Wrinkle free geometric opening in a vacuum insulated panel

An apparatus for minimizing wrinkles and/or creases in barrier film of a vacuum insulated panel, the apparatus comprising:

• (a) a first puck, wherein the first puck comprises:
• (i) a base, wherein the base of the first puck comprises a top surface and a bottom surface, and
• (ii) a protrusion, wherein the protrusion of the first puck extends from the top surface of the base of the first puck, wherein the protrusion of the first puck comprises a top surface and an exterior surface, wherein the exterior surface of the protrusion of the first puck defines a first shape;
• and
• (b) a second puck, wherein the second puck comprises:
• (i) a base, wherein the base of the second puck comprises a top surface and a bottom surface, and
• (ii) a protrusion, wherein the protrusion of the second puck extends from the top surface of the base of the second puck, wherein the protrusion of the second puck comprises a top surface and an exterior surface, wherein the exterior surface of the protrusion of the second puck defines a second shape;
• wherein the first puck and the second puck are oriented such that at least one barrier film is configured to be compressed between the top surface of the protrusion of the first puck and the top surface of the protrusion of the second puck to thereby minimize wrinkles and/or creases within the at least one barrier film.

A method of manufacturing a vacuum insulated panel, wherein at least one puck comprises a base comprising a top surface and a bottom surface and a protrusion extending from the top surface of the base, wherein the protrusion comprises a top surface and an exterior surface, the method comprising the steps of:

• (a) providing an insulated core having at least one opening defined within the insulated core;
• (b) disposing at least one barrier film about the insulated core;
• (c) disposing the protrusion of the at least one puck within the at least one opening of the insulated core;
• (d) subjecting the insulated core to a vacuum;
• (e) heat scaling the at least one barrier film to thereby seal the insulated core in an evacuated state;
• (f) removing the at least one puck from the at least one opening of the insulate core;
• and
• (g) removing excess barrier film of the at least one barrier film.