Method to create vacuum insulated cabinets for refrigerators
AssigneeWhirlpool Corporation
InventorsGuolian Wu, Nihat Cur, Jurgen Pannock
Life of this patent
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Abstract
A method of forming a vacuum insulated refrigerator cabinet, the method comprising providing first and second sheets of material. The first sheet of material is thermoformed over a first forming tool forming a first intermediate structure. The first intermediate structure is then thermoformed over a second forming mold to create a second intermediate structure. The second sheet of material is then sealing connected with the second intermediate structure forming an annular space. A vacuum is created in the annular space creating a vacuum insulated cabinet.
Claims20
A method of forming a vacuum insulated refrigerator cabinet, the method comprising:
- providing a first sheet of material comprising at least a first layer of thermoplastic material that is at least partially permeable to oxygen, nitrogen and water vapor, and a second layer of material that is substantially impermeable to oxygen, nitrogen and water vapor;
- heating at least a portion of the first sheet of material to a temperature at which the first sheet of material can be plastically deformed;
- applying a first force to the first sheet of material to form four first sidewalls extending transversely from a central portion of the first sheet of material;
- applying a second force to the first sheet to form a base sidewall and four inner sidewalls extending transversely from the base sidewall in a first direction, and a transverse end wall interconnecting the first sidewalls and the inner sidewalls to define an annular space that opens in the first direction, and wherein the base sidewall and the inner sidewalls define a refrigerator cavity that opens in a second direction that is substantially opposite the first direction;
- securing a second sheet of material to the first sheet of material to close off the annular space;
- filling the annular space with porous material;
- and
- forming a vacuum in the annular space containing the porous material.
A method of forming a vacuum insulated refrigerator cabinet, the method comprising:
- providing first and second sheets of material wherein the first sheet comprises at least a first layer of thermoplastic material that is at least partially permeable to oxygen, nitrogen and water vapor, and a second layer of material that is substantially impermeable to oxygen, nitrogen and water vapor;
- heating at least a portion of the first sheet of material to a temperature at which the first sheet of material can be plastically deformed;
- utilizing a first forming tool to deform the first sheet of material and form a first intermediate structure having a base sidewall and a first sidewall extending transversely from the base sidewall to define a cavity having an opening that opens in a first direction and defines a peripheral edge extending around the opening;
- plastically deforming the base sidewall utilizing a second forming tool to form a second intermediate structure having a base sidewall and an inner sidewall extending transversely from the base sidewall, wherein the inner sidewall is spaced apart inwardly from the first sidewall to define a space;
- at least partially filling the space with a porous material;
- sealingly connecting the second sheet of material to the second intermediate structure around the peripheral edge to substantially close off the opening;
- and
- forming a vacuum in the space containing the porous material.
A method of forming a vacuum insulated refrigerator cabinet, the method comprising:
- providing first and second sheets of material;
- heating and plastically deforming the first sheet of material to form a first intermediate structure having a base sidewall and a first sidewall extending transversely from the base sidewall to define a cavity having an opening, the first sidewall defining a peripheral edge extending around the opening;
- plastically deforming the first intermediate structure to form a second intermediate structure having a base sidewall and an inner sidewall extending transversely from the base sidewall, wherein the inner sidewall is spaced apart from the first sidewall to define a space;
- sealingly connecting the second sheet of material to the second intermediate structure around the peripheral edge to substantially close off the opening;
- filling the space with a porous material;
- and
- forming a vacuum in the space.
Dependencies are inferred from the claim text.