Insulation compaction device and method for forming an insulated structure for an appliance

An insulation compaction device for installing insulation within an insulating structure of an appliance, the insulation compaction device comprising:

• an outer wrapper and an inner liner that are attached together to define the insulating structure having an insulating cavity defined therein, at least one of the outer wrapper and the inner liner including a compression panel that defines a pressing surface having reinforcing structures;
• an insulating media disposed within the insulating cavity;
• an operable piston selectively engaging the insulating structure, wherein the operable piston operates to define a selected cavity volume of the insulating cavity and a selected insulation density of the insulating media within the insulating cavity, the operable piston having a surface contour that matingly engages the reinforcing structures of the pressing surface to prevent lateral displacement of the pressing surface during operation of the operable piston to the selected cavity volume;
• a valve attached to the insulating structure and defining selective communication between the insulating cavity and an exterior of the insulating structure, wherein the valve in a passive state releases gas disposed within the insulating cavity to the exterior during operation of the operable piston;
• and
• a pump mechanism in communication with the valve, wherein selective operation of the pump mechanism places the valve in an active state to extract gas from the insulating cavity and define a cavity pressure of the insulating cavity, the cavity pressure being less than an equalized pressure, and wherein the operable piston and the pump mechanism are at least one of sequentially operable and simultaneously operable to define a selected piston chamber environment defined by the selected cavity volume and the cavity pressure.