structure having an inner side surface facing an enlarged interior space.
- The method of claim 7, including:forming a polymer liner;positioning the liner in the enlarged interior space;providing thermosetting form insulation between the polymer liner and the inner side surface of the cabinet structure.
- The method of claim 7, including:providing at least one of the upper and lower insulated panels with a powered cooling module that cools the enlarged interior space.
- The method according to any one of the preceding claims, wherein:the first and second blanks each include first and second opposite ends; and including:forming at least three grooves in the second blank;folding the first and second blanks in at least three places to form four side walls, including first and second upright side walls and vertically spaced apart upper and lower side walls extending between the first and second upright side walls;connecting the first and second opposite ends of the first and second blanks together to form a primary cabinet structure having vertically enlarged front and read openings.
- The method of claim 10, including:securing an insulated panel to the primary cabinet structure to close off the rear opening and form an insulated space, optionally the method including:positioning a divider in the insulated space to form first and second compartments, wherein the divider includes a cooling module that cools the first and second compartments.
- A method of forming a vacuum insulated cabinet structure, the method comprising:forming inner and outer shells, the inner and outer shells defining vertical side walls having front and read edges, horizontal upper and lower side walls having front and rear edges, and extending between the side walls, and a generally vertical rear wall extending between the rear edges of vertical side walls and the upper and lower side walls, whereby the inner and outer shells define generally rectangular front edges;positioning the inner shell inside the outer shell with the rectangular front edges of the inner and outer shells spaced apart to define an annular space therebetween;filling the space between the inner and outer shells with a porous filler material;forming an elongated cap member that forms a sufficient barrier with respect to gasses and water vapor to maintain a vacuum, and wherein the cap member substantially inhibits conductive heat transfer through the cap member;sealing the elongated cap member to the front edges of the inner and outer shells to form an air-tight insulating space between the inner and outer shells; andforming a vacuum in the insulting space.
- The method of claim 12, wherein:at least one of the inner and outer shells comprises sheet metal.
- The method of claim 12 or 13, wherein:the elongated cap member comprises a thermoplastic polymer having an barrier layer; optionally comprising EVOH, disposed in the thermoplastic polymer material.
- The method of claim 12, 13 or 14, wherein:the elongated cap member forms a continuous ring including four generally linear portions that are joined at four corner portions.
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US13/836,669 US9140481B2 (en) | 2012-04-02 | 2013-03-15 | Folded vacuum insulated structure |
Publications (2)
Publication Number | Publication Date |
---|---|
EP2778581A2 true EP2778581A2 (en) | 2014-09-17 |
EP2778581A3 EP2778581A3 (en) | 2015-12-02 |
Family
ID=50238254
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP14158615.6A Withdrawn EP2778581A3 (en) | 2013-03-15 | 2014-03-10 | Folded vacuum insulated structure |
Country Status (2)
Country | Link |
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EP (1) | EP2778581A3 (en) |
BR (1) | BR102014006063A2 (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB2515903A (en) * | 2014-06-05 | 2015-01-07 | Daimler Ag | A container deliminating a cargo space and a method for varying the insulation property of at least parts of a container |
EP3330651A1 (en) * | 2016-11-30 | 2018-06-06 | Liebherr-Hausgeräte Lienz GmbH | Refrigeration and/or freezer device |
Family Cites Families (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
IT1201782B (en) * | 1986-09-18 | 1989-02-02 | Zanussi Zeltron Inst | PROCEDURE FOR THE MANUFACTURE OF REFRIGERATING APPLIANCES |
US5066437A (en) * | 1990-03-19 | 1991-11-19 | Barito Robert W | Method for insulating thermal devices |
JP3968612B2 (en) * | 1998-01-27 | 2007-08-29 | 三菱電機株式会社 | FULL VACUUM INSULATION BOX, REFRIGERATOR USING THE VACUUM VACUUM INSULATION BOX, METHOD FOR PRODUCING THE FULL VACUUM INSULATION BOX, AND METHOD OF DECOMPOSING |
US6109712A (en) * | 1998-07-16 | 2000-08-29 | Maytag Corporation | Integrated vacuum panel insulation for thermal cabinet structures |
JP3559035B2 (en) * | 2002-12-05 | 2004-08-25 | 松下冷機株式会社 | Vacuum insulation material, method of manufacturing the same, and cold protection equipment and personal computer using vacuum insulation material |
US20120285971A1 (en) * | 2011-05-09 | 2012-11-15 | General Electric Company | Integrated vacuum insulation panel |
-
2014
- 2014-03-10 EP EP14158615.6A patent/EP2778581A3/en not_active Withdrawn
- 2014-03-14 BR BR102014006063A patent/BR102014006063A2/en not_active IP Right Cessation
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB2515903A (en) * | 2014-06-05 | 2015-01-07 | Daimler Ag | A container deliminating a cargo space and a method for varying the insulation property of at least parts of a container |
EP3330651A1 (en) * | 2016-11-30 | 2018-06-06 | Liebherr-Hausgeräte Lienz GmbH | Refrigeration and/or freezer device |
Also Published As
Publication number | Publication date |
---|---|
EP2778581A3 (en) | 2015-12-02 |
BR102014006063A2 (en) | 2016-01-05 |
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