Method for manufacturing a vacuum insulated structure

A method for manufacturing a vacuum insulated structure includes adhering a trim breaker to a wrapper and a liner via an adhesive to define an insulated structure. The insulated structure is positioned within an evacuation chamber proximate to a first heater and a second heater. The insulated structure and the evacuation chamber are heated via the first heater and the second heater. The evacuation chamber is evacuated via a first vacuum pump, and the insulated structure is evacuated via a second vacuum pump.

BACKGROUND OF THE DISCLOSURE

The present disclosure generally relates to a vacuum insulated structure, and more specifically, to a method for manufacturing the vacuum insulated structure.

SUMMARY OF THE DISCLOSURE

According to one aspect of the present disclosure, a method for manufacturing a vacuum insulated structure includes heating a trim breaker within an evacuation chamber. The heated trim breaker is outgassed via a first vacuum pump operably coupled to the evacuation chamber to define a vacuum within the evacuation chamber. A metallic coating is applied to the trim breaker. The trim breaker is adhered to a first panel and a second panel via an adhesive to define an insulated structure, and heat is applied to the insulated structure to cure the adhesive. The insulated structure is filled with insulation materials via ports, which are then sealed. The heated insulated structure is positioned within the evacuation chamber. The insulated structure is evacuated via the first vacuum pump, which is operably coupled to the evacuation chamber, and by a second vacuum pump, which is operably coupled to the insulated structure.

According to another aspect of the present disclosure, a method for manufacturing a vacuum insulated structure includes applying a metallic coating to a trim breaker. The trim breaker is adhered to a first panel and a second panel via an adhesive to define an insulated structure, and the adhesive is cured via heat. Insulation materials are disposed within an insulation cavity defined between the first panel and the second panel. The insulated structure is positioned in an evacuation chamber. The evacuation chamber is evacuated via a first pump, and the insulated structure is evacuated via a second pump.

According to yet another aspect of the present disclosure, a method for manufacturing a vacuum insulated structure includes adhering a trim breaker to a wrapper and a liner via an adhesive to define an insulated structure. The insulated structure is positioned within an evacuation chamber proximate to a first heater and a second heater. The insulated structure and the evacuation chamber are heated via the first heater and the second heater. The evacuation chamber is evacuated via a first vacuum pump, and the insulated structure is evacuated via a second vacuum pump.

DETAILED DESCRIPTION

The present illustrated embodiments reside primarily in combinations of method steps related to a method for manufacturing a vacuum insulated structure. Accordingly, the method steps have been represented, where appropriate, by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. Further, like numerals in the description and drawings represent like elements.

Referring toFIGS. 1-7, reference numeral10generally designates a vacuum insulated structure for an appliance12that includes a first panel14coupled to a second panel16via a trim breaker18. An insulation cavity20is defined between the first panel14and the second panel16, such that insulation materials22may be dispensed within the insulation cavity20. The vacuum insulated structure10is formed in an evacuation chamber24and is braced during evacuation of the evacuation chamber24by a support frame26, described in more detail below.

Referring toFIGS. 1-4, the appliance12is illustrated as a refrigerating appliance, but it is also contemplated that the vacuum insulated structure10described herein may be used with a variety of appliances or insulation purposes other than within an appliance. Moreover, the vacuum insulated structure10may be in the form of a vacuum insulated structural cabinet or a vacuum insulated panel that may be used as an insulation member for the appliance12. According to various examples, the vacuum insulated structure10includes the first panel14and the second panel16, mentioned above, which may form a liner and a wrapper, respectively. The first panel14and the second panel16each have an interior surface28and an exterior surface30, such that the interior surface28defines the insulation cavity20in which the insulation materials22are disposed. The first panel14and the second panel16are typically formed from a metallic material, which minimizes potential exposure of the insulation cavity20to air molecules.

It is generally contemplated that the insulation materials22may be a glass-type material, a carbon-based powder, silicon oxide-based materials, insulating gasses, and other standard insulation materials known in the art. The insulation materials22are disposed via a port32to substantially fill the insulation cavity20forming a substantially continuous layer between the first panel14and the second panel16. Once the insulation cavity20is substantially filled, the port32is sealed to close the insulated structure10before evacuation, described in further detail below.

Referring toFIGS. 2-5B, the insulation cavity20is further defined by the trim breaker18, which couples the first panel14to the second panel16, and a connector40, which is disposed around an aperture42defined by each of the first panel14and the second panel16. The connector40provides a space through which wiring and other tubing for the appliance12may pass. As illustrated inFIG. 5A, the first panel14is disposed within a first groove44of the trim breaker18, and the second panel16is disposed within a second groove46of the trim breaker18. In addition, the first panel14is disposed within a first circumferential groove48of the connector40, and the second panel16is disposed within a second circumferential groove50of the connector40, as illustrated inFIG. 5B. An adhesive52is disposed within each of the first groove44, the second groove46, the first circumferential groove48, and the second circumferential groove50to securely couple the first panel14and the second panel16, respectively, to the trim breaker18and the connector40.

It is generally contemplated that the trim breaker18and the connector40are formed from a polymeric material, such as plastic. Conventional trim breakers and connectors are typically porous, such that, over time, air molecules can pass through conventional trim breakers and connectors into the insulation cavity20. Accordingly, the trim breaker18and the connector40of the present disclosure are evacuated, described in further detail below, to remove the air molecules present. Moreover, a metallic coating54is applied to the evacuated trim breaker18and the evacuated connector40to minimize future penetration of air molecules into the insulation cavity20. It is also contemplated that the metallic coating54may be applied regardless of whether the trim breaker18and the connector40are evacuated. The metallic coating54can trap potential air molecules present in the trim breaker18and the connector40, such that future air permeation is minimized by the metallic coating54.

Referring toFIGS. 3-5B, the metallic coating54seals the trim breaker18and the connector40from the pass-through of gasses into the insulation cavity20. The metallic coating54can be formed from aluminum and can be applied to the trim breaker18and the connector40using physical vapor deposition. The metallic coating54can be applied to the trim breaker18and the connector40in a vapor phase under physical vapor deposition, which then condenses to form the film on the trim breaker18and the connector40.

While the metallic coating54may be formed from an aluminum base, it is also contemplated that the metallic coating54can be chrome, titanium, or any other metal typically used in physical vapor deposition. Additionally or alternatively, the metallic coating54can be applied to the trim breaker18using electroplating methods. Electroplating is a process in which the trim breaker18and the connector40are plated with the metallic coating54, which typically results in a thicker coating as compared to using physical vapor deposition. The use of metals to form the metallic coating54forms a barrier, such that potential entry of gasses into the insulated structure10is minimized.

With further reference toFIGS. 3-5B, the metallic coating54is applied under a vacuum to secure the metallic coating54to the trim breaker18and the connector40, described in further detail below. The metallic coating54is applied to an inner channel56and an outer surface58of each of the trim breaker18and the connector40. The application of the metallic coating54to both the inner channel56and the outer surface58further diminishes the rate of gas permeation into the insulated structure10. Thus, the integrity of the insulated structure10, whether the vacuum insulated structural cabinet or panel may be maintained, ultimately increases the useful life of the insulated structure10. Thus, coating the trim breaker18and the connector40generally minimizes outgassing into the insulation cavity20.

Referring now toFIG. 6, the insulated structure10, illustrated as an insulated panel, is disposed within the evacuation chamber24and is positioned between the support frame26, described below. A lid70and a body72form the evacuation chamber24in which the insulated structure10is disposed. The lid70is sealed to the body72using a gasket74disposed along an upper portion76of the body72. The lid70and the gasket74define a seal for the evacuation chamber24, such that as a vacuum is drawn within the evacuation chamber24, the vacuum defined within the evacuation chamber24is maintained. In order to draw the vacuum, it is generally contemplated that a first vacuum pump78and a second vacuum pump80are coupled to the body72of the evacuation chamber24. The first vacuum pump78is configured to evacuate an interior cavity82of the evacuation chamber24, such that the insulated structure10positioned within the evacuation chamber24is also evacuated within the interior cavity82of the evacuation chamber24.

The second vacuum pump80extends through the body72of the evacuation chamber24and is coupled to the insulated structure10via a valve84. The valve84is coupled to the port32of the insulated structure10, such that the second vacuum pump80draws a vacuum within the insulation cavity20via the valve84. Air present within the insulation cavity20is drawn out, or evacuated, as the second vacuum pump80draws the vacuum. It is generally contemplated that the first vacuum pump78and the second vacuum pump80can be activated simultaneously, such that the interior cavity82of the evacuation chamber24and the insulation cavity20of the insulated structure10are evacuated at approximately the same time.

Referring toFIGS. 4-6, first and second heaters90,92may be positioned along a bottom surface94of the evacuation chamber24. Additionally or alternatively, the first and second first and second heaters90,92may be positioned along any surface within the evacuation chamber24proximate to the insulated structure10. It is also contemplated that a single heater90may be used. The first and second heaters90,92are adjusted to cure the adhesive52in order to adhere the first panel14and the second panel16to the trim breaker18and the connector40to form the insulated structure10. The first and second heaters90,92also increase the speed in which the insulated structure10is evacuated and the trim breaker18and the connector40are outgassed. For example, as the insulation materials22are heated by the first and second heaters90,92, the insulation materials22are typically more energized and, as a result, the air molecules are easier to remove from the insulation materials22. Similarly, the air molecules present in the adhesive52are more rapidly removed as a result of the heat applied by the first and second heaters90,92.

Overall, the efficiency of the evacuation process is improved by keeping the insulated structure10at a high temperature using the first and second heaters90,92. By way of example, not limitation, the first and second heaters90,92may generate a temperature of approximately 60-degrees to 65-degrees Celsius. However, temperatures within the range of 40-degrees to 49-degrees Celsius, 50-degrees to 59-degrees Celsius, as well as other temperature ranges are similarly contemplated. While higher temperatures increase overall efficiency, the first and second heaters90,92are maintained at a high temperature, such as 65-degrees Celsius, which can also maintain the integrity of the adhesive52and the polymeric material that forms the trim breaker18and the connector40.

While it is contemplated that the trim breaker18and the connector40can be outgassed under heated conditions prior to assembly of the insulated structure10, it is also contemplated that the trim breaker18and the connector40are heated and outgassed after being assembled with the first panel14and the second panel16. For example, the inner channels56and the outer surfaces58of both the trim breaker18and the connector40are evacuated via both the first vacuum pump78and the second vacuum pump80, which is further expedited via the first and second heaters90,92.

The outer surfaces58of the trim breaker18and the connector40are typically evacuated more efficiently as a result of minimal resistance as compared to the potential interference with insulation materials22and the inner channels56of the trim breaker18and the connector40. Thus, the overall efficiency of the evacuation process can be increased by heating and simultaneously evacuating the interior cavity82of the evacuation chamber24and the insulation cavity20of the insulated structure10. In addition, the metallic coating54can be applied under the vacuum to seal the evacuated trim breaker18and connector40. The metallic coating54is typically cured during the curing of the adhesive52by way of the heat from the first and second heaters90,92.

Referring still toFIGS. 4-6, the insulated structure10is braced by the support frame26as the interior cavity82of the evacuation chamber24is evacuated by the first vacuum pump78. The support frame26includes a first frame portion96and a second frame portion98that stabilizes the insulated structure10as the interior cavity82is evacuated. The stabilization minimizes potential outward bowing of the insulated structure10as a result of the vacuum pressure generated by the first vacuum pump78. The support frame26is configured to brace each side of the insulated structure10, such that the first panel14and the second panel16are braced on the exterior surfaces30. For example, the insulated structure10illustrated inFIG. 6is an insulated panel braced between the first and second frame portions96,98, such that the first frame portion96braces the first panel14and the second frame portion98braces the second panel16. The support frame26can also be configured to brace the insulated structure10when it is formed from the liner and wrapper, such that the first frame portion96and the second frame portion98can be formed to similarly correspond to each of the liner and the wrapper, respectively.

Referring toFIGS. 1-7, the method200for manufacturing the vacuum insulated structure10can begin with heating the trim breaker18within the evacuation chamber24(step202). It will be understood that the steps of the method may be performed in any order, simultaneously, and/or omitted without departing from the teachings provided herein. Prior to outgassing the trim breaker18, the first vacuum pump78is operably coupled to the evacuation chamber24to define the first vacuum pump78within the evacuation chamber24(step204). Subsequently, the heated trim breaker18is outgassed using at least the first vacuum pump78(step206). The metallic coating54can then be applied to the trim breaker18(step208). A similar process is used when heating, outgassing, and applying the metallic coating54to the connector40, which is generally described above (step210). For example, the metallic coating54can be applied to the trim breaker18and the connector40using physical vapor deposition of aluminum (step212). Additionally or alternatively, the metallic coating54can be applied by electroplating the trim breaker18and the connector40(step214).

The first panel14and the second panel16are coupled to the trim breaker18to form the insulated structure10(step216). As mentioned above, the first panel14and the second panel16are adhered to the trim breaker18using an adhesive52(step218), which is cured by applying heat to the insulated structure10(step220). Additionally or alternatively, the adhesive52, the trim breaker18, and the connector40may be evacuated while the adhesive52is being cured by the heat (step221). The insulation cavity20is filled with insulation materials22, described above, via the port32disposed on the first panel14and/or the second panel16(step222). Once the insulation cavity20is filled, the port32is sealed (step224). The insulated structure10is placed within the evacuation chamber24(step226), which is operably coupled to the first vacuum pump78. The insulated structure10is positioned within the support frame26between the first frame portion96and the second frame portion98within the evacuation chamber24(step230). The second vacuum pump80is operably coupled to the insulated structure10(step232) once the insulated structure10is positioned within the support frame26. The first vacuum pump78evacuates the interior cavity82of the evacuation chamber24and the exterior surfaces30of the insulated structure10(step234), and the second vacuum pump80evacuates the insulation cavity20of the insulated structure10(step236).

During evacuation, the insulated structure10braces against the support frame26while the interior cavity82of the evacuation chamber24is evacuated by the first vacuum pump78(step238). The first and second heaters90,92are positioned proximate to the insulated structure10(step240), such that the insulated structure10is heated by the first and second heaters90,92to more efficiently outgas the insulated structure10(step242).

Referring still toFIGS. 1-7, the insulation cavity20is defined by the metal of the first panel14, the second panel16, and the metallic coating54. Accordingly, the metal of the first and second panels14,16along with the metallic coating54on the trim breaker18form an envelope of materials that resist gas permeation. Further, the evacuation of the insulated structure10under the heat generated by the first and second heaters90,92expedites the curing process of both the adhesive52and the metallic coating54. Thus, the overall efficiency of forming the insulated structure10is increased and improved.

According to the various examples, the insulated structure10can be used in various appliances that can include, but are not limited to, refrigerators, freezers, coolers, ovens, dishwashers, laundry appliances, water heaters, and other similar appliances and fixtures within household and commercial settings. Additionally, the insulation materials22can be a free-flowing material that can be poured, blown, compacted, or otherwise disposed within the insulation cavity20. This free-flowing material can be in the form of various silica-based materials, such as fumed silica, precipitated silica, nano-sized and/or micro-sided aerogel powder, rice husk ash powder, perlite, glass spheres, hollow glass spheres, cenospheres, diatomaceous earth, combinations thereof, and other similar insulating particulate material.

According to one aspect of the present disclosure, a method for manufacturing a vacuum insulated structure includes heating a trim breaker within an evacuation chamber. The method further includes outgassing the heated trim breaker via a first vacuum pump that is operably coupled to the evacuation chamber to define a vacuum within the evacuation chamber. The method further includes applying a metallic coating to the trim breaker, adhering the trim breaker to a first panel and a second panel via an adhesive to define an insulated structure, applying heat to the insulated structure to cure the adhesive, filling the insulated structure with insulation materials via ports, sealing the ports, positioning the heated insulated structure in the evacuation chamber, and evacuating the insulated structure via the first vacuum pump that is operably coupled to the evacuation chamber and a second vacuum pump that is operably coupled to the insulated structure.

According to another aspect, evacuating a heated insulated structure includes evacuating an exterior surface of an insulated structure and an interior cavity of an evacuation chamber via a first vacuum pump.

According to another aspect, the method includes evacuating an insulation cavity of an insulated structure via a second vacuum pump.

According to another aspect, the method includes bracing an exterior surface of an insulated structure with a support frame.

According to another aspect, applying a metallic coating includes using physical vapor deposition of aluminum on a trim breaker.

According to another aspect, the method includes applying a metallic coating to a connector that is coupled to an aperture defined by each of a first panel and a second panel.

According to another aspect, evacuating an insulated structure includes applying additional heat to an insulated structure within an evacuation chamber.

According to another aspect of the present disclosure, a method for manufacturing a vacuum insulated structure includes applying a metallic coating to the trim breaker, adhering the trim breaker to a first panel and a second panel via an adhesive to define an insulated structure, curing the adhesive via heat, depositing insulation material within an insulation cavity defined between the first panel and the second panel, positioning the insulated structure in an evacuation chamber, evacuating the evacuation chamber via a first pump, and evacuating the insulated structure via a second pump.

According to another aspect, the method includes applying a metallic coating to an inner channel and an external surface of a trim breaker.

According to another aspect, the method includes evacuating a trim breaker via evacuation of an evacuation chamber via a first pump.

According to another aspect, the method includes bracing an exterior surface of an insulated structure with a support frame.

According to another aspect, the method includes outgassing a trim breaker via heat that is applied to an insulated structure.

According to another aspect, the method includes coupling a connector to an aperture that is defined by a first panel and a second panel. The method further includes applying a metallic coating to the connector.

According to yet another aspect of the present disclosure, a method for manufacturing a vacuum insulated structure includes adhering a trim breaker to a wrapper and a liner via an adhesive to define an insulated structure. The method further includes positioning the insulated structure within an evacuation chamber proximate to a first heater and a second heater. The method further includes heating the insulated structure and the evacuation chamber via the first heater and the second heater. The method further includes evacuating the evacuation chamber via a first vacuum pump, and evacuating the insulated structure via a second vacuum pump.

According to another aspect, the method includes outgassing a trim breaker via a first heater and a second heater.

According to another aspect, the method includes evacuating an external surface of a trim breaker via a first vacuum pump. The method further includes evacuating an internal channel of the trim breaker via a second vacuum pump.

According to another aspect, the method includes applying a metallic coating to a trim breaker.

According to another aspect, applying a metallic coating includes electroplating a trim breaker with the metallic coating.

According to another aspect, the method includes positioning a first heater and a second heater proximate to a trim breaker. The method further includes applying heat to the trim breaker via the first heater and the second heater.

According to another aspect, the method includes positioning an insulated structure within a support frame, and bracing the insulated structure via the support frame.