# US 9,038,403 B2 · Vacuum insulated door structure and method for the creation thereof

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- Number: US 9,038,403 B2
- Document ID: US9038403B2
- Status: Granted
- Kind: B2
- Application number: 13/833,696
- Filed: 2013-03-15
- Published: 2013-10-03
- Granted: 2015-05-26
- Earliest claimed: 2012-04-02
- Assignees: Whirlpool Corporation
- Applicants: Whirlpool Corporation
- Inventors: Nihat Cur; Guolian Wu
- Web page: https://patentgrep.com/patent/US9038403B2

## CPC

- F25D 23/065: {Details}
- B23P 15/26: heat exchangers {or the like (making heat exchangers by methods covered by other subclasses B21D53/02)}
- B29C 53/00: Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor (B29C61/10 takes precedence)
- F25B 39/00: Evaporators; Condensers
- F25B 39/02: Evaporators
- F25C 1/00: Producing ice (F25C3/00 takes precedence)
- F25D 11/00: Self-contained movable devices, e.g. domestic refrigerators
- F25D 23/028: {Details}
- F25D 23/062: {defining a cabinet}
- F25D 23/063: {formed by an assembly of panels}
- H04R 3/12: for distributing signals to two or more loudspeakers {(specially adapted for hearing aids H04R25/407)}
- F25D 2201/14: using subatmospheric pressure
- Y10T 29/49002: Electrical device making
- Y10T 29/49359: Cooling apparatus making, e.g., air conditioner, refrigerator
- Y10T 29/49616: Structural member making
- Y10T 29/49826: Assembling or joining
- Y10T 29/49879: Spaced wall tube or receptacle
- Y10T 29/49947: by applying separate fastener
- Y10T 156/1051: by folding
- Y10T 428/231: Filled with gas other than air; or under vacuum
- F25D: REFRIGERATORS; COLD ROOMS; ICE-BOXES; COOLING OR FREEZING APPARATUS NOT OTHERWISE PROVIDED FOR (refrigerated showcases A47F3/04; thermally-insulated vessels for domestic use A47J41/00; refrigerated vehicles, see the appropriate subclasses of classes B60 - B64; containers with thermal insulation in general B65D81/38; heat-transfer, heat-exchange or heat-storage materials, e.g. refrigerants, or materials for the production of heat or cold by chemical reactions other than by combustion C09K5/00; thermally-insulated vessels for liquefied or solidified gases F17C; air-conditioning or air-humidification F24F; refrigeration machines, plants, or systems F25B; cooling of instruments or comparable apparatus without refrigeration G12B)
- B23P: METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS (arrangements for copying or controlling B23Q)
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- F25B: REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25C: PRODUCING, WORKING OR HANDLING ICE
- H04R: LOUDSPEAKERS, MICROPHONES, GRAMOPHONE PICK-UPS OR LIKE ACOUSTIC ELECTROMECHANICAL TRANSDUCERS; ELECTRIC HEARING AIDS; PUBLIC ADDRESS SYSTEMS (producing sounds with frequency not determined by supply frequency G10K)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A vacuum insulated door structure comprises a first wall having a first edge, outer sidewalls that extend from the first edge to a perimetrical lip, a first inner surface and a first outer surface. A second wall has a second inner surface, a second outer surface and a second edge coupled to the perimetrical lip forming a cavity volume. The second wall includes inner sidewalls defining a second wall opening. The inner sidewalls extend to a back wall and define a second wall offset. A tubular member includes a first end coupled to a first conduit opening in the first wall and a second end coupled to a second conduit opening in the second wall offset. A barrier layer is disposed on the first and second walls and the tubular member. A cavity insulation material is disposed within the cavity volume which is hermetically sealed.

## Claims

### Claim 1

A vacuum insulated door structure comprising:
a first wall member having a first perimetrical edge, at least four outer sidewalls that extend substantially perpendicular from the first perimetrical edge and to a perimetrical lip, a barrier layer having a hermetic barrier film and a heat sealing layer, a first inner facing surface and a first outer facing surface;
a second wall member having a second inner facing surface, a second outer facing surface, a second barrier layer having a hermetic barrier film and a heat sealing layer, and a second perimetrical edge coupled to the first wall member proximate the perimetrical lip, wherein the second wall member comprises at least four inner side walls defining a second wall opening distal from at least a portion of the second perimetrical edge, and wherein the at least four inner sidewalls extend from the second wall opening toward the first wall member to a back wall, wherein the at least four sidewalls and the back wall define a second wall offset;
at least one tubular member having first and second conduit ends, an inner conduit surface and an outer conduit surface, wherein the first conduit end is coupled to a first wall conduit opening defined by the first wall member and the second conduit end is coupled to a second wall conduit opening defined by the second wall offset, and wherein the inner conduit surface provides a fluid communication between the first wall outer facing surface and the second wall outer facing surface, and wherein the first and second wall members and the at least one tubular member form a door structure; and
a cavity insulation material disposed within a cavity volume defined by an interior volume of the door structure, wherein the cavity volume is hermetically sealed, wherein the cavity volume includes an at least partial vacuum.

### Claim 2 (depends on 1)

The vacuum insulated door structure of claim 1, wherein the first wall member comprises at least four offset sidewalls defining a first wall opening distal from the first perimetrical edge, and wherein the at least four offset sidewalls extend from the first wall opening to an offset back wall, wherein the at least four offset sidewalls and the offset back wall include a first wall offset.

### Claim 3 (depends on 1)

The vacuum insulated door structure of claim 1 further comprising:
a module receptacle defined at least partially by the first wall member and in communication with the inner conduit surface, wherein the module receptacle is configured to receive at least one cooling module configured to dispense a cooled material through the at least one tubular member and into the second wall offset.

### Claim 4 (depends on 1)

The vacuum insulated door structure of claim 1 further comprising:
a metal clad covering having a finished outer surface and an interior surface, wherein the interior surface of the metal clad covering is disposed on at least a portion of an exterior surface of the vacuum insulated door structure.

### Claim 5 (depends on 1)

The vacuum insulated door structure of claim 1, wherein the cavity insulation material is polyurethane foam disposed within the cavity volume via at least one port disposed on the door structure.

### Claim 6 (depends on 3)

The vacuum insulated door structure of claim 3 further comprising:
at least one cooling module coupled with the module receptacle and configured to be in fluid communication with the inner conduit surface, wherein each at least one cooling module is in fluid communication with a cooling loop having an evaporator, a condenser, and a coolant fluid.

### Claim 7 (depends on 3)

The vacuum insulated door structure of claim 3, wherein polyurethane foam is disposed within the module receptacle about the at least one cooling module.

### Claim 8 (depends on 6)

The vacuum insulated door structure of claim 6, wherein the at least one cooling module includes an ice maker and dispenser and a water dispenser, wherein the ice and water dispensers are in fluid communication with the inner conduit surface and the second wall offset.

### Claim 9

A refrigerator having a vacuum insulated door structure, the refrigerator comprising:
an insulative first wall member having a first perimetrical edge, a first inner facing surface and a first outer facing surface, wherein the first wall member comprises at least four offset sidewalls defining a first wall opening distal from at least a portion the first perimetrical edge, and wherein the at least four offset sidewalls extend substantially orthogonally from the first wall opening to a first back wall, wherein the at least four offset sidewalls and the first back wall include a first wall offset;
an insulative perimetrical flange having a first lip and a second lip, wherein the first lip is coupled to the first wall member proximate the first perimetrical edge;
an insulative second wall member having a second inner facing surface, a second outer facing surface, and a second perimetrical edge coupled to the perimetrical flange proximate the second lip, wherein the second wall member comprises at least four inner side walls defining a second wall opening distal from at least a portion of the second perimetrical edge, and wherein the at least four inner sidewalls extend from the second wall opening toward the first wall member to a second back wall, wherein the at least four inner sidewalls and the second back wall include a second wall offset disposed proximate the first wall opening;
an insulative tubular member having first and second conduit ends, an inner conduit surface, and an outer conduit surface, wherein the first conduit end is coupled to the first wall member proximate a first wall conduit opening defined by the first wall offset and the second conduit end is coupled to the second wall member proximate a second wall conduit opening defined by the second wall offset, and wherein the inner conduit surface provides a fluid communication between the first wall outer facing surface and the second wall outer facing surface, and wherein the first and second wall members, the perimetrical flange, and the tubular member form a door structure;
a barrier layer comprising a hermetic barrier film and a heat sealing layer disposed on at least a portion of the first and second wall members, the perimetrical flange, and the tubular member; and
a cavity insulation material disposed within a cavity volume defined by the inner facing surface of the first wall member, the inner facing surface of the second wall member, the perimetrical flange, and the outer conduit surface, wherein the cavity volume is hermetically sealed and is configured to maintain an at least partial vacuum within the cavity volume.

### Claim 10 (depends on 9)

The vacuum insulated door structure of claim 9 further comprising:
a module receptacle defined at least partially by the first wall offset and in communication with the inner conduit surface, wherein the module receptacle is configured to receive a cooling module configured to dispense a cooled material through the tubular member and into the second wall offset.

### Claim 11 (depends on 9)

The vacuum insulated door structure of claim 9 further comprising:
a metal clad covering having an interior surface, wherein the interior surface is disposed to at least a portion of an exterior surface of the door structure.

### Claim 12 (depends on 9)

The vacuum insulated door structure of claim 9, wherein the cavity insulation material is polyurethane foam that is injected into the cavity volume via at least one port disposed on the door structure.

### Claim 13 (depends on 10)

The vacuum insulated door structure of claim 10 further comprising:
a cooling module coupled with the module receptacle and configured to be in fluid communication with the inner conduit surface, wherein the cooling module is in fluid communication with a cooling loop having an evaporator, a condenser, and a coolant fluid, and wherein polyurethane foam is disposed within at least a portion of the module receptacle about the cooling module.

### Claim 14 (depends on 13)

The vacuum insulated door structure of claim 13, wherein the at least one cooling module includes an ice maker and dispenser and a water dispenser, wherein the ice and water dispensers are in fluid communication with the inner conduit surface and the second wall offset.

### Claim 15

A method for creating an integral vacuum insulated door structure comprising the steps of:
providing a first wall member having a first perimetrical edge, at least four outer sidewalls that extend substantially perpendicular from the first perimetrical edge to a perimetrical lip, a barrier layer having a hermetic barrier film and a heat sealing layer, a first inner facing surface, and a first outer facing surface, wherein the first wall member comprises at least four offset sidewalls defining a first wall opening distal from at least a portion of the first perimetrical edge, and wherein the at least four offset sidewalls extend substantially orthogonally from the first wall opening to a first back wall, wherein the at least four offset sidewalls and the first back wall include a first wall offset;
providing a second wall member having a second inner facing surface, a second outer facing surface, and a second perimetrical edge disposed proximate the perimetrical lip, wherein the second wall member comprises at least four inner sidewalls defining a second wall opening distal from at least a portion of the second perimetrical edge, a second barrier layer having a hermetic barrier film and a heat sealing layer, and wherein the at least four inner sidewalls extend from the second wall opening toward the first wall member to a back wall, wherein the at least four sidewalls and the back wall define a second wall offset;
providing a tubular member having first and second conduit ends, an inner conduit surface and an outer conduit surface, wherein the first conduit end is disposed to a first wall conduit opening defined by the first wall member and the second conduit end is disposed to a second wall conduit opening defined by the second wall offset, and wherein the inner conduit surface provides a fluid communication between the first wall outer facing surface and the second wall outer facing surface;
disposing a cavity insulation material within a cavity volume defined by the inner facing surface of the first wall member, the inner facing surface of the second wall member, and the outer conduit surface;
hermetically sealing the cavity volume; and
extracting gas from the cavity volume via at least one port disposed on the first wall member proximate a port opening defined by the first wall member, wherein the cavity volume is configured to maintain an at least partial vacuum within the cavity volume.

### Claim 16 (depends on 15)

The method of claim 15, wherein the door structure includes a module receptacle at least partially defined by the first wall offset and in communication with the inner conduit surface, wherein the module receptacle is configured to receive a cooling module.

### Claim 17 (depends on 15)

The method of claim 15 further comprising the steps of:
providing a metal clad covering having an interior surface; and
disposing the metal clad covering to at least a portion of an exterior of the vacuum insulated door structure such that the interior surface of the metal clad covering is proximate the vacuum insulated door structure.

### Claim 18 (depends on 15)

The method of claim 15, wherein the step of disposing a cavity insulation material within a cavity volume includes injecting polyurethane foam into the cavity volume via the at least one port after the first and second wall members and the tubular member have been hermetically sealed together, wherein the at least one port includes at least one injection port through which the polyurethane foam is injected, and wherein the at least one port includes at least one vacuum port through which the gas is extracted from the cavity volume.

### Claim 19 (depends on 16)

The method of claim 16 further comprising the step of:
providing a cooling module;
disposing the cooling module within the module receptacle, wherein the cooling module is configured to be in fluid communication with the inner conduit surface,
providing a cooling loop in fluid communication with the cooling module, wherein the cooling loop includes an evaporator, a condenser, and a coolant fluid; and
disposing polyurethane foam within at least a portion of the module receptacle about the cooling module.

### Claim 20 (depends on 19)

The method of claim 19, wherein the at least one cooling module includes an ice maker and dispenser and a water dispenser, wherein the ice and water dispensers are in fluid communication with the inner conduit surface and the second wall offset.