[특허]Folding approach to create a 3D vacuum insulated door from 2D flat vacuum insulation panels

Whirlpool Corporation

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Folding approach to create a 3D vacuum insulated door from 2D flat vacuum insulation panels

국가/구분	United States(US) Patent 등록
국제특허분류(IPC7판)	F25D-023/02
출원번호	US-0187622 (2014-02-24)
등록번호	US-9599392 (2017-03-21)
발명자 / 주소	Wu, Guolian
출원인 / 주소	Whirlpool Corporation
인용정보	피인용 횟수 : 0 인용 특허 : 109

초록

An appliance door includes a vacuum insulated structure having a plurality of core sections that are folded to form an ice and/or water dispensing cavity on an outer side of the appliance door. The vacuum insulated door structure may be positioned between an outer door member and a door liner.

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1. A method of making a vacuum insulated appliance door having an outwardly opening dispensing cavity for dispensing ice and/or liquid water, the method comprising: providing a first core material board corresponding to an upright lower portion of an appliance door below a dispensing cavity of an appliance door;providing a second core material board corresponding to an inwardly extending lower side of a dispensing cavity of an appliance door;providing third and fourth core material boards corresponding to upright opposite sides of a dispensing cavity of an appliance door;providing a fifth core material board corresponding to an upright inner side of a dispensing cavity of an appliance door;providing a sixth core material board corresponding to an inwardly extending upper side of a dispensing cavity of an appliance door, wherein the sixth core material board has an opening therethrough;providing a seventh core material board corresponding to an upright upper portion of an appliance door above a dispensing cavity of an appliance door;positioning the first, second, third, fourth, fifth, sixth, and seventh core material boards adjacent one another inside an envelope formed from substantially impermeable barrier material to form a generally flat subassembly, wherein the envelope has at least one opening;positioning the generally flat subassembly in a vacuum chamber;forming a vacuum in the vacuum chamber;sealing the opening of the envelope in the vacuum chamber;removing the generally flat subassembly from the vacuum chamber;folding the first and second core material boards relative to one another;folding the third core material board relative to a selected one of the second and fifth core material boards;folding the fourth core material board relative to a selected one of the second and fifth core material boards;folding the fifth and sixth core material boards relative to one another;folding the sixth and seventh core material boards relative to one another;wherein the folded core material boards form a three dimensional vacuum insulated structure having a dispensing cavity defined by the second, third, fourth, fifth, and sixth core material boards, an upright lower portion below the dispensing cavity defined by the first core material board, and an upright upper portion above the dispensing cavity defined by the seventh core material board;positioning an ice and/or water dispensing unit adjacent the sixth core material board whereby, in use, ice and/or water from the dispensing unit travels downwardly through the opening through the sixth core material board;providing an outer door skin;providing a door liner;positioning the three dimensional vacuum insulated structure between the outer door skin and the door liner; andconnecting the outer door skin to the door liner to form an appliance door. 2. The method claim 1, wherein: the first, second, fifth, sixth, and seventh core material boards are disposed in a row prior to positioning the generally flat subassembly in a vacuum chamber. 3. The method of claim 2, wherein: the third and fourth core material boards are positioned on opposite sides of the row prior to positioning the generally flat subassembly in a vacuum chamber. 4. The method of claim 3, including: foldably interconnecting the first and second core material boards along a first fold line;foldably interconnecting the second and fifth core material boards along a second fold line that is generally parallel to the first fold line;foldably interconnecting the fifth and sixth core material boards along a third fold line that is generally parallel to the first and second fold lines; andfoldably interconnecting the sixth and seventh core material boards along a fourth fold line that is generally parallel to the first, second, and third fold lines. 5. The method of claim 4, including: foldably interconnecting the fifth and third core material boards along a fifth fold line that is transverse relative to the third fold line; andfoldably interconnecting the fifth and fourth core material boards along a sixth fold line that is transverse relative to the third fold line. 6. The method of claim 5, wherein: the first, second, third, fourth, fifth, and sixth fold lines comprise V-shaped grooves formed in edge portions of the core material boards. 7. The method of claim 6, wherein: the first, second, third, fourth, fifth, sixth, and seventh core material boards are formed from a single piece of core material board by pressing a V-shaped forming tool into the single pieces of core material board to form V-shaped grooves defining the fold lines. 8. The method of claim 1, wherein: the opening through the sixth core material board comprises an elongated U-shaped slot having an open edge portion that opens along a side edge of the sixth core material board prior to folding the core material boards to form the three dimensional vacuum insulated structure. 9. The method of claim 8, wherein: folding the core material boards includes positioning an edge of either the third or fourth core material boards such that it extends across the open edge portion of the elongated U-shaped slot. 10. The method of claim 1, wherein: the opening through the sixth core material board comprises a generally circular aperture through the sixth core material board. 11. The method of claim 1, wherein: folding the core material boards includes positioning the fifth core material board at a right angle relative to the sixth core material board and positioning the seventh core material board at a right angle relative to the sixth core material board. 12. The method of claim 11, wherein: folding the core material boards includes positioning the third and fourth core material boards transversely relative to the fifth core material board. 13. The method of claim 12, wherein: folding the core material boards includes positioning the second core material board at an angle in a range of about one hundred and ten degrees to about one hundred and sixty degrees relative to the first core material board. 14. The method of claim 13, including: forming an open seam between the second core material board and the third core material board that is defined by open edge portions of the second and third core material boards prior to folding the core material boards;forming an open seam between the second core material board and the fourth core material board that is defined by open edge portions of the second and fourth core material boards prior to folding the core material boards;positioning the open edge portions of the second and third core material boards directly adjacent one another by folding the second and third material boards directly adjacent one another by folding the second and third core material boards relative to the fifth core material board; andpositioning the open edge portions of the second and fourth core material boards directly adjacent one another by folding the second and fourth core material boards relative to the fifth core material board. 15. A method of making a vacuum insulated appliance door having an outwardly opening dispensing cavity for dispensing ice and/or liquid water, the method comprising: providing a plurality of core material boards;positioning the plurality of core material boards in an envelope defining an inside and having at least one opening to the inside, the envelope comprising substantially impermeable barrier material, whereby the core material boards and the envelope form a generally flat subassembly;foldably interconnecting each core material board to at least one adjacent core material board along a fold line;forming a vacuum around the generally flat subassembly in a vacuum to evacuate the inside of the envelope;sealing the at least one opening of the envelope;folding the core material boards relative to one another to form a three dimensional vacuum insulated structure having a dispensing cavity with an opening and five sides defined by core material boards, the three dimensional vacuum insulated structure further including upright lower and upper portions below and above, respectively, the opening of the dispensing cavity;positioning the three dimensional vacuum insulated structure between a door liner and an outer door skin;forming an access opening through at least one of the core material boards, defining the dispensing cavity; andpositioning the dispensing unit that dispenses at least ice and/or liquid water above the dispensing cavity whereby ice and/or liquid water from the dispensing unit travels through the access opening into the dispensing cavity. 16. The method of claim 15, wherein: providing a plurality of core material boards comprises providing seven core material boards, and wherein:the generally flat subassembly includes five of the core material boards that are positioned adjacent one another to form a row, and two of the core material boards are positioned on opposite sides of the row. 17. The method of claim 16, wherein: the row comprises first, second, third, fifth, sixth and seventh core material boards, and wherein the two core material boards positioned on opposite sides of the row comprise third and fourth core material boards; and wherein;the first and second core material boards are foldably interconnected along a fold line, the second and third core material boards are foldably interconnected along a fold line, the third and fourth core material boards are foldably interconnected along a fold line, the fourth and fifth core material boards are foldably interconnected along a fold line, the fifth and sixth core material boards are foldably interconnected along a fold line, and the sixth and seventh core material boards are foldably interconnected along a fold line. 18. The method of claim 17, wherein: the third and fifth core material boards are foldably interconnected along a fold line, and the fourth and fifth core material boards are foldably interconnected along a fold line. 19. The method of claim 15, including: positioning at least one preformed spacer between the three dimensional vacuum insulated structure and the outer door skin. 20. The method of claim 15, wherein: the fold lines comprise V-shaped grooves that are formed by pressing a V-shaped forming tool into a surface of a sheet of core material board.

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Folding approach to create a 3D vacuum insulated door from 2D flat vacuum insulation panels

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Folding approach to create a 3D vacuum insulated door from 2D flat vacuum insulation panels

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이 특허에 인용된 특허 (109)

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