Structural insulating component for a multi-layer insulation system of a vacuum insulated structure

A structural cabinet for an appliance, the structural cabinet comprising:

• an outer wrapper and an inner liner defining an insulating cavity therebetween;
• a first insulating structural layer disposed against an inner surface of the outer wrapper;
• a second insulating structural layer disposed against the inner surface of the inner liner, wherein the first and second structural insulating layers are adhered to the outer wrapper and the inner liner, respectively;
• and
• a core insulating material disposed between the first and second structural insulating layers, wherein the first and second insulating structural layers reinforce the outer wrapper and inner liner, respectively, and resist deflection when the core insulating material is in a compressed state within the insulating cavity, wherein the first and second insulating structural layers are glass spheres.

An appliance comprising:

• a structural cabinet having an inside surface that defines an insulating cavity within the structural cabinet, wherein the insulating cavity defines an at least partial vacuum;
• an insulating structural layer disposed against the inside surface, wherein the insulating structural layer is defined by a plurality of hollow glass spheres, wherein the insulating structural layer defines an interstitial insulating space within the insulating cavity, wherein the plurality of hollow glass spheres include at least one of microspheres and nanospheres;
• and
• a core insulating material disposed within the interstitial insulating space, wherein the insulating structural layer reinforces the structural cabinet and resists deflection when the core insulating material is in a compressed state within the insulating cavity, wherein the insulating structural layer reinforces the structural cabinet such that an outer surface of the structural cabinet maintains a consistent shape in response to an inward compressive force generated by the at least partial vacuum of the insulating cavity, and wherein the insulating structural layer prevents the outer surface of the structural cabinet from conforming to a shape of an insulation profile of the core insulating material within the interstitial insulating space.

A method for forming a structural cabinet for an appliance, the method comprising steps of:

• disposing an adhesive onto an inner surface of an outer wrapper and an inward surface of an inner liner;
• disposing a plurality of glass spheres onto the adhesive to define first and second layers of glass spheres, respectively;
• coupling the inner liner and the outer wrapper together to define an insulating cavity therein and also defining an interstitial insulating space between the first and second layers of glass spheres;
• disposing a core insulating material within the interstitial insulating space;
• expressing gas from the insulating cavity to define an at least partial vacuum therein;
• and
• sealing the inner liner and the outer wrapper to define a vacuum insulated structure.