Patent Description:
A method of producing an insulated structure according to the invention is disclosed in any one of the claims <NUM>-<NUM>.

According to one aspect of the present disclosure, a method of producing an insulated structure includes introducing a raw material into a feed hopper. The method also includes compacting the raw material with at least one roller. The method further includes directing the raw material that has been compacted to a crusher. Additionally, the method includes directing the raw material that has been compacted to a granulator. Further, the method includes collecting the raw material, which has been compacted and exposed to both the crusher and the granulator, as a core material precursor. The method also includes filtering the core material precursor with a filter member.

According to another aspect of the present disclosure, an insulated structure includes a plurality of walls and a cavity defined by the plurality of walls. A core material is disposed within the cavity. The core material includes particles with a diameter that is in a range of <NUM>-<NUM>. The core material can be disposed within the cavity to a density in a range of greater than <NUM>/m<NUM> to <NUM>/m<NUM>.

The present illustrated embodiments reside primarily in combinations of method steps and apparatus components related to an 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.

In this document, relational terms, such as first and second, top and bottom, and the like, are used solely to distinguish one entity or action from another entity or action, without necessarily requiring or implying any actual such relationship or order between such entities or actions. 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.

As used herein, the term "and/or," when used in a list of two or more items, means that any one of the listed items can be employed by itself, or any combination of two or more of the listed items, can be employed.

As used herein, the term "about" means that amounts, sizes, formulations, parameters, and other quantities and characteristics are not and need not be exact, but may be approximate and/or larger or smaller, as desired, reflecting tolerances, conversion factors, rounding off, measurement error and the like, and other factors known to those of skill in the art. When the term "about" is used in describing a value or an end-point of a range, the disclosure should be understood to include the specific value or end-point referred to. Whether or not a numerical value or end-point of a range in the specification recites "about," the numerical value or end-point of a range is intended to include two embodiments: one modified by "about," and one not modified by "about. " It will be further understood that the end-points of each of the ranges are significant both in relation to the other end-point, and independently of the other end-point.

Referring to <FIG> and <FIG>, reference numeral <NUM> generally designates an insulated structure. The insulated structure <NUM> can be employed as a component of an appliance, such as a thermally insulated appliance. In various examples, the appliance may be capable of passively or actively controlling a thermal environment within the appliance (e.g., a refrigerator, a freezer, a cooler, an oven, etc.). The insulated structure <NUM> includes a plurality of walls <NUM>. For example, the plurality of walls <NUM> can include a top wall <NUM>, a bottom wall <NUM>, a first side wall <NUM>, a second side wall <NUM>, an exterior wall <NUM>, and/or an interior wall <NUM>. The first and second side walls <NUM>, <NUM> each extend between the top and bottom walls <NUM>, <NUM>. Similarly, the exterior wall <NUM> and the interior wall <NUM> each extend between the top wall <NUM>, the bottom wall <NUM>, the first side wall <NUM>, and the second side wall <NUM>. The top and bottom walls <NUM>, <NUM> may define a thickness of the insulated structure <NUM> and/or a width of the insulated structure <NUM>. The first and second side walls <NUM>, <NUM> may also define the thickness of the insulated structure <NUM>. Additionally, or alternatively, the first and second side walls <NUM>, <NUM> may define a height of the insulated structure <NUM>. The exterior wall <NUM> and the interior wall <NUM> may extend in the height direction and the width direction of the insulated structure <NUM>. The exterior wall <NUM> is opposite to the interior wall <NUM> and is therefore indicated with a phantom lead line in <FIG>. The exterior wall <NUM> may be closest to a user when the insulated structure <NUM> is fully assembled with the appliance. The interior wall <NUM> may be further from the user than the exterior wall <NUM> when the insulated structure <NUM> is fully assembled with the appliance. In examples where the insulated structure <NUM> is employed as at least a portion of an access door (e.g., refrigerator door, cooler door, oven door, etc.), the interior wall <NUM> may be furthest from the user when the access door is in a closed position.

Referring again to <FIG> and <FIG>, the plurality of walls <NUM> define a cavity <NUM> therebetween. A core material <NUM> is disposed within the cavity <NUM>. The core material <NUM> can include particles <NUM> with a diameter that is in a range of <NUM>-<NUM>. For example, the diameter of the particles <NUM> can be about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, and/or combinations or ranges thereof. While the size of the particles <NUM> is referred to with regard to a diameter, the present disclosure is not limited to circular or spherical particles. Rather, the particles <NUM> may be any polygon and the reference to a diameter thereof may refer to a dimension from one side of the particle <NUM> to an opposing side of the particle <NUM>. In some examples, the dimensions referred to with regard to the diameter of the particles <NUM> may apply to a maximum distance or dimension across the particle <NUM> when the particle <NUM> is a polygon other than a circle or sphere. In various examples, the dimensions referred to with regard to the diameter of the particles <NUM> may apply to a minimum distance or dimension across the particle <NUM> when the particle <NUM> is a polygon other than a circle or sphere. Regardless of the shape of the particles <NUM>, the core material <NUM> can include at least one component chosen from fumed silica, carbon black, perlites, silicon carbide, glass fibers, and glass microspheres.

Referring further to <FIG> and <FIG>, the core material <NUM> can be disposed within the cavity <NUM> to a density in a range of greater than <NUM>/m<NUM> to <NUM>/m<NUM>. For example, the core material <NUM> can be present within the cavity <NUM> at a density of about <NUM>/m<NUM>, about <NUM>/m<NUM>, about <NUM>/m<NUM>, about <NUM>/m<NUM>, about <NUM>/m<NUM>, about <NUM>/m<NUM>, and/or combinations or ranges thereof. In various examples, a thermal conductivity of the core material <NUM> within the cavity <NUM> and/or the insulated structure <NUM> when fully assembled can be in a range of <NUM> mW/mK to <NUM> mW/mK. For example, the thermal conductivity of the core material <NUM> within the cavity <NUM> and/or the insulated structure <NUM> when fully assembled can be about <NUM> mW/mK, about <NUM> mW/mK, about <NUM> mW/mK, about <NUM> mW/mK, about <NUM> mW/mK, about <NUM> mW/mK, about <NUM> mW/mK, about <NUM> mW/mK, about <NUM> mW/mK, about <NUM> mW/mK, about <NUM> mW/mK, about <NUM> mW/mK, about <NUM> mW/mK, about <NUM> mW/mK, about <NUM> mW/mK, and/or combinations or ranges thereof. A pressure within the cavity <NUM> can be less than <NUM> Pascal when the insulated structure <NUM> is fully assembled. For example, the pressure within the cavity <NUM> when the insulated structure is fully assembled can be less than about <NUM> Pascal, less than about <NUM> Pascal, less than about <NUM> Pascal, less than about <NUM> Pascal, less than about <NUM> Pascal, less than about <NUM> Pascal, less than about <NUM> Pascal, less than about <NUM> Pascal, less than about <NUM> Pascal, less than about <NUM> Pascal, and/or combinations or ranges thereof.

Referring now to <FIG> and <FIG>, a method <NUM> of producing the insulated structure <NUM> includes step <NUM> of introducing a raw material <NUM> into a feed hopper <NUM>. The method <NUM> also includes step <NUM> of compacting the raw material <NUM> with at least one roller <NUM>. For example, the at least one roller <NUM> can include a first roller <NUM> and a second roller <NUM>. In the depicted example of <FIG>, the first roller <NUM> and the second roller <NUM> are vertically oriented relative to one another such that the first roller <NUM> is positioned vertically above the second roller <NUM>. However, alternative arrangements are contemplated and alternative arrangements do not depart from the concepts discussed herein. The first and second rollers <NUM>, <NUM> are positioned in close proximity to one another to facilitate the compaction of the raw material <NUM> as the raw material <NUM> passes between the first and second rollers <NUM>, <NUM>. Accordingly, any alternative arrangement of the at least one roller <NUM> that facilitates compaction of the raw material <NUM> is contemplated herein. In some examples, the raw material <NUM> may be directed to a screw feeder <NUM> by the feed hopper <NUM>. In such examples, the screw feeder <NUM> can direct the raw material <NUM> toward the at least one roller <NUM>.

Referring again to <FIG> and <FIG>, the method <NUM> also includes step <NUM> of directing the raw material <NUM> that has been compacted to a crusher <NUM>. Additionally, the method <NUM> includes step <NUM> of directing the raw material <NUM> that has been compacted to a granulator <NUM>. In various examples, the raw material <NUM> may be directed to the crusher <NUM> and the granulator <NUM> by a chute <NUM>. The method <NUM> further includes step <NUM> of collecting the raw material <NUM> that has been compacted and exposed to both the crusher <NUM> and the granulator <NUM>. The raw material <NUM> that has been compacted and exposed to both the crusher <NUM> and the granulator <NUM> may be referred to as a core material precursor <NUM>. The core material precursor <NUM> may include coarse particles and fine particles. The method <NUM> also includes step <NUM> of filtering the core material precursor <NUM> with a filter member <NUM>. In various examples, the filter member <NUM> includes a pore size that is less than <NUM> such that particulates <NUM> (e.g., fine particles) that are less than <NUM> pass through the filter member <NUM>. In such examples, a portion <NUM> of the core material precursor <NUM> that remains on the filter member <NUM> represents the core material <NUM> for use in the insulated structure <NUM>. The particles <NUM> may be referred to as coarse particles and the particulates <NUM> may be referred to as fine particles. The terms "coarse" and "fine" are not intended to describe a particular texture or shape. Rather, the terms "coarse" and "fine," as used herein, are intended to differentiate between particles within the core material precursor <NUM> that do not pass through the filter member <NUM> and particles within the core material precursor <NUM> that do pass through the filter member <NUM>. Accordingly, the terms "coarse" and "fine," as used herein, can be relative to the pore size of the filter member <NUM>. Removal of the particulates <NUM>, or fine particles, can improve the manufacturing process for the insulated structure <NUM>. Specifically, by removing the particulates <NUM> from the core material precursor <NUM>, the particulates <NUM> are prevented from impeding the decrease of the pressure within the cavity <NUM>. For example, if the particulates <NUM> were to remain, the filter or screen that prevents the pump from taking up, or pulling in, the core material <NUM> can be plugged or clogged, thereby restricting flow of the gaseous components being evacuated and potentially over-working the pump. If the particulates <NUM> were to remain, it is also possible for the particulates <NUM> to bypass the filter or screen used to protect the pump and decrease an efficiency and/or operating lifetime of the pump.

Referring further to <FIG> and <FIG>, the core material <NUM> can include particles <NUM> with a diameter of <NUM> or greater. A size distribution of the particles <NUM> of the core material <NUM> can depend on the pore size or pore sizes of the filter member <NUM>. In some examples, a plurality of filter members <NUM> may be employed. In such examples, the plurality of filter members <NUM> may be provided with successively smaller pore sizes such that the particles <NUM> collected on the plurality of filter members <NUM> are stratified or segregated by size. Such an arrangement may be beneficial in controlling a given distribution of diameters for the particles <NUM> that are deposited within the cavity <NUM>. For example, during production, a first amount of the particles <NUM> may be taken from a first of the filter members <NUM>, a second amount of the particles <NUM> may be taken from a second of the filter members <NUM>, and a third amount of the particles <NUM> may be taken from a third of the filter members <NUM>. In such an example, the first of the filter members <NUM> may have the largest pore size, the third of the filter members <NUM> may have the smallest pore size, and the second of the filter members <NUM> may have a pore size that is intermediate to the pore sizes of the first of the filter members <NUM> and the second of the filter members <NUM>. Accordingly, the first amount of the particles <NUM>, the second amount of the particles <NUM>, and the third amount of the particles <NUM> may be chosen to control a size distribution of the particles <NUM> that are deposited into the cavity <NUM>.

Referring still further to <FIG> and <FIG>, in some examples, the diameter of the particles <NUM> of the core material <NUM> are in a range of <NUM>-<NUM>. For example, the diameter of the particles <NUM> can be about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, and/or combinations or ranges thereof. Once the particles <NUM> of the core material <NUM> have been collected on the filtering member(s) <NUM> and, if desired, mixed to a predetermined ratio, these particles <NUM> can be placed within the cavity <NUM>. Accordingly, the method <NUM> can include a step of depositing the core material <NUM> within the cavity <NUM> of the insulated structure <NUM>. For example, the core material <NUM> may be deposited within the cavity <NUM> by blowing the core material <NUM> into the cavity <NUM> and/or activating a pump to decrease a pressure within the cavity <NUM>. If a pump is used to decrease the pressure within the cavity <NUM> during deposition of the core material <NUM>, a filter or screen may be employed to prevent the pump from taking up the core material <NUM>, which could damage the pump. As stated above, the cavity <NUM> of the insulated structure <NUM> is defined by the plurality of walls <NUM>.

Referring again to <FIG> and <FIG>, in the step of depositing the core material <NUM> within the cavity <NUM> of the insulated structure <NUM>, the core material <NUM> can be disposed within the cavity <NUM> to a density that is within the range of greater than <NUM>/m<NUM> to <NUM>/m<NUM>. For example, the core material <NUM> can be present within the cavity <NUM> at a density of about <NUM>/m<NUM>, about <NUM>/m<NUM>, about <NUM>/m<NUM>, about <NUM>/m<NUM>, about <NUM>/m<NUM>, about <NUM>/m<NUM>, and/or combinations or ranges thereof. The dimensions of the cavity <NUM> are known at the time of manufacture. Accordingly, the volume of the cavity <NUM> is also known at the time of manufacture. Therefore, in disposing the core material <NUM> within the cavity <NUM> to a desired density within the range of greater than <NUM>/m<NUM> to <NUM>/m<NUM>, a change in weight of the insulated structure <NUM> may be monitored to determine when the desired density has been reached. Additionally, or alternatively, a flow rate of the core material <NUM> during the disposing or dispensing of the core material <NUM> may be known in terms of mass per unit time (e.g., kilograms per minute). In such examples, a predetermined time duration may be used to dispense or dispose the desired amount of core material <NUM> into the cavity <NUM> to attain the desired density of the core material <NUM> within the cavity <NUM>. In some examples, a change in weight of the insulated structure <NUM> and an elapsed time of disposing the core material <NUM> within the cavity <NUM> may be monitored to determine when a desired density of the core material <NUM> within the cavity <NUM> has been reached. In such an example, the core material <NUM> may cease being added to the cavity <NUM> once a predetermined amount of time has elapsed and a predetermined change in the weight of the insulated structure <NUM> has been observed.

Referring yet again to <FIG> and <FIG>, the method <NUM> can include a step of evacuating at least a portion of gaseous components (e.g., air) within the cavity <NUM> of the insulated structure <NUM>. For example, a pump may be attached to the insulated structure <NUM> and activated to evacuate, or pull, at least a portion of the gaseous components from the cavity <NUM>. In various examples, the pump used to remove at least a portion of the gaseous components within the cavity <NUM> may be the same pump that can be employed during the deposition of the core material <NUM> within the cavity <NUM>. In evacuating at least a portion of the gaseous components within the cavity <NUM>, a pressure within the cavity <NUM> is decreased (e.g., to attain a less-than-atmospheric pressure). The term "atmospheric pressure" is intended to refer to the pressure exerted by the weight of the atmosphere, which at sea level has a mean value of <NUM>,<NUM> Pascal. Said another way, at the time of manufacture, a pressure that is less than the environment immediately surrounding the insulated structure <NUM> may be established within the cavity <NUM>. For example, the pressure within the cavity <NUM> when the insulated structure <NUM> is fully assembled can be less than about <NUM> Pascal, less than about <NUM> Pascal, less than about <NUM> Pascal, less than about <NUM> Pascal, less than about <NUM> Pascal, less than about <NUM> Pascal, less than about <NUM> Pascal, less than about <NUM> Pascal, less than about <NUM> Pascal, less than about <NUM> Pascal, and/or combinations or ranges thereof.

Referring still further to <FIG> and <FIG>, the method <NUM> can include a step where the cavity <NUM> of the insulated structure <NUM> is sealed from the environment such that gaseous components of the environment are prevented from entering into the cavity <NUM>. For example, an aperture defined by one of the plurality of walls <NUM> may be employed in depositing the core material <NUM> within the cavity <NUM>. The same aperture employed to deposit the core material <NUM> within the cavity <NUM> may be used when reducing the pressure within the cavity <NUM>. In such an example, a filter or screen may be placed over the aperture following deposition of the core material <NUM> within the cavity <NUM> and prior to decreasing the pressure within the cavity <NUM> to prevent the deposited core material <NUM> from entering the pump. In alternative examples, a separate, or second, aperture may be employed for reducing the pressure within the cavity <NUM>. In one example, once the core material <NUM> has been deposited within the cavity <NUM>, the cavity <NUM> may be sealed to complete assembly of the insulated structure <NUM>. Alternatively, the sealing of the cavity <NUM> of the insulated structure <NUM> from the environment can be executed after the core material <NUM> has been deposited within the cavity <NUM> and the pressure within the cavity <NUM> has been decreased to a level that is less-than-atmospheric pressure. In any of the preceding examples, upon completion of the step of sealing the cavity <NUM> of the insulated structure <NUM> (e.g., sealing one or more apertures defined by one or more of the plurality of walls <NUM>), manufacture and/or assembly of the insulated structure <NUM> may be completed. The insulated structure <NUM> can be a subassembly of a larger assembly (e.g., an appliance). In various examples, a thermal conductivity of the core material <NUM> within the cavity <NUM> and/or the insulated structure <NUM> when fully assembled can be in a range of <NUM> mW/mK to <NUM> mW/mK. For example, the thermal conductivity of the core material <NUM> within the cavity <NUM> and/or the insulated structure <NUM> when fully assembled can be about <NUM> mW/mK, about <NUM> mW/mK, about <NUM> mW/mK, about <NUM> mW/mK, about <NUM> mW/mK, about <NUM> mW/mK, about <NUM> mW/mK, about <NUM> mW/mK, about <NUM> mW/mK, about <NUM> mW/mK, about <NUM> mW/mK, about <NUM> mW/mK, about <NUM> mW/mK, about <NUM> mW/mK, about <NUM> mW/mK, and/or combinations or ranges thereof.

According to another aspect, a portion <NUM> of a core material precursor <NUM> that remains on a filter member <NUM> represents a core material <NUM> for use in an insulated structure <NUM>. The core material <NUM> can include particles <NUM> with a diameter of <NUM> or greater.

According to another aspect, a diameter of particles <NUM> of a core material <NUM> can be in a range of <NUM>-<NUM>.

According to another aspect, a range of a diameter of particles <NUM> of a core material <NUM> can be <NUM>-<NUM>.

According to another aspect, a core material <NUM> is deposited within a cavity <NUM> of an insulated structure <NUM>. The cavity <NUM> of the insulated structure <NUM> can be defined by a plurality of walls <NUM>.

According to another aspect, a core material <NUM> disposed within a cavity <NUM> has a density in a range of greater than <NUM>/m<NUM> to <NUM>/m<NUM>.

According to another aspect, a method of producing an insulated structure <NUM> includes evacuating at least a portion of gaseous components within a cavity <NUM> of the insulated structure <NUM>.

According to another aspect, a method of producing an insulated structure <NUM> includes sealing a cavity <NUM> of an insulated structure <NUM> from an environment such that gaseous components from the environment do not enter into the cavity <NUM>.

According to another aspect, a pressure within a cavity <NUM> can be less than <NUM> Pascal following evacuation of at least a portion of gaseous components within the cavity <NUM> of an insulated structure <NUM> and sealing of the cavity <NUM> of the insulated structure <NUM> from an environment such that gaseous components from the environment do not enter into the cavity <NUM>.

According to another aspect, a thermal conductivity of a core material <NUM> within a cavity <NUM> is in a range of <NUM> mW/mK to <NUM> mW/mK.

According to another aspect, a method of producing an insulated structure <NUM> includes directing a raw material <NUM> to a screw feeder <NUM>. The screw feeder <NUM> directs the raw material <NUM> toward at least one roller <NUM>.

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 scope of the present innovations.

Claim 1:
A method (<NUM>) of producing an insulated structure (<NUM>), the method comprising:
introducing a raw material (<NUM>) into a feed hopper (<NUM>);
compacting the raw material (<NUM>) with at least one roller (<NUM>, <NUM>, <NUM>);
directing the raw material (<NUM>) that has been compacted to a crusher (<NUM>);
directing the raw material (<NUM>) that has been crushed to a granulator (<NUM>);
collecting the raw material (<NUM>) that has been compacted and exposed to both the crusher (<NUM>) and the granulator (<NUM>) as a core material precursor (<NUM>); characterized by
filtering the core material precursor (<NUM>) with a filter member (<NUM>);
wherein a portion (<NUM>) of the core material precursor (<NUM>) that remains on the filter member (<NUM>) represents a core material (<NUM>) for use in the insulated structure (<NUM>).