Patent Publication Number: US-11035607-B2

Title: Use of multiple port locations for achieving faster vacuum evacuation time in vacuum insulated structures

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims priority to International Application No. PCT/US2017/013949, filed on Jan. 18, 2017, entitled “USE OF MULTIPLE PORT LOCATIONS FOR ACHIEVING FASTER VACUUM EVACUATION TIME IN VACUUM INSULATED STRUCTURES,” the disclosure of which is hereby incorporated herein by reference in its entirely. 
     This application is related to U.S. application Ser. No. 16/303,549, filed Nov. 20, 2018, which claims priority to International Application No. PCT/US2017/013936, filed on Jan. 18, 2017, entitled “INCREASED VACUUM PORT AREA FOR ACHIEVING FASTER VACUUM EVACUATION TIME IN VACUUM INSULATED STRUCTURES,” and U.S. application Ser. No. 16/302,923, filed Nov. 19, 2018, which claims priority to International Application No. PCT/US2017/013940, filed on Jan. 18, 2017, entitled “USE OF RIGID OR PERMEABLE CONDUITS FOR ACHIEVING FASTER VACUUM EVACUATION TIME IN VACUUM INSULATED STRUCTURES.” 
     FIELD OF THE DISCLOSURE 
     The present device generally relates to a vacuum insulated structure, and more specifically, to the use of multiple port locations for achieving faster vacuum evacuation time in vacuum insulated structures. 
     BACKGROUND OF THE DISCLOSURE 
     Increasing the insulative qualities of appliances, and particularly refrigerating appliances, is helpful to provide efficient, quality products for consumer use. In addition, manufacturing appliances with speed and efficiency is lowers energy consumption and speed to market. Processes to achieve these qualities are useful. 
     SUMMARY 
     In one aspect, an appliance includes an outer wrapper having a plurality of joined walls that define a plurality of vertices and edges. An inner liner is sealed with the outer wrapper to define an insulation space. A vacuum port is disposed on an external surface of the outer wrapper. A channel is in fluid communication with the vacuum port and extends along at least one edge defined by first and second walls of the outer wrapper. An insulative material is disposed between the outer wrapper and the inner liner. A filter media is disposed along the channel such that air can be drawn from the insulation space past the filter media, into the channel, and through each vacuum port. 
     In another aspect, an appliance includes an outer wrapper having a plurality of joined walls. An inner liner is sealed with the outer wrapper to define an insulation space. A vacuum port is disposed on an external surface of the outer wrapper. A channel is in fluid communication with the vacuum port and extends along a junction formed by first and second walls of the outer wrapper. An insulative material is disposed between the outer wrapper and the inner liner. A filter media is disposed along the channel such that air can be drawn from the insulation space past the filter media, into the channel, and through each vacuum port. 
     In yet another aspect, an appliance includes an outer wrapper having a plurality of joined walls. An inner liner is sealed with the outer wrapper to define an insulation space. A vacuum port is disposed on an external surface of the outer wrapper. An insulative material is disposed between the outer wrapper and the inner liner. A permeable filter tube is in fluid communication with the vacuum port and extends along a junction formed by first and second walls of the outer wrapper such that air can be drawn from the insulation space past the filter media, into the permeable filter tube, and through each vacuum port. 
     These and other features, advantages, and objects of the present device will be further understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the drawings: 
         FIG. 1  is a front elevational view of one embodiment of an appliance of the present disclosure; 
         FIG. 1A  is a front elevational view of the appliance of  FIG. 1  with first and second doors of the appliance in an open position; 
         FIG. 2  is a top perspective view of a rear portion of an appliance of the present disclosure; 
         FIG. 2A  is a bottom perspective view of the appliance of  FIG. 2 ; 
         FIG. 2B  is a partial perspective cross-sectional view of a vacuum port on an appliance of the present disclosure; 
         FIG. 3  is a bottom perspective view of another appliance of the present disclosure; 
         FIG. 3A  is a rear elevational view of the appliance of  FIG. 3 ; 
         FIG. 3B  is a bottom plan view of the appliance of  FIG. 3 ; 
         FIG. 3C  is a partial perspective cross-sectional view of a channel on an appliance of the present disclosure; 
         FIG. 4  is a bottom perspective view of an appliance of the present disclosure that includes vacuum channels; 
         FIG. 4A  is a partial perspective cross-sectional view of an insulation space of an appliance of the present disclosure with a channel extending therethrough; 
         FIG. 5  is a front top perspective view of another appliance of the present disclosure; 
         FIG. 6  is a bottom perspective view of the appliance of  FIG. 5 ; 
         FIG. 7  is a side elevational view of the appliance of  FIG. 5 ; 
         FIG. 8  is a bottom plan view of the appliance of  FIG. 5 ; 
         FIG. 9  is a top plan view of the appliance of  FIG. 5 ; 
         FIG. 10  is a rear top perspective view of another appliance of the present disclosure; 
         FIG. 11  is a top partial elevational cross-sectional view of a portion of the insulation space of an appliance of the present disclosure; 
         FIG. 11A  is a partial elevational view of a filter tube for use with an appliance of the present disclosure; 
         FIG. 12  is a partial elevational cross-sectional view of a portion of an appliance of the present disclosure; 
         FIG. 13  is a partial side elevational view of a vacuum port of the present disclosure; 
         FIG. 14  is a front elevational view of a vacuum port panel of the present disclosure; and 
         FIG. 15  is a top plan cross-sectional view of vacuum ports extending through a panel of an appliance of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
     It is 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, other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise. 
     The present illustrated embodiments reside primarily in combinations of method steps and apparatus components related to a vacuum insulated structure. Accordingly, the apparatus components and 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. 
     For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the disclosure as oriented in  FIG. 1 . Unless stated otherwise, the term “front” shall refer to the surface of the device closer to an intended viewer of the device, and the term “rear” shall refer to the surface of the device further from the intended viewer of the device. However, it is to be understood that the disclosure may assume various alternative orientations, 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. 
     The terms “including,” “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element proceeded by “comprises a . . . ” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element. 
     Referring now to  FIGS. 1-15 , reference numeral  10  generally designates an appliance having an outer wrapper  12  that defines a top wall  14 , a bottom wall  16 , a rear wall  18 , and first and second side walls  20 ,  22  and includes an inner liner  24 . A trim breaker  26  seals the outer wrapper  12  to the inner liner  24  to define an insulation space  30 . A single vacuum port  32  is disposed on each of the top wall  14 , the bottom wall  16 , and the first and second side walls  20 ,  22 . A plurality of vacuum ports  32  is disposed on the rear wall  18 . An insulative material  34  is disposed between the outer wrapper  12  and the inner liner  24 . A filter media  40  is disposed proximate each vacuum port  32  such that air can be drawn from the insulation space  30  past the filter media  40  and through each vacuum port  32 . 
     With reference again to  FIG. 1 , the illustrated appliance  10  is a refrigerator assembly that includes French doors  50 ,  52  that are pivotally coupled with a refrigerator compartment  54  and operable between open and closed positions. The refrigerator assembly also includes a lower pull out drawer  56  that defines a freezer compartment  58 . It will generally be understood that the features, as set forth herein, could be applied to any appliance having any general configuration. Further, the door configuration of the appliance  10  can vary from that shown in  FIG. 1 . The doors  50 ,  52 , as illustrated in  FIG. 1 , include handles  60  configured to allow a user to move the doors  50 ,  52  between open and closed positions. The refrigerator compartment  54  and the freezer compartment  58  include shelving  62 , as shown in  FIG. 1A , that can be adjusted and moved, depending on consumer preference. The outer wrapper  12  of the appliance  10  is generally formed from a metal material, which may be steel, aluminum, etc. The inner liner  24  is also constructed from a metal material, which may be steel, aluminum, etc. However, sealed plastics, or other materials that can maintain an airtight seal, could also be used in conjunction with the systems, as set forth herein. 
     With reference now to  FIG. 2 , the illustrated embodiment includes a plurality of vacuum ports  32  that are spaced at predetermined positions to draw a sufficient amount of vacuum from areas of the insulation space  30 . As a result of the additional vacuum ports  32 , the total vacuum time to place the insulative material  34  in a vacuum state and draw fluid (in the form of air) from the insulation space  30  is lessened. Consequently, refrigerator assemblies can be constructed at a faster rate and with a greater degree of negative pressure between the inner liner  24  and the outer wrapper  12 . Each of the ports  32  include a valve system  70  configured to prevent air from entering the insulation space  30  after the vacuum process has been completed. In the illustrated embodiment of  FIGS. 2 and 2A , a vacuum port  32  is disposed on each of the top wall  14 , the bottom wall  16 , the rear wall  18 , and the first and second side walls  20 ,  22 . However, it will be noted that more vacuum ports  32  could be disposed on any of the top wall  14 , the bottom wall  16 , the rear wall  18 , and the first and second side walls  20 ,  22  to increase the speed in which a negative pressure is obtained within the insulation space  30 . 
     In some instances, the vacuum ports  32  may be removed from certain walls of the appliance  10 . For example, in the event the appliance  10  will have exposed first and second side walls  20 ,  22  that are readily viewable by the consumer, the vacuum ports  32  may be omitted from the first and second side walls  20 ,  22 . In this instance, additional vacuum ports  32  may be disposed on first and second sides of the top wall  14  proximate the first and second side walls  20 ,  22  or on first and second sides of the bottom wall  16  in close proximity to the first and second side walls  20 ,  22 . In addition, more vacuum ports  32  on the rear wall  18  may also be positioned on the outer wrapper  12  to compensate for the loss of a vacuum port  32  of each of the first and second side walls  20 ,  22 . The valves that make up the vacuum ports  32  are configured to attached with a vacuum hose  80  ( FIG. 13 ) and may include ball valves, butterfly valves, check valves, choke valves, diaphragm valves, gate valves, globe valves, poppet valves, etc. A simple crimping solution or an end cap can also be used to close the vacuum hose  80 . It will be understood that any kind and any number of valves may be used and that this disclosure is not limited by any of the valve systems noted above. 
     It will be understood that the inner liner  24  and the outer wrapper  12  are connected at the trim breaker  26  generally disposed proximate the opening of the appliance  10 . The trim breaker  26  is sealed and airtight such that air can neither escape nor enter into the insulation space  30  between the outer wrapper  12  and the inner liner  24  at the trim breaker  26 . In addition, it will be understood that the insulative material  34  is disposed throughout the appliance  10  in the insulation space  30 . During assembly of the appliance  10 , the insulative material  34  is poured, or otherwise blown into, the insulation space  30  before the insulation space  30  is sealed airtight. In addition, it will be noted that, as illustrated in  FIGS. 2 and 2A , the filter media  40  is disposed between the vacuum port  32  and the insulative material  34 . The filter media  40  acts to prevent insulative material  34  from being drawn through the vacuum port  32  when a negative pressure is placed on the insulation space  30 . Accordingly, the insulative material  34  is maintained in the insulation space  30  between the outer wrapper  12  and the inner liner  24  as air is drawn from the insulation space  30  by an external vacuum pump. The filter media  40  may have a variety of constructions and may be constructed from sintered metal, plastic, etc. The filter media  40 , or portions of the filter media  40 , may also be constructed from a fiberglass based filter media. Regardless of the filter media material choice, the pores of the filter media  40 , and specifically, the size of the pores, will be dictated by the size of the granules, fibers, or strands that make up the insulative material  34  disposed in the insulation space  30 . The pores of the filter media  40  will be smaller than the fibers, strands, or granules of the insulative material  34 . Accordingly, air can be drawn from the insulation space  30  without removing the insulative material  34  after the insulative material  34  is installed between the inner liner  24  and the outer wrapper  12 . 
     With reference now to  FIGS. 3-3C , the illustrated appliance  100  includes a plurality of channels  102  that are in fluid communication with each vacuum port  32 . The channels  102  are disposed on each of the rear wall  18  and the bottom wall  16 . The channels  102  are configured to extend to distal corners  104  of the rear wall  18  and distal corners  106  of the bottom wall  16 . Accordingly, when the insulation space  30  is being vacuumed at the vacuum port  32 , air is drawn through the channels  102  from the insulation space  30  and out the vacuum port  32 . In this instance, the filter media  40  is elongate and disposed along each of the channels  102  to prevent the insulative material  34  from entering into the channel  102  and being withdrawn from the vacuum port  32 . By increasing the overall vacuum space on the back wall and the bottom wall  16  of the appliance  10 , the time to place the insulation space  30  under a suitable negative pressure is lessened. 
     As shown in  FIG. 3C , the filter media  40  may include a relatively elongate, planar filter screen formed from a sintered metal, porous plastic, or fiberglass material that extends along the entire length of each channel  102 . In this instance, the channel  102  is defined from a protruding outer casing  110  that protrudes from a planar extent of the rear wall  18  and the bottom wall  16 . The casing  110  may be integrally formed with a wall of the appliance  10 , or may be sealingly coupled with a wall of the appliance  10  via welding, adhesives, mechanical gaskets, etc. The casing  110  may include an arcuate cross-section, as shown, or have a square, triangular, etc. cross-section. The channel  102  draws air through the filter media  40  of the planar filter screen, while maintaining the insulative material  34  within the insulation space  30 . It will be understood that the filter media  40  may be any of a number of variety of shapes and does not necessarily need to be flat. 
     With reference now to  FIGS. 4 and 4A , the appliance  100  is shown with the channels  102  formed within the insulation space  30 . The filter media  40  for this assembly includes an elongate filter screen having a curved cross-section. In this instance, the planar extent of the rear wall  18  and/or the bottom wall  16  forms a first portion of the channel  102 . The filter media  40  in the form of the elongate filter screen forms a second portion of the channel  102 . Also, it will be understood that the channels  102 , although shown in a linear configuration, may also have a curved shape or a circular shape that extends about the bottom wall  16  and the rear wall  18 . The channels  102  could also include multiple branches that extend at any angle from the channels  102 . Moreover, it will be understood that the channels may be disposed on any of the walls of the appliance  10  and are not limited to the rear wall  18  and the bottom wall  16 . However, in the illustrated embodiments of  FIGS. 3-4A , the channels  102  are disposed on the back wall and the bottom wall  16  as these are typically portions of the appliance  10  that are not exposed to the consumer. Accordingly, the first and second side walls  20 ,  22  can be exposed with no apparent additional structure that relates to the vacuuming process disposed thereon. 
     With reference now to  FIGS. 5-9 , the illustrated appliance  10  includes the channel  102  extending in a loop configuration. Specifically, the channel includes one vacuum port  32 , which, in this instance is disposed on the bottom wall  16  of the appliance  10 . The channel  102  extends about the bottom wall  16 , the first side wall  20 , the top wall  14 , the second side wall  22 , and back to the bottom wall  16 , before returning to the second side wall  22 , the top wall  14 , and the first side wall  20  and back to the bottom wall  16 . In this instance, negative pressure is obtained within the insulation space  30  when the vacuum port  32  is operably coupled with the external vacuum system. Air is then drawn through the channel  102 , which extends through each of the four walls between the outer wrapper  12  and the inner liner  24  until a suitable negative pressure has been reached. It will be understood that the loop configuration for drawing air from the appliance  10  is not limited to the configuration shown. For example, another looped channel could extend about the back wall and could be operably coupled with the loop shown in  FIGS. 5-9 , or could be a separate loop with a separate vacuum port  32 , which may depend on the needed speed and negative pressure that is desirable for the insulation space  30  of the appliance  10 . It will be understood that the channels  102  of the appliance  10  may protrude from one or more of the walls, as shown in  FIG. 3C , or may be formed within the insulative material  34  in the insulation space  30  of the appliance  10 . 
     With reference now to  FIGS. 10-15 , an appliance  200  is illustrated having channels  202  that are again applied to the insulation space  30  between the inner liner  24  and the outer wrapper  12 . However, in this instance, the channels  202  extend along edges  204  and vertices  206  of adjacent and joined walls of the outer wrapper  12 . For example, one channel  202  is looped about a periphery of the second side wall  22 , starting at the edge  204  defined by the second side wall  22  and the bottom wall  16 , extending upward at the edge  204  defined by the front of the second side wall  22 , the edge  204  defined between the second side wall  22  and the top wall  14 , the edge  204  defined between the second side wall  22  and the rear wall  18 , and back to the second side wall  22  and the bottom wall  16 . This looped channel  102  is in fluid communication with a looped channel  102  extending about the periphery of the rear wall  18  and the vacuum port  32 . The looped channel  102  extending about the periphery of the rear wall  18  starts at the edge  204  defined between the second side wall  22  and the rear wall  18 , the edge  204  extending between the top wall  14  and the rear wall  18 , the edge  204  extending between the first side wall  20  and the rear wall  18 , and returning to the vacuum port  32  by way of the edge  204  extending between the bottom wall  16  and the rear wall  18 . 
     As shown in  FIGS. 11 and 11A , for the filter media  40 , it is generally contemplated that a permeable filter tube  210  having a multitude of perforations  212  may be disposed along the edges  204  of joined walls, with the permeable filter tube  210  being in fluid communication with the vacuum port  32 . The permeable filter tube  210  extends along multiple edges  204  and vertices  206  before terminating at the vacuum port  32 . The permeable filter tube  210  may be coupled with an interior surface  214  of one or more of the walls  14 ,  16 ,  18 ,  20 ,  22  of the outer wrapper  12 . The permeable filter tube  210  may be constructed from a sintered metal, porous plastic, or fiberglass material, for example, that allows air to be withdrawn from the insulation space  30  without removing the insulative material  34 . Other air permeable structures may also be used to filter air from the insulation space  30  without removing the insulative material  34 . 
     With reference now to  FIG. 12 , it is also generally contemplated that the channel  202  may be formed in an edge space  220  defined between the edge  204  of the appliance  10  and the filter media  40  that prevents the insulative material  34  from entering into the channel  202 . In this instance, the channels  202  extend along the edge spaces  220  and eventually terminate at the vacuum port  32  located at a bottom of the rear wall  18 . In the illustrated of  FIG. 12 , the filter media  40  is curvilinear outward (convex) and prevents the insulative material  34  from entering into the channel  202 . However, it will be understood that the filter media  40  may be flat, or may be concave inward toward the insulative material  34 . The structure of the channels  202  may depend upon the needed construction time determined for a particular appliance. 
     With reference now to  FIGS. 13-15 , in the illustrated embodiment, the vacuum ports  32  are in fluid communication with the channels  202  and may include a vacuum port panel  230  having apertures  232  for receiving and securing the vacuum ports  32 . that places all of the vacuum ports  32  in close proximity. As shown in  FIG. 13 , the vacuum port  32  includes a valve that is configured to allow air to escape from the vacuum port  32 , but not enter into the vacuum port  32  from the environment. As the channels  202  enter into the insulation space  30 , the channels  202  extend in a variety of directions generally directed at distal vertices of the appliance  10 . Consequently, a strong vacuum can be placed on the channels  202  and a negative pressure of the appliance  10 , and specifically, the insulation space  30  of the appliance  10 , can be maintained in a minimal amount of time. Accordingly, production, product quality, and energy efficiency in both making and using the appliance  10  can be increased. 
     For each of the embodiments set forth herein, the filter media  40  may include any of a variety of materials, including sintered material (metal, stainless steel, steel, alloys, aluminum, stone, ceramic, etc.), porous plastic, permeable fiberglass, etc. The filter media  40  will be understood to maintain structural integrity even under high vacuum environments with high negative pressure values. Consequently, the insulative material  34  is kept in the insulation space  30  and high thermal efficiency can be obtained. 
     It will be understood by one having ordinary skill in the art that construction of the described disclosure and other components is not limited to any specific material. Other exemplary embodiments of the disclosure disclosed herein may be formed from a wide variety of materials, unless described otherwise herein. 
     For purposes of this disclosure, the term “coupled” (in all of its form, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Such joining may be permanent in nature or may be removable or releasable in nature unless otherwise stated. 
     It is also important to note that the construction and arrangement of the elements of the disclosure as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations. 
     It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present disclosure. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting. 
     It is also to be understood that variations and modifications can be made on the aforementioned structures and methods without departing from the concepts of the present disclosure, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.