Patent Description:
The invention is defined by the features of independent claim <NUM>. A vacuum insulated structure includes a wrapper that has a bottom surface. A liner is operably coupled to the wrapper and defines an insulation cavity that includes materials. A machine compartment is at least partially defined by the wrapper. A base plate is operably coupled to the bottom surface of the wrapper proximate the machine compartment. Base rails are operably coupled to the base plate and at least partially defines the machine compartment. Each of the base rails include attachment flanges and a mounting wall. A machine plate is operably coupled to the base rails and define a lower portion of the machine compartment.

An insulated structure for an appliance includes a wrapper. A liner is operably coupled to the wrapper. A base plate has a first surface and a second surface. The base plate is operably coupled to the wrapper via the first surface and is configured to distribute a load of the wrapper and the liner. Base rails are operably coupled to the second surface of the base plate. Each of the base rails include a first attachment flange, a second attachment flange, and a mounting wall. A machine compartment is defined by the wrapper and the base rails proximate to the base plate. A machine plate is operably coupled to the first attachment flange and the second attachment flange of each of the base rails and define a lower portion of the machine compartment.

A support assembly for a vacuum insulated structure includes a base plate that has a perimeter support surface and centrally defines an aperture. The base plate includes fasteners that extend outwardly from the base plate. Base rails each include a support body that has a first attachment flange, a second attachment flange, and a mounting wall that is operably coupled to the support body. The first attachment flange and the second attachment flange operably couple each of the base rails to the base plate. A front plate is operably coupled to the mounting wall of each of the base rails. A machine plate is operably coupled to each of the first attachment flange and the second attachment flange of each of the base rails proximate to the base plate.

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

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 to <FIG>, reference numeral <NUM> generally designates a vacuum insulated structure that includes a wrapper <NUM>. The wrapper <NUM> has a bottom surface <NUM>, and a liner <NUM> is operably coupled to the wrapper <NUM>. The liner <NUM> defines an insulation cavity <NUM> that includes insulation materials <NUM>. A machine compartment <NUM> is at least partially defined by the wrapper <NUM>. A base plate <NUM> is operably coupled to the bottom surface <NUM> of the wrapper <NUM> proximate to the machine compartment <NUM>. Base rails <NUM> are operably coupled to the base plate <NUM>. The base rails <NUM> at least partially define the machine compartment <NUM>, and each of the base rails <NUM> includes attachment flanges <NUM> and a mounting wall <NUM>. A machine plate <NUM> is operably coupled to the base rails <NUM> and defines a lower portion <NUM> of the machine compartment <NUM>.

Referring to <FIG>, the vacuum insulated structure <NUM> is illustrated as being part of a refrigerating appliance <NUM>, but it is also contemplated that the vacuum insulated structure <NUM> described herein may be used with a variety of appliances. The refrigerating appliance <NUM>, referred to as the appliance herein, is illustrated as a built-in appliance, such that a rear wall <NUM> and sidewalls <NUM> of the wrapper <NUM> may be generally exposed. The appliance <NUM> includes first and second doors <NUM>, <NUM> operably coupled to the appliance <NUM> via hinges <NUM>, described further below. It is generally contemplated that the wrapper <NUM> and the liner <NUM> generally form a cabinet <NUM>, which may define the vacuum insulated structure <NUM>. The wrapper <NUM> and the liner <NUM> may be formed from metals, polymers, metal alloys, combinations thereof, and other suitably rigid materials that can be used for vacuum insulated structures within appliances. The cabinet <NUM> defined by the wrapper <NUM> and the liner <NUM> may incorporate the vacuum insulated structure <NUM>, such that the cabinet <NUM> is equivalent to the vacuum insulated structure <NUM>. Stated differently, the cabinet <NUM> may be an insulated structure that incorporates the insulation materials <NUM> as described above.

The liner <NUM> and the wrapper <NUM> are typically coupled to a trim breaker <NUM> to form the vacuum insulated structure <NUM>. It is generally contemplated that the trim breaker <NUM> may be formed from glass, plastic, metal, or other materials suitable for retaining a vacuum defined between the wrapper <NUM> and the liner <NUM> within the insulation cavity <NUM>. It is also contemplated that the liner <NUM> and the wrapper <NUM> are operably coupled to the trim breaker <NUM> via an adhesive material that may be configured with materials, such as glass or other generally insulating materials, to minimize outgassing of the insulation cavity <NUM>. The liner <NUM> and the wrapper <NUM> also define the insulation cavity <NUM> therebetween in which one or more of the insulation materials <NUM> may be disposed. It is generally contemplated that the insulation materials <NUM> may be a glass type material, a carbon-based powder, silicone oxide-based materials, insulating gases, and other standard insulation materials <NUM> known in the art. The insulation materials <NUM> substantially fill the insulation cavity <NUM> to form a substantially continuous layer between the liner <NUM> and the wrapper <NUM>. The insulation cavity <NUM> is evacuated to define the vacuum insulated structure <NUM>.

With further reference to <FIG>, holes <NUM> are defined by the wrapper <NUM> and the liner <NUM> to provide a passage for electrical wiring <NUM> and other typical appliance lines <NUM>. For example, when the appliance <NUM> is a refrigerator and/or freezer, the appliance lines <NUM> configured to direct water are connected to the appliance <NUM> and may pass through the holes <NUM> toward the machine compartment <NUM>, described further below. Typically, the openings <NUM> are defined along at least the rear wall <NUM> of the wrapper <NUM>. The holes <NUM> may also be defined by a rear panel <NUM> of the liner <NUM>, which is disposed within the wrapper <NUM> to define the vacuum insulated structure <NUM>, as mentioned above. The liner <NUM> also defines at least one opening <NUM> that may correspond to an appliance compartment. By way of example, not limitation, the at least one opening <NUM> can include a first opening <NUM> that corresponds to a refrigeration compartment and a second opening <NUM> that corresponds to a freezer compartment with a mullion <NUM> disposed therebetween. In such configuration, the liner <NUM> is generally divided, at least in part, by the mullion <NUM> to define the first and second openings <NUM>, <NUM>. For purposes of this disclosure, the first and second openings <NUM>, <NUM> are illustrated as being divided by a vertically oriented mullion <NUM>, such that the depicted appliance <NUM> is a side-by-side appliance <NUM>. It is also contemplated that other configurations of the appliance <NUM> are contemplated including, but not limited to, a stacked configuration.

Referring still to <FIG>, the refrigeration compartment <NUM> may include an illumination feature <NUM> operably coupled to a reed switch <NUM>. The reed switch <NUM> is communicatively coupled to the first door <NUM>, such that when the first door <NUM> is in an open position the reed switch <NUM> activates the illumination feature <NUM> to distribute light within the refrigeration compartment <NUM>. The reed switch <NUM> is operably coupled to a front plate <NUM>, which is operably coupled to the base rails <NUM>, described further below. The reed switch <NUM> is disposed within a gap <NUM> defined between the base rails <NUM>. The base rails <NUM> include a first rail <NUM> and a second rail <NUM>, which may be collectively referred to as the base rails <NUM>, described in more detail below. The front plate <NUM> is coupled to the mounting wall <NUM> of each of the base rails <NUM> and conceals the gap <NUM> defined between the base rails <NUM>.

With reference now to <FIG> the first and second doors <NUM>, <NUM> are also operably coupled to the mounting walls <NUM> of the base rails <NUM> via the hinges <NUM> coupled to the front plate <NUM>. The nature of the vacuum insulated structure <NUM> defined by the wrapper <NUM> and the liner <NUM> is such that the wrapper <NUM> and the liner <NUM> remain free from penetration or direct attachment with other features of the appliance <NUM>. For example, the doors <NUM>, <NUM> are instead coupled to the vacuum insulated structure <NUM> via the front plate <NUM> coupled to the base rails <NUM> and via a top plate <NUM> coupled to the top surface <NUM> of the wrapper <NUM>. Stated differently, the vacuum defined within the insulation cavity <NUM> is maintained through the coupling of the doors <NUM>, <NUM> to the front plate <NUM> and the top plate <NUM>. The top plate <NUM> can be spot welded to a top surface <NUM> of the wrapper <NUM> to minimize potential contact between the top surface <NUM> of the wrapper <NUM> and the hinges <NUM> to mount the doors <NUM>, <NUM>. The placement of the hinges <NUM> on the top plate <NUM> and the front plate <NUM> minimize the strain placed upon the vacuum insulated structure <NUM> as the doors <NUM>, <NUM> are instead coupled to the top plate <NUM> and the base plate <NUM> via the base rails <NUM> and front plate <NUM>.

The base rails <NUM>, as mentioned above, include the attachment flanges <NUM> and the mounting wall <NUM> to which the front plate <NUM> is coupled. The base rails <NUM> each include a support body <NUM> from which the attachment flanges <NUM> extend and to which the mounting wall <NUM> is coupled. The support body <NUM> includes a bottom portion <NUM> from which the mounting wall <NUM> and parallel side portions <NUM> extend. The attachment flanges <NUM> are coupled to and generally extend from the side portions <NUM>. The attachment flanges <NUM> include a first attachment flange <NUM> and a second attachment flange <NUM>. The first attachment flange <NUM> extends medially toward a center <NUM> of the support body <NUM>, and the second attachment flange <NUM> extends laterally away from the support body <NUM>. For example, the second attachment flange <NUM> of the first rail <NUM> extends toward the second attachment flange <NUM> of the second rail <NUM>. Stated differently, the first attachment flange <NUM> extends toward the second attachment flange <NUM>, and the second attachment flange <NUM> extends away from the first attachment flange <NUM>. Additionally or alternatively, the first and second attachment flanges <NUM>, <NUM> may each extend laterally and/or medially relative to the support body <NUM> of each base rail <NUM>.

With further reference to <FIG>, each of the base rails <NUM> define a front portion <NUM> and a rear portion <NUM>, such that the base plate <NUM> is operably coupled to the front portion <NUM> of the base rails <NUM>. The machine plate <NUM> is coupled to the rear portion <NUM> to at least partially define the lower portion <NUM> of the machine compartment <NUM>, described further below. The base plate <NUM> is coupled to the first and second attachment flanges <NUM>, <NUM> via spot welding of a plurality of fasteners <NUM>, described below. The plurality of fasteners <NUM> extend through apertures <NUM> defined by the attachment flanges <NUM>. The plurality of fasteners <NUM> couple the base plate <NUM> to the front portion <NUM> of the base rails <NUM>, and the machine plate <NUM> is coupled to the rear portion <NUM> to define the lower portion <NUM> of the machine compartment <NUM>, described below.

Referring now to <FIG> and as mentioned above, the wrapper <NUM> includes the sidewalls <NUM>, the top and bottom surfaces <NUM>, <NUM>, and the rear wall <NUM>. The rear wall <NUM> of the wrapper <NUM> defines a curved surface <NUM> to at least partially define the machine compartment <NUM>. The bottom surface <NUM> of the wrapper <NUM> is operably coupled to the base plate <NUM>, described further below. The machine compartment <NUM> is defined by the curved surface <NUM> of the wrapper <NUM> along with the base rails <NUM> and the machine plate <NUM>. It is generally contemplated that machine components <NUM> are positioned on the machine plate <NUM> within the machine compartment <NUM> beneath the rear wall <NUM> and proximate to the curved surface <NUM> of the wrapper <NUM>. For example, the machine components <NUM> may include, but are not limited to, a compressor <NUM>, a fan <NUM>, and an evaporator <NUM>. The machine components <NUM> define a collective load L<NUM> on the machine plate <NUM>, which is generally dispersed across the machine plate <NUM> and the base rails <NUM>, described further below. The load L<NUM> is also dispersed and supported by the connection of the base rails <NUM> to the base plate <NUM>.

The machine plate <NUM> is configured to support the machine components <NUM> within the machine compartment <NUM> and can be positioned over and coupled to the base rails <NUM>. As mentioned above, the gap <NUM> is defined between the first and second base rails <NUM>, <NUM> and the machine plate <NUM> may at least partially conceal the gap <NUM> defined between the first and second base rails <NUM>, <NUM>. As mentioned above, the gap <NUM> may provide passage for the electrical wiring <NUM> and/or appliance lines <NUM> of the appliance <NUM>. The gap <NUM> may also provide passage for the electrical wiring <NUM> and other connection lines of the machine components <NUM> to pass between the machine plate <NUM> and the curved surface <NUM> and within the gap <NUM>.

As mentioned above, the machine components <NUM> generally exert the load L<NUM> upon the machine plate <NUM> based on the gravitational pull on the machine components <NUM>. It is generally contemplated that the load L<NUM> defined by the machine components <NUM> may account for approximately <NUM>- to <NUM>-percent of the overall weight of the appliance <NUM>. The machine plate <NUM> is configured to evenly distribute the load L<NUM> of the machine components <NUM> to the base rails <NUM>. The machine plate <NUM> can be coupled to the base rails <NUM> via spot welding to fixedly couple the machine plate <NUM> with the base rails <NUM>. It is also contemplated that the machine plate <NUM> can be coupled to the base rails <NUM> via fasteners, adhesives, screws, or other coupling methods generally known. The load L<NUM> of the machine components <NUM> is ultimately dispersed along the base rails <NUM> to minimize the engagement and stress placed upon the vacuum insulated structure <NUM>, as described further below. The base rails <NUM> may engage the base plate <NUM> in offsetting the load L<NUM> applied by the machine components <NUM>. The base rails <NUM> are operably coupled to the base plate <NUM> via the plurality of fasteners <NUM>, mentioned above.

Referring still to <FIG>, the wrapper <NUM> is positioned on and coupled to the base plate <NUM>, which structurally supports the machine components <NUM> as well as the appliance <NUM> as a whole. The base plate <NUM> has a first surface <NUM> and a second surface <NUM>, such that the first surface <NUM> defines a perimeter support surface <NUM> of the base plate <NUM>. The first surface <NUM> may be defined as an engagement surface, as the first surface <NUM> is configured to engage and support the insulated structure <NUM>. An aperture <NUM> can be defined in a central portion <NUM> of the base plate <NUM>, described further below. The second surface <NUM> defines a plurality of recesses <NUM> that are configured to receive the plurality of fasteners <NUM>, described below.

The perimeter support surface <NUM> of the first surface <NUM> supports the vacuum insulated structure <NUM> above the base rails <NUM>, and the base plate <NUM> is operably coupled to the bottom surface <NUM> of the wrapper <NUM> via the perimeter support surface <NUM>. The base plate <NUM> generally provides added structural base support for the appliance <NUM> by supporting at least a load L<NUM> of the liner <NUM> and the wrapper <NUM>. It is also contemplated that the base plate <NUM> supports the load L<NUM> of the machine components <NUM> within the machine compartment <NUM> through the coupled engagement with the base rails <NUM>. The second surface <NUM> of the base plate <NUM> may be referred to as an attachment surface, as the second surface <NUM> is configured to couple the base plate <NUM> to the base rails <NUM> via the plurality of fasteners <NUM>, described below.

Referring still to <FIG>, the base plate <NUM> is illustrated as defining the aperture <NUM> in the central portion <NUM> of the base plate <NUM>. A rib <NUM> may be defined along the bottom surface <NUM> of the wrapper <NUM> that can be at least partially disposed within the aperture <NUM> defined by the base plate <NUM>. The rib <NUM> may assist in redistributing the load L<NUM> to the base plate <NUM> through lateral engagement with the base plate <NUM> within the aperture <NUM>. The incorporation of the aperture <NUM> may provide advantageous cost benefits during manufacturing of the appliance <NUM>. Additionally or alternatively, the base plate <NUM> can be a single piece of material extending along the bottom surface <NUM> of the wrapper <NUM>. It is generally contemplated that the base plate <NUM> may be formed from metal. It is also contemplated that the base plate <NUM> may be formed from a rigid plastic, composite material, or other practicable materials for supporting the loads L<NUM>, L<NUM> of the machine components <NUM> and the liner <NUM> and the wrapper <NUM>, respectively.

As illustrated in <FIG> and <FIG>, the base plate <NUM> at least partially extends over the gap <NUM> defined between the base rails <NUM>. The extension of the base plate <NUM> across the gap <NUM> structurally supports the vacuum insulated structure <NUM> along the bottom surface <NUM> of the wrapper <NUM>. The base rails <NUM> assist in structurally supporting the vacuum insulated structure <NUM>, and the base plate <NUM> extending over the gap <NUM> assists in supporting a front edge <NUM> and a rear edge <NUM> of the vacuum insulated structure <NUM>.

The base plate <NUM> is operably coupled to the base rails <NUM> along the second surface <NUM>. The plurality of fasteners <NUM> extend from the recesses <NUM> defined by the second surface <NUM> to couple to the attachment flanges <NUM> of the base rails <NUM> to the base plate <NUM>. As mentioned above, the base rails <NUM> are positioned proximate to the sidewalls <NUM> of the wrapper <NUM> and coupled to the base plate <NUM>. The base rails <NUM> may at least partially extend beyond the curved surface <NUM> of the wrapper <NUM> to lie substantially perpendicular with the rear wall <NUM> of the wrapper <NUM>. As mentioned above, the base rails <NUM> are coupled to the machine plate <NUM> and are configured to assist in distributing the load L<NUM> of the machine components <NUM> from the machine plate <NUM> along each of the base rails <NUM>. The base rails <NUM> may engage the base plate <NUM> in redistributing the load L<NUM> of the machine components <NUM>. The base plate <NUM> may cooperate with the base rails <NUM> to balance the loads L<NUM>, L<NUM> of the machine components <NUM> and the vacuum insulated structure <NUM>, respectively.

Referring again to <FIG>, the base plate <NUM> and the base rails <NUM> are configured to assist in overall load distribution of the appliance <NUM> to minimize the forces acting upon the vacuum insulated structure <NUM>. The load bearing configuration of the base plate <NUM> and the base rails <NUM> minimizes the strain placed on the bottom surface <NUM> of the wrapper <NUM>, which minimizes potential for outgassing via lapse in structural integrity that may otherwise occur. The base plate <NUM> is spot welded along the first surface <NUM> to the bottom surface <NUM> of the wrapper <NUM> to avoid penetrating the wrapper <NUM>. Further, the plurality of fasteners <NUM> are welded to the second surface <NUM> within the recesses <NUM> defined along the second surface <NUM> and then coupled to each of the base rails <NUM>. The attachment flanges <NUM> of the base rails <NUM> assist in coupling the base rails <NUM> to the base plate <NUM> with minimal additional structural configuration of the support body <NUM>, which helps to minimize overall production and manufacturing costs.

In addition, the mounting walls <NUM> assist in attachment of the front plate <NUM> and, ultimately, the doors <NUM>, <NUM> to the appliance <NUM> while leaving the vacuum insulated structure <NUM> free from penetration. The front plate <NUM> can be coupled directly to the base rails <NUM> via the mounting wall <NUM>, such that the vacuum insulated structure <NUM> can remain free from penetration by attachment features, such as the hinges <NUM>. The gap <NUM> assists in placement of the reed switch <NUM> within the gap <NUM> behind the front plate <NUM> as well as room for other appliance lines <NUM> to be positioned beneath the vacuum insulated structure <NUM> between the base rails <NUM>. The front plate <NUM> also assists in covering and concealing the gap <NUM> defined between the first and second rails <NUM>, <NUM>. The concealment of the gap <NUM> by the front plate <NUM> minimizes the potential for items to be positioned beneath the appliance <NUM> within the gap <NUM>. For example, the front plate <NUM> blocks items from being kicked or otherwise repositioned beneath the appliance <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.

Claim 1:
An insulated structure (<NUM>), comprising:
a wrapper (<NUM>) having a top surface (<NUM>) and a bottom surface (<NUM>);
a liner (<NUM>) operably coupled to the wrapper (<NUM>) and defining an insulation cavity (<NUM>) that includes insulation materials (<NUM>);
a machine compartment (<NUM>) at least partially defined by the wrapper (<NUM>);
a base plate (<NUM>) operably coupled to the bottom surface (<NUM>) of the wrapper (<NUM>) proximate the machine compartment (<NUM>);
base rails (<NUM>, <NUM>, <NUM>) operably coupled to the base plate (<NUM>) and at least partially defining the machine compartment (<NUM>), each of the base rails (<NUM>, <NUM>, <NUM>) including attachment flanges (<NUM>, <NUM>, <NUM>) and a mounting wall (<NUM>), and
a machine plate (<NUM>) operably coupled to the base rails (<NUM>, <NUM>, <NUM>) and defining a lower portion (<NUM>) of the machine compartment (<NUM>),
wherein the base rails (<NUM>) each include a support body (<NUM>) from which the attachment flanges (<NUM>) extend and to which the mounting wall (<NUM>) is coupled,
wherein the attachment flanges (<NUM>) include a first attachment flange (<NUM>) and a second attachment flange (<NUM>) and
wherein the support body (<NUM>) includes a bottom portion (<NUM>) from which the mounting wall (<NUM>) and parallel side portions (<NUM>) extend,
characterised in that the attachment flanges (<NUM>) are coupled to and extend from the side portions (<NUM>),
wherein the first attachment flange (<NUM>) extends medially toward a center (<NUM>) of the support body (<NUM>),
wherein the second attachment flange (<NUM>) extends laterally away from the support body (<NUM>) and
wherein the insulated structure is a vacuum insulated structure (<NUM>).