Method of making a folded vacuum insulated structure
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
F25D-023/06
F25D-023/02
F25B-039/00
F25D-011/00
B29C-053/00
H04R-003/12
B23P-015/26
F25B-039/02
F25C-001/00
출원번호
US-0635313
(2015-03-02)
등록번호
US-9874394
(2018-01-23)
발명자
/ 주소
Cur, Nihat
Ramm, Axel Julio
Wu, Guolian
Kendall, James
출원인 / 주소
Whirlpool Corporation
대리인 / 주소
Price Heneveld LLP
인용정보
피인용 횟수 :
0인용 특허 :
167
초록▼
A vacuum insulated cabinet structure includes panels having sheet metal outer side walls and polymer inner side walls. The polymer inner side walls are heat-sealed to a layer of polymer material laminated to a flat sheet metal blank to form vacuum cavities. The blank is then bent along fold lines to
A vacuum insulated cabinet structure includes panels having sheet metal outer side walls and polymer inner side walls. The polymer inner side walls are heat-sealed to a layer of polymer material laminated to a flat sheet metal blank to form vacuum cavities. The blank is then bent along fold lines to form a cabinet structure.
대표청구항▼
1. A method of fabricating a vacuum insulated cabinet structure, the method comprising: providing a first sheet of material, the first sheet comprising a metal layer and a thermoplastic polymer material, wherein the metal layer has sufficient stiffness to form a self-supporting freestanding cabinet
1. A method of fabricating a vacuum insulated cabinet structure, the method comprising: providing a first sheet of material, the first sheet comprising a metal layer and a thermoplastic polymer material, wherein the metal layer has sufficient stiffness to form a self-supporting freestanding cabinet structure when deformed;providing a second sheet of material, the second sheet comprising a barrier layer capable of maintaining a vacuum;positioning porous filler material between the first and second sheets;sealing the first and second sheets together around the porous filler material to form an airtight space containing the porous filler material. 2. The method of claim 1, including: providing a vacuum in the airtight space; andbending the first sheet of material to form a vacuum insulated cabinet structure. 3. A method of fabricating a vacuum insulated cabinet structure, the method comprising: providing a first sheet of material, the first sheet comprising a metal layer and a thermoplastic polymer material on a first side of the first sheet, wherein the metal layer has sufficient stiffness to form a self-supporting freestanding cabinet structure when deformed;providing a second sheet of material, the second sheet comprising a barrier layer capable of maintaining a vacuum;providing a plurality of pouches having porous filler material disposed in the pouches;positioning the pouches between the first and second sheets;sealing the first and second sheets together to form a seal line that extends around the pouches to form an airtight space containing the pouches;providing a vacuum in the airtight space;bending the first sheet of material to form a vacuum insulated cabinet structure. 4. A method of fabricating a vacuum insulated cabinet structure, the method comprising: providing a first sheet of material, the first sheet comprising a metal layer and a thermoplastic polymer material on a first side of the first sheet, wherein the metal layer has sufficient stiffness to form a self-supporting freestanding cabinet structure when deformed;providing a second sheet of material, the second sheet comprising a barrier layer capable of maintaining a vacuum;positioning porous filler material between the first and second sheets;sealing the first and second sheets together around the porous filler material to form an airtight space containing the porous filler material;providing a vacuum in the airtight space;bending the first sheet of material to form a vacuum insulated cabinet structure. 5. The method of claim 4, wherein: the first and second sheets are sealed together in a vacuum chamber. 6. The method of claim 4, wherein: the first and second sheets are sealed together utilizing a heat sealing process that includes heating at least one of the first and second sheets of material to form a seal line that extends around the porous filler material. 7. The method of claim 4, wherein: the second sheet comprises at least first and second layers, the first layer comprising thermoplastic material, the second layer comprising polymer material that forms a barrier with respect to at least one of oxygen, nitrogen, and water vapor; andthe porous filler material is disposed in a plurality of pouches that are positioned between the first and second sheets prior to sealing the first and second sheets together. 8. The method of claim 4, including: thermoforming the second sheet of material to define a retaining structure that includes a generally planar central sidewall portion having a perimeter, and edge sidewall portions extending transversely from the perimeter, the retain structure further including a peripheral edge flange including outwardly from the edge sidewall portions. 9. The method of claim 8, including: positioning the peripheral edge flange in contact with the thermoplastic polymer material of the first sheet; andheat-sealing the peripheral edge flange to the thermoplastic polymer material. 10. The method of claim 6, including: forming a second airtight space between the first and second sheets of material, wherein at least one seal line extends between the two airtight spaces;bending the first sheet of material in an area between the two airtight spaces. 11. The method of claim 10, including: forming a third air-tight space between the first and second sheets of material;bending the first sheet of material to a structure define at least three generally planar sidewalls. 12. The method of claim 11, wherein: the three panel sidewalls define spaced apart upright sidewalk and a horizontal upper wall extending between the side walls; and including:forming a floor structure that extends between and interconnects the upright sidewalls;securing a rear panel to the upright sidewalls, the horizontal upper wall, and the floor structure to form a primary cabinet structure that defines a forwardly-opening compartment. 13. The method of claim 12, including: forming a polymer liner;positioning the polymer liner in the compartment; andproviding a thermosetting foam insulating material between the polymer liner and the primary cabinet structure. 14. The method of claim 4, wherein: the vacuum insulated cabinet structure comprises an insulated refrigerator cabinet structure. 15. The method of claim 4, wherein: the metal layer comprises low carbon steel; andthe thermoplastic polymer material is laminated to the metal layer. 16. The method of claim 4, wherein: providing a vacuum in the airtight space includes positioning the first and second sheets of material and the porous filler material in a vacuum chamber prior to sealing the first and second sheets together. 17. The method of claim 4, wherein: providing a vacuum comprising forming a vacuum in the airtight space occurs prior to bending the first sheet of material to form a vacuum insulated cabinet structure. 18. The method of claim 4, wherein: the porous filler material is disposed in a plurality of individual pouches that are positioned on the first side of the first sheet prior to sealing the first and second sheets together. 19. The method of claim 4, wherein: the first sheet of material forms an outer cabinet skin blank, the blank including an elongated portion having a generally rectangular perimeter with elongated side edges and end edges extending between the side edges, the blank defining a plurality of bend lines extending between the side edges to define a plurality of generally planar panel regions; andbending the cabinet skin blank along the bend lines to form a vacuum insulated cabinet structure having upright outer sidewalls and a transverse wall extending between the outer sidewalls. 20. The method of claim 4, including: movably mounting a door to the vacuum insulated cabinet structure; andconnecting an electrically powered cooling system to the vacuum insulated cabinet structure to cool an interior space thereof.
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