Patent Description:
In the invention, a vacuum insulated structure includes all the features of the independent claim.

For purposes of description herein the terms "upper," "lower," "right," "left," "rear," "front," "vertical," "horizontal," and derivatives thereof shall relate to the device as oriented in <FIG>.

Referring to the embodiment illustrated in <FIG>, reference numeral <NUM> generally designates an appliance shown in the form of a refrigerator that includes a vacuum insulated cabinet structure <NUM>. The refrigerator <NUM> further includes first and second doors <NUM>, <NUM> that are disposed in a French-style door configuration and are pivotally coupled to the vacuum insulated cabinet structure <NUM> for selectively providing access to a refrigerator compartment <NUM>. The refrigerator <NUM> shown in <FIG> also includes a lower pull-out freezer drawer <NUM> having a handle <NUM> that selectively provides access to a freezer compartment <NUM>. 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 refrigerator <NUM> can vary from that shown in FIG. 1A to include a single door or multiple doors in other configurations. The first and second doors <NUM>, <NUM> illustrated in <FIG> include handles <NUM>, <NUM>, respectively, which are configured to allow a user to selectively move the first and second doors <NUM>, <NUM> between open and closed positions, either separately or together. The first and second doors <NUM>, <NUM> and the freezer drawer <NUM> are also contemplated to be vacuum insulated structures, as further described below.

Referring now to <FIG>, a vacuum insulated structure <NUM> is shown. The vacuum insulated structure is contemplated to be an insulating part of the first door <NUM> (<FIG>) that supports an aesthetic outer skin on the first door <NUM>. The vacuum insulated structure <NUM> is exemplary of a door panel for use with the present concept. As such, the description herein of the vacuum insulated structure <NUM> of the first door <NUM> will also generally describe a vacuum insulated structure of the second door <NUM> and the freezer drawer <NUM> shown in <FIG>. While the vacuum insulated structure <NUM> is exemplified as a vacuum insulated structure for a door, the present concept can be used with any type of vacuum insulated structure, and therefore, is not limited to use with a door panel. As specifically shown in <FIG>, the vacuum insulated structure <NUM> includes first panel <NUM> coupled to a second panel <NUM>. The first panel <NUM> and the second panel <NUM> may be interconnected by a trim breaker, such as trim breaker <NUM> shown in <FIG>. It is contemplated that the first panel <NUM> and the second panel <NUM> are comprised of a metal material, such as a sheet metal material. An interconnecting trim breaker may be comprised of a polymeric material. As coupled to one another, the first panel <NUM> and the second panel <NUM> cooperate to define an insulating space <NUM> disposed therebetween. As shown in <FIG>, the first panel <NUM> may include an access aperture <NUM> disposed therethrough and opening into the insulating space <NUM>. In use, the access aperture <NUM> can be used to fill the insulating space <NUM> with an insulating material, such as an insulating powder, and may also be used with an evacuation port to draw a vacuum on the vacuum insulated structure <NUM>, as further described below.

As further shown in the embodiment of <FIG>, the first panel <NUM> includes a first body portion <NUM> which surrounds a second body portion <NUM>. In the embodiment shown in <FIG>, the second body portion <NUM> is centrally disposed and outwardly extending from the first body portion <NUM>. Thus, the second body portion <NUM> defines a raised portion of the first panel <NUM> relative to the first body portion <NUM>. The second body portion <NUM> and the first body portion <NUM> are interconnected by an intermediate portion <NUM> which is best shown in <FIG>. The intermediate portion <NUM> is an outwardly angled portion which outwardly extends the second body portion <NUM> relative to the first body portion <NUM> in a range from <NUM> to <NUM>, or about <NUM>. With specific reference to <FIG>, the distance spanned by the intermediate portion <NUM> between the first body portion <NUM> and the second body portion <NUM> is indicated by reference D2. With the second body portion <NUM> extending outwardly by a distance D2, the intermediate portion <NUM> of the first panel <NUM> defines an integrated stiffener for the first panel <NUM>. Having an integrated stiffener in the first panel <NUM>, the first panel <NUM> is provided with increased rigidity, as compared to a standard flat panel. This increased rigidity counters vacuum forces VF that act on the first panel <NUM> when a vacuum is drawn on the insulating space <NUM>. As further shown in <FIG>, the first body portion <NUM> extends from an outer edge <NUM> of the first panel <NUM> to the intermediate portion <NUM> a distance D1. The distance D1 shown in <FIG> is contemplated to be approximately in a range from about <NUM> to <NUM>, or about <NUM>. As shown in <FIG> the first panel <NUM> includes inner and outer surfaces <NUM>, <NUM>. With the rigidifying features integrated into the first panel <NUM>, the outer surface <NUM> thereof will show little bowing during an evacuation procedure.

With reference to <FIG>, the first panel <NUM> is shown as removed from the vacuum insulated structure <NUM> of <FIG>. It is contemplated that the first panel <NUM> may define an inner portion or liner of the vacuum insulated structure <NUM> shown in <FIG>. As such, the second panel <NUM> may define an outer portion or exterior wrapper of the vacuum insulated structure <NUM> shown in <FIG>.

With a standard flat panels under vacuum pressure, vacuum induced bowing will generally occur around the outer edge of a panel, such as outer edge <NUM> of first panel <NUM> shown in <FIG>, adjacent to an adhesion joint between the panels and a trim breaker. As such, an outer surface of a standard flat panel may bow inwardly about <NUM> or more from its pre-vacuum position. This bowing effect reduces the thermal insulation thickness within the insulating space, such as insulating space <NUM> shown in <FIG>. Further, this bowing effect is unpredictable and affects the overall shape of the panel, thus making the overall aesthetic of the panel unsightly and further makes incorporation of the panel into a completed assembly complicated and unpredictable. By providing the integrated stiffener in the first panel <NUM> of the present concept at a distance D1 from the outer edge <NUM> of the first panel <NUM>, vacuum bowing is reduced to approximately <NUM> or less. This reduced bowing helps to maintain a thermal insulation thickness requirement (<NUM> or more) within the insulating space <NUM> and provides greater predictability of the overall shape and flatness of the vacuum insulated structure <NUM> (<FIG>) of which the first panel <NUM> is a part. While a raised central portion <NUM> is shown and described herein with regards to the first panel <NUM>, it is contemplated that the second panel <NUM> can also include such an anti-bowing configuration.

With further reference to <FIG>, the vacuum insulated structure <NUM> includes an airway system <NUM> disposed within the insulating space <NUM>. The airway system <NUM> is housed within the insulating space <NUM> between the first and second panels <NUM>, <NUM> and is contemplated to be fluidically coupled to an access aperture of either one of the first and second panels <NUM>, <NUM>, such as access aperture <NUM> of the first panel <NUM>. In assembly, the airway system <NUM> is contemplated to be coupled to an inner surface of the second panel <NUM> of the vacuum insulated structure <NUM>. In this way, the airway system <NUM> is contemplated to couple to an inner surface of an exterior wrapper of a vacuum insulated structure, however, it is also contemplated that the airway system <NUM> may be suspended within the insulating space <NUM>, and may also be coupled to the liner, or first panel <NUM> of the vacuum insulated structure <NUM>.

Referring now to <FIG>, the first and second panels <NUM>, <NUM> of the vacuum insulated structure <NUM> are shown in phantom to reveal the airway system <NUM> disposed within the insulating space <NUM>. With the first and second panels <NUM>, <NUM> shown in phantom, the specific features of the airway system <NUM> are revealed. In the embodiment shown in <FIG>, the airway system <NUM> includes first and second vertical portions <NUM>, <NUM> which substantially run the vertical length of the first and second panels <NUM>, <NUM>. As further shown in <FIG>, the airway system <NUM> further includes first, second and third horizontal portions <NUM>, <NUM> and <NUM> which interconnect the first and second vertical portions <NUM>, <NUM>, such that all of the portions <NUM>, <NUM>, <NUM>, <NUM> and <NUM> are fluidically interconnected. The various portions <NUM>, <NUM>, <NUM>, <NUM> and <NUM> of the airway system <NUM> are shown in <FIG> as being vertical and horizontal portions, however, it is contemplated that the various portions of the airway system <NUM> may be provided in any configuration within an insulating space of a vacuum insulated structure for improving the efficiency of drawing a vacuum on the vacuum insulated structure. Other such exemplary designs and configurations for the airway system <NUM> include serpentine structures and diagonal sections to provide further coverage within a vacuum insulated structure. The various portions of the airway system <NUM> shown in <FIG> are comprised of tubing <NUM> which is a porous or perforated tubing, such that air can be drawn from the insulating space <NUM> through the tubing <NUM> along an entire length of each interconnected portion <NUM>, <NUM>, <NUM>, <NUM> and <NUM> of the tubing <NUM> during an evacuation procedure of the vacuum insulated structure <NUM>. In <FIG>, the interconnected portions <NUM>, <NUM>, <NUM>, <NUM> and <NUM> of porous tubing <NUM> are disposed around an outer perimeter <NUM> of the insulating space <NUM>, such that the airway system <NUM> can reach to all corners of the insulating space <NUM>.

As further shown in <FIG>, a plurality of connectors 54A-54E are used to interconnect portions of the tubing <NUM> of the airway system <NUM>. In the invention, as shown in <FIG>, connectors 54A-54C include respective support members 56A-56C which outwardly extend from the connectors 54A-54C to interconnect inner surfaces of the second panel <NUM> and first panel <NUM>, as further described below with reference to <FIG>. The support members 56A-56C define stiffeners between the first and second panels <NUM>, <NUM> and act to internally support the vacuum insulated structure <NUM> to combat the effects of vacuum bow on the vacuum insulated structure <NUM> when a vacuum is drawn on the insulating space <NUM> thereof.

Referring now to <FIG>, the vacuum insulated structure <NUM> is shown from a cross-sectional view wherein the first panel <NUM> is coupled to the second panel <NUM> by interconnecting trim breaker <NUM>. As coupled to the trim breaker <NUM>, the first and second panels <NUM>, <NUM> define the vacuum insulated structure <NUM> having the insulating space <NUM> disposed therebetween. As further shown in <FIG>, the airway system <NUM> is shown disposed within the insulating space <NUM> between the first and second panels <NUM>, <NUM>. The second panel <NUM> includes inner and outer surfaces <NUM>, <NUM>. Connectors 54D, 54B and 54E of the airway system <NUM> are shown in <FIG> as being coupled to the inner surface <NUM> of the second panel <NUM>. As such, it is contemplated that the airway system <NUM> is coupled to an inner surface of a wrapper within a vacuum insulated structure to reinforce the stiffness of the vacuum insulated structure and help with increasing the efficiency of evacuating air from the vacuum insulated structure. With specific reference to connector 54D, a first portion <NUM> of the connector 54D is coupled to the second horizontal portion <NUM> of the airway system <NUM>. A second portion <NUM> of the connector 54D is further coupled to the first vertical portion <NUM> of the airway system <NUM>. Similarly, connector 54E includes a first portion <NUM> coupled to the second horizontal portion <NUM> of the airway system <NUM> on an opposite side of connector 54B relative to connector 54D. A second portion <NUM> of the connector 54D is further coupled to the second vertical portion <NUM> of the airway system <NUM>. The second horizontal portion <NUM> of the airway system <NUM> is interconnects connectors 54D, 54E with connector 54B. Connector 54B includes a first portion <NUM> which is connected to the second horizontal portion <NUM> of the airway system <NUM>. The connectors 54B, 54D and 54E shown in <FIG> exemplify the various connectors shown in <FIG> which operate in a similar manner.

As noted above, the various portions of the airway system <NUM> comprise tubes <NUM> having body portions <NUM> that are porous or perforated to draw air into the tubes <NUM> in the airflow direction as indicated by arrows AF along the entire length of the portions of the tubes <NUM> that make up the various horizontal and vertical portions (<NUM>, <NUM>, <NUM>, <NUM>, <NUM> (<FIG>)) of the airway system <NUM>. The body portions <NUM> of the tubing <NUM> are contemplated to filter insulation material that may be disposed within the insulating space <NUM>. As such, the body portions <NUM> are thought to be akin to a soaker hose having a porous material configuration. Having outwardly extending portions (<NUM>, <NUM>, <NUM>, <NUM>, <NUM> (<FIG>)) covering an increased amount of area within the insulating space <NUM>, the airway system <NUM> provides for better coverage as opposed to a single evacuation site for drawing air from the insulating space <NUM> of the vacuum insulated structure <NUM>. In <FIG>, the second panel <NUM> includes an access aperture <NUM> that is coupled to an evacuation port <NUM>. The airway system <NUM> includes a connector <NUM> that fluidically connects the airway system <NUM> to the evacuation port <NUM>. The increased coverage provided by outwardly extending portions <NUM>, <NUM>, <NUM>, <NUM> and <NUM> of the airway system <NUM> for drawing air from the insulating space <NUM> of the vacuum insulated structure <NUM> via the porous tubing <NUM> can reduce the overall evacuation time of the vacuum insulated structure <NUM>. Evacuation time can be reduced from approximately <NUM> hours to reach an internal air pressure of 1mbar using a single evacuation site, to approximately <NUM> hour by providing better airflow AF and coverage within the insulating space <NUM> through an insulating or core material disposed therein.

As further shown in <FIG>, connector 54B further includes a second portion <NUM> which is connected to a first end <NUM> of support member 56B. The support member 56B further includes a second end <NUM> which abuts the inner surface <NUM> of first panel <NUM>. Thus, as shown in <FIG>, the support member 56B outwardly extends from the connector 54B across a width of the insulating space <NUM> to abut the inner surface <NUM> of the first panel <NUM>, while the connector 54B, as noted above, is coupled to the inner surface <NUM> of the second panel <NUM>. In this way, the configuration of the connector 54B and the support member 56B spans the width of the insulating space <NUM> of the vacuum insulated structure <NUM> to interconnect the inner walls (the inner surfaces <NUM>, <NUM> of the second and first panels <NUM>, <NUM>) to provide rigidity between the first and second panels <NUM>, <NUM> of the vacuum insulated structure <NUM> to counter bowing effects on the vacuum insulated structure <NUM> realized during evacuation of air from the vacuum insulated structure <NUM>. Thus, as air flows in the direction as indicated by arrows AF into the various portions of the airway system <NUM> disposed within the insulating space <NUM> of the vacuum insulated structure <NUM>, the interaction of the connector 54B and the outwardly extending support member 56B thereof will counteract the inwardly directed vacuum forces VF realized on the first and second panels <NUM>, <NUM> of the vacuum insulated structure <NUM> during the evacuation of the vacuum insulated structure <NUM> via the airway system <NUM>. The insulating space <NUM> defined between the first panel <NUM>, the second panel <NUM> and the trim breaker <NUM> may have an air pressure level of less than about <NUM> atm, about <NUM> atm, about <NUM> atm, about <NUM> atm, about <NUM> atm, about <NUM> atm, about <NUM> atm, or less than about <NUM> atm (<NUM> mbar) after a vacuum is drawn through the airway system <NUM> during an evacuation procedure. Such pressure provides the vacuum forces VF acting to draw the first and second panels <NUM>, <NUM> inwardly. Thus, the present concept provides a vacuum insulated structure <NUM> having an integrated stiffener via the configuration of the first body portion <NUM> and the raised second body portion <NUM> of the first panel <NUM>, as well as the plurality of support members, such as support member 56B shown in <FIG>, to counteract the vacuum forces VF as air is drawn from the insulating space <NUM> via the airway system <NUM>.

Further, it is contemplated that the support members 56A-56C (<FIG>) are comprised of a material having a low thermal conductivity, such as a nonconductive polymeric material. In this way, as the support members 56A-56C contact the metal bodies of the first and second panels <NUM>, <NUM>, heat is not transferred from the exterior wrapper (or second panel <NUM>) to the liner (or first panel <NUM>) of the vacuum insulated structure <NUM> as incorporated into a refrigerator, such as refrigerator <NUM> is shown in <FIG>. It is further contemplated that other support members and connector configurations, much like the support members 56A-56C shown in <FIG>, can be positioned at frequent intervals along the porous tubing <NUM> of the airway system <NUM> for providing better interconnection between the inner surfaces <NUM>, <NUM> of the second and first panels <NUM>, <NUM>, respectively.

Referring now to <FIG>, the vacuum insulated structure <NUM> is again shown with the first panel <NUM> coupled to the second panel <NUM>. As noted above, the first panel <NUM> and the second panel <NUM> may be interconnected by a trim breaker, such as trim breaker <NUM> shown in <FIG>. As further shown in <FIG>, the vacuum insulated structure <NUM> includes an airway system <NUM> disposed within the insulating space <NUM>. The airway system <NUM> is housed within the insulating space <NUM> between the first and second panels <NUM>, <NUM> and is contemplated to be fluidically coupled to an access aperture of either one of the first and second panels <NUM>, <NUM>, such as access aperture <NUM> of the first panel <NUM>. In assembly, the airway system <NUM> is contemplated to be coupled to the inner surface <NUM> (<FIG>) of the second panel <NUM> of the vacuum insulated structure <NUM>. In this way, the airway system <NUM> is contemplated to couple to an exterior wrapper of a vacuum insulated structure, however, it is also contemplated that the airway system <NUM> may be suspended within the insulating space <NUM>, and may also be coupled to the liner, or first panel <NUM> of the vacuum insulated structure <NUM>.

Referring now to <FIG>, the first and second panels <NUM>, <NUM> of the vacuum insulated structure <NUM> are shown in phantom to reveal the airway system <NUM> disposed within the insulating space <NUM>. With the first and second panels <NUM>, <NUM> shown in phantom, the specific features of the airway system <NUM> are revealed. In the embodiment shown in <FIG>, the airway system <NUM>, much like the airway system <NUM> shown in <FIG>, includes first and second vertical portions <NUM>, <NUM> and first, second and third horizontal portions <NUM>, <NUM> and <NUM> which interconnect the first and second vertical portions <NUM>, <NUM>. As noted above, the various portions of the airway system <NUM> shown in <FIG> are comprised of tubing <NUM> which is contemplated to be a porous or perforated tubing, such that air can be drawn from the insulating space <NUM> through the tubing <NUM> during an evacuation procedure of the vacuum insulated structure <NUM>.

As further shown in <FIG>, a plurality of connectors 54D, 54E and 92A-92C are used to interconnect portions of the tubing <NUM> of the airway system <NUM>. In the embodiment shown in <FIG>, connectors 90A-90C include respective support members 92A-92C which outwardly extend from the connectors 90A-90C to interconnect inner surfaces <NUM>, <NUM> of the first and second panels <NUM>, <NUM>, much like support members 56A-56C described above with reference to <FIG>. The support members 92A-92C define stiffeners between the first and second panels <NUM>, <NUM> and act to internally support the vacuum insulated structure <NUM> to combat the effects of vacuum bow on the vacuum insulated structure <NUM> when a vacuum is drawn on the insulating space <NUM> thereof. Connectors 90A-90C include first portions <NUM> coupled to the tubing <NUM> of the airway system <NUM>. The connectors 90A-90C further include second portions <NUM> which are configured to couple to the inner surface <NUM> of the second panel <NUM>. In this way, the airway system <NUM> is contemplated to couple to an inner surface of an exterior wrapper of a vacuum insulated structure. The second portions <NUM> of connectors 90A-90C are shown in the form of plates that are used to couple the airway system <NUM> to the inner surface <NUM> of the second panel <NUM>. As shown in <FIG>, connector 90B includes upper and lower plates 96A, 96B disposed on opposite sides of the first portion <NUM> of connector 90B. It is contemplated that any number of plates can be used to couple the airway system <NUM> to the inner surface <NUM> of the second panel <NUM>. With either of the support members 56A-56C or 92A-92C in place within the insulating space <NUM> of the vacuum insulated structure <NUM>, vacuum bowing can be significantly reduced or eliminated during an evacuation procedure. The stiffened first panel <NUM> can reduce vacuum bowing to approximately <NUM> or less.

Claim 1:
A vacuum insulated structure (<NUM>), comprising:
a first panel (<NUM>) having inner and outer surfaces (<NUM>, <NUM>);
a second panel (<NUM>) having inner and outer surfaces (<NUM>, <NUM>), wherein the second panel (<NUM>) is operably coupled to the first panel (<NUM>) to define an insulating space (<NUM>) therebetween; and
an airway system (<NUM>) disposed within the insulating space (<NUM>), wherein the airway system (<NUM>) includes portions (<NUM>, <NUM>, <NUM>, <NUM> and <NUM>) of porous tubing (<NUM>) configured to draw air along lengths of the portions (<NUM>, <NUM>, <NUM>, <NUM> and <NUM>) of porous tubing (<NUM>) from the insulating space (<NUM>) during an evacuation procedure,
characterised in that the vacuum insulated structure (<NUM>) includes a plurality of connectors (54A-54C) interconnecting the portions (<NUM>, <NUM>, <NUM>, <NUM> and <NUM>) of porous tubing (<NUM>) of the airway system (<NUM>) with the inner surface (<NUM>) of the second panel (<NUM>),
wherein each connector (54A-54C) of the plurality of connectors (54A-54C) is coupled to the inner surface (<NUM>) of the second panel (<NUM>),
wherein each connector (54A-54C) of the plurality of connectors (54A-54C) includes a support member (56A-56C) outwardly extending therefrom, and
wherein each support member (56A-56C) extends across the insulating space (<NUM>) and abuts the inner surface (<NUM>) of the first panel (<NUM>).