A method for manufacturing an insulated structure for a refrigerator

A method of making a vacuum insulated refrigerator structure, the method comprising:

• forming a wrapper from a sheet of material whereby the wrapper has a first opening and a first edge extending around the first opening;
• forming a liner from a sheet of material whereby the liner has a second opening and a second edge extending around the second opening;
• positioning the liner inside of the wrapper with the first and second edges being spaced apart to form a gap therebetween, and to form a cavity between the wrapper and the liner;
• forming a plurality of rails utilizing a co-extrusion process that includes co-extruding a base material and a barrier material to form a barrier to gases and/or liquids;
• forming an insulating thermal bridge by molding corner portions to end portions of adjacent rails in an injection molding device, wherein the insulating thermal bridge includes elongated first and second channels;
• coupling the insulating thermal bridge across the gap by inserting the first and second edges into the first and second channels, respectively;
• positioning curable sealant in the first and second channels;
• causing a porous material to at least partially fill the cavity between the wrapper and the liner;
• forming a vacuum in the cavity;
• and
• sealing the cavity to maintain the vacuum.

A vacuum insulated refrigerator structure, comprising:

• an outer wrapper having a first opening and a first edge extending around the first opening;
• a liner having a second opening and a second edge extending around the second opening, wherein the liner is disposed inside the wrapper with the first and second edges being spaced apart to form a gap therebetween and to form a vacuum cavity between the wrapper and the liner;
• an insulating thermal bridge extending across the gap, wherein the insulating thermal bridge includes elongated first and second channels, wherein at least one of the elongated first and second channels includes one or more flexible locators protruding into the elongated first and/or second channels from both channel walls, and wherein the first and second edges are disposed in the first and second channels, respectively;
• sealant disposed in the first and second channels to seal the vacuum cavity and maintain a vacuum in the vacuum cavity;
• and
• porous material disposed in the vacuum cavity.