Vacuum insulation structure with thin metal sheet features for controlling vacuum bow-shaped portion

Abstract

This invention relates to a vacuum insulation structure featuring a sheet metal element with a controlled vacuum bow shape. The vacuum insulation structure includes a first cover member, a monolithic sheet member defining a peripheral portion, an outer frame portion defined radially inward of the peripheral portion, and an internal region surrounded and supported by the outer frame portion. The internal region defines a first horizontal plane, and a portion of the outer frame portion extends to a second horizontal plane, which is parallel to and axially spaced from the first horizontal plane. The vacuum insulation structure also includes a second monolithic sheet cover member and a thermal bridge that interconnects the first and second cover members at their peripheral portions to define an insulation cavity between them. Deformation of the outer frame portion causes the internal region to move axially inward away from the second horizontal plane under the influence of vacuum forces within the insulation cavity.

Description

Technical Field

[0001] This disclosure generally relates to a vacuum insulation structure for a refrigerator, and more specifically, to the geometry of a cover member for controlling the effect of vacuuming on the structure. Summary of the Invention

[0002] According to one aspect of this disclosure, a vacuum insulation structure includes a first cover member of an integral sheet member defining a peripheral portion, an outer frame portion defined radially inward of the peripheral portion, and an internal region surrounded and supported by the outer frame portion. The internal region defines a first horizontal plane, and a portion of the outer frame portion extends to a second horizontal plane parallel to and axially spaced from the first horizontal plane. The vacuum insulation structure also includes a second cover member of an integral sheet member and a thermal bridge interconnecting the first and second cover members at their peripheral portions to define an insulation cavity between them. The insulation cavity is a sealed cavity from which a vacuum is drawn, and deformation of the outer frame portion causes the internal region to move axially inward away from the second horizontal plane under the influence of the vacuum force within the insulation cavity.

[0003] According to another aspect of this disclosure, a method of manufacturing a vacuum-insulated cabinet structure includes assembling a first cover member and a second cover member using thermal bridges. At least the first cover member defines a peripheral portion, an outer frame portion defined radially inward of the peripheral portion, and an internal region surrounded and supported by the outer frame portion. The internal region defines a first horizontal plane, and a portion of the outer frame portion extends to a second horizontal plane parallel to and spaced outward from the first horizontal plane. The first and second cover members, assembled using thermal bridges, define a sealed, insulated cavity between them. The method further includes evacuating the sealed, insulated cavity, which causes deformation of the outer frame portion, such that the internal region moves axially inward from the second horizontal plane under the influence of the vacuum force within the insulated cavity.

[0004] According to another aspect of this disclosure, a refrigerator includes a vacuum-insulated cabinet structure having an outer enclosure having a first side portion defining a peripheral portion, an outer frame portion defined radially inward of the peripheral portion, and an internal region surrounded and supported by the outer frame portion. The internal region defines a first horizontal plane, a portion of the outer frame portion extending to a second horizontal plane parallel to and spaced outward from the first horizontal plane. The refrigerator also includes an inner lining disposed inside the outer enclosure and a thermal bridge interconnecting a first cover member and a second cover member at their peripheral portions to define an insulated cavity therebetween. The insulated cavity is a sealed cavity evacuated therefrom, and deformation of the outer frame portion causes the internal region to move axially inward away from the second horizontal plane under the influence of the vacuum force within the insulated cavity.

[0005] These and other features, advantages and objectives of this disclosure will be further understood and appreciated by those skilled in the art upon reference to the following description, claims and drawings. Attached Figure Description

[0006] In the attached diagram:

[0007] Figure 1A It is a 3D view of a refrigerator including its vacuum-insulated cabinet structure;

[0008] Figure 1B This is an exploded 3D view of another type of vacuum insulated cabinet structure;

[0009] Figure 2A This is a top-down 3D view of the structure of a vacuum insulation cabinet before the vacuuming process.

[0010] Figure 2B yes Figure 2A A schematic top-view perspective of the vacuum-insulated cabinet structure after vacuuming.

[0011] Figure 3A yes Figure 2A A schematic cross-sectional view of the vacuum insulated cabinet structure taken at point IIIA along the line;

[0012] Figure 3B yes Figure 2B A schematic cross-sectional view of the vacuum insulated cabinet structure taken at point IIIB along the line;

[0013] Figure 4 This is a side plan view of a cover member that can be combined with a vacuum insulation structure to control deformation caused by vacuuming, according to one aspect of this disclosure.

[0014] Figure 5 It includes Figure 4An exploded top-view perspective of the schematic vacuum insulated cabinet structure of the cover component;

[0015] Figure 6 yes Figure 5 A schematic diagram of the vacuum insulated cabinet structure in its assembled state and before being evacuated;

[0016] Figure 7 yes Figure 6 The side walls of the vacuum insulated cabinet structure along Figure 6 A sectional view taken from line VII-VII;

[0017] Figure 8 yes Figure 7 A cross-sectional view of the side wall of the vacuum-insulated cabinet structure after vacuuming.

[0018] Figure 9A and Figure 9B These are side plan and sectional views of alternative cover members according to other aspects of this disclosure;

[0019] Figure 10A and Figure 10B These are side plan and sectional views of alternative cover members according to other aspects of this disclosure;

[0020] Figure 11A and Figure 11B These are side plan and sectional views of alternative cover members according to other aspects of this disclosure;

[0021] Figure 12A and Figure 12B These are side plan and sectional views of alternative cover members according to other aspects of this disclosure;

[0022] Figure 13A and Figure 13B These are side plan and sectional views of alternative cover members according to other aspects of this disclosure;

[0023] Figure 14A and Figure 14B These are side plan and sectional views of alternative cover members according to other aspects of this disclosure;

[0024] Figure 15A and Figure 15B These are side plan and sectional views of alternative cover members according to other aspects of this disclosure;

[0025] Figure 16A and Figure 16B These are side plan and sectional views of alternative cover members according to other aspects of this disclosure;

[0026] Figure 17 It includes Figure 10AAn exploded top-view perspective of the schematic vacuum insulated cabinet structure of the cover component;

[0027] Figure 18A yes Figure 17 A schematic diagram of the vacuum insulated cabinet structure in its assembled state and before being evacuated;

[0028] Figure 18B yes Figure 18A A schematic vacuum-insulated cabinet structure after vacuuming has been removed from the structure;

[0029] Figure 19 This is a cross-sectional view of the side wall of the vacuum insulated cabinet structure in Figure 18 taken at line XIX-XIX in Figure 18.

[0030] Figure 20 yes Figure 19 A cross-sectional view of the side wall of the vacuum-insulated cabinet structure after vacuuming.

[0031] Figure 21A This is a cross-sectional view of a vacuum insulation structure according to another aspect of this disclosure; and

[0032] Figure 21B yes Figure 21A A cross-sectional view of the vacuum insulation structure after the structure has been evacuated.

[0033] The components in the diagram are not necessarily to scale; the focus is on illustrating the principles described in this article. Detailed Implementation

[0034] The embodiments shown here primarily involve combinations of method steps and apparatus components related to vacuum insulation structures. Therefore, where appropriate, apparatus components and method steps are indicated by conventional symbols in the accompanying drawings, showing only those specific details relevant to understanding the embodiments of this disclosure, so as not to obscure this disclosure with details readily apparent to those skilled in the art as described herein. Furthermore, the same reference numerals denote the same elements in the specification and drawings.

[0035] For the purposes of this description, the terms “upper,” “lower,” “right,” “left,” “back,” “front,” “vertical,” “horizontal,” and their derivatives should refer to the disclosure oriented as shown in Figure 1. Unless otherwise stated, the term “front” should refer to the surface of the element closer to the intended observer, and the term “back” should refer to the surface of the element farther from the intended observer. However, it should be understood that this disclosure may take various alternative orientations unless explicitly stated otherwise. It should also be understood that the specific devices and processes shown in the figures and described in the following description are merely exemplary embodiments of the inventive concept defined in the appended claims. Therefore, specific dimensions and other physical characteristics associated with the embodiments disclosed herein should not be considered limiting unless explicitly stated otherwise in the claims.

[0036] The terms “comprising,” “including,” or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements may include not only those elements but also other elements not expressly listed or inherent to such process, method, article, or apparatus. An element following “comprising…” does not exclude the presence of additional identical elements in the process, method, article, or apparatus that includes that element, unless further limited.

[0037] Reference Figures 1A to 8 Reference numeral 12 generally indicates that it is used for, for example Figure 1A and Figure 1B The refrigerator 10 shown has a vacuum insulation structure. The vacuum insulation structure 12 includes a first cover member, a monolithic sheet member defining a peripheral portion, an outer frame portion defined radially inward of the peripheral portion, and an internal region surrounded and supported by the outer frame portion. The internal region defines a first horizontal plane, and a portion of the outer frame portion extends to a second horizontal plane, which is parallel to and axially spaced from the first horizontal plane. The vacuum insulation structure also includes a second cover member, a monolithic sheet member, and a thermal bridge interconnecting the first and second cover members at their peripheral portions to define an insulation cavity between them. The insulation cavity is a sealed cavity from which a vacuum is evacuated, and deformation of the outer frame portion causes the internal region to move axially inward away from the second horizontal plane under the influence of the vacuum force within the insulation cavity.

[0038] Now refer to Figure 1AThe refrigerator 10 is shown having a vacuum-insulated cabinet structure 12. The vacuum-insulated cabinet structure 12 includes one or more front openings 14A, 14B that can be closed via doors 16A, 16B, and 16C. Doors 16A, 16B are intended to pivot relative to the upper front opening 14A between an open position and a closed position. As further observed in the illustrated example, door 16C is in the form of a sliding drawer that slides horizontally between the open and closed positions to selectively provide access to the lower front opening 14B of the insulated cabinet structure 12.

[0039] like Figure 1A As further shown, the vacuum insulated cabinet structure 12 includes an outer enclosure 18, an upper liner 20A, and a lower liner 20B. Figure 1A In the illustrated embodiment, the upper liner 20A and the lower liner 20B generally represent the refrigerator compartment and the freezer compartment, respectively. During assembly, the upper liner 20A and the lower liner 20B are interconnected with the outer casing 18 via a thermal bridge 22. The thermal bridge 22... Figure 1B It is best shown in the middle. Figure 1A The diagram further shows that the outer enclosure 18 is spaced apart from the upper liner 20A and the lower liner 20B to define an insulating cavity 24 between them. The insulating cavity 24 is intended to be a sealed cavity that may include a vacuum core material, such as silica powder or other suitable loose filler material, added (e.g., blown in) after the outer enclosure 18, the upper liner 20A, the lower liner 20B, and the thermal bridge 22 have been coupled together.

[0040] Now refer to Figure 1B The vacuum-insulated cabinet structure 12 is shown in an exploded view. The thermal bridge 22 of the vacuum-insulated cabinet structure 12 includes a first side member 22A and a second side member 22B, as well as an upper opening 25 and a lower opening 26, which are configured to align with the upper liner 20A and the lower liner 20B during assembly. The thermal bridge 22 also includes a vertical frame portion 28 disposed between the upper opening 25 and the lower opening 26 and extending between the first side member 22A and the second side member 22B. The upper liner 20A is shown having a top wall 30, a bottom wall 32, opposing side walls 34, 36, and a rear wall 38 (collectively referred to herein as side walls), all of which cooperate to define a refrigerator compartment 40. Similarly, the lower liner 20B includes a top wall 42, a bottom wall 44, interconnected side walls 46, 48, and a rear wall 49, all of which cooperate to define a freezer compartment 50. The rear wall 49 is shown with a stepped construction to define a space 52, which can be used to accommodate various cooling components for cooling the refrigerator compartment 40 and the freezer compartment 50. The upper liner 20A and the lower liner 20B can be made of sheet metal material that is folded and welded to define the parameters of the refrigerator compartment 40 and the freezer compartment 50.

[0041] like Figure 1B As further shown, the outer packaging 18 includes a top wall 54, a bottom wall 56, opposing side walls 58, 60, and a rear wall 62 (collectively referred to herein as side walls), which together cooperate to define a receiving cavity 64. The outer packaging 18 may be constructed from a sheet metal material folded and / or welded to define the parameters of the receiving cavity 64, such that the packaging 18 has a generally integral structure. During assembly, the upper liner 20A and the lower liner 20B are received in the receiving cavity 64 of the outer packaging 18 such that the outer surfaces of the upper liner 20A and the lower liner 20B mate with the inner surface of the outer packaging 18 to define... Figure 1A The insulating cavity 24 is shown positioned between them. The insulating cavity 24 can directly receive the insulating material and has a vacuum drawn directly from the insulating cavity 24 to provide a vacuum-insulated cabinet structure 12. In this way, the vacuum-insulated cabinet structure 12 can include a thinner overall profile, thereby maximizing the amount of space available for the refrigerator compartment 40 and the freezer compartment 50 during assembly.

[0042] Now refer to Figure 2A The schematic component 70 is used to illustrate the deformation effect of the vacuuming process. Component 70 includes a first cover member 72 and a second cover member 74 spaced apart from each other and interconnected by side members 75-78. The side members 75-78 may be side members of an integral frame structure to which the first cover member 72 and the second cover member 74 are attached. Component 70 includes a cavity 80 defined by the first cover member 72 and the second cover member 74 spaced apart from each other and interconnected by the side members 75-78. The cavity 80 may be filled with a compressed cake of particulate material, such as activated carbon black or silica gel, or a mixture of both. These fillers are designed to fill the cavity 80 and are placed into the cavity 80 before the component 70 is vacuumed. The filler is indicated by reference numeral 82 and... Figure 3A It is best shown in the middle.

[0043] Now refer to Figure 2B The illustrative component 70 already has a vacuum created by evacuating the cavity 80, so that the cavity 80 now defines an evacuated cavity 80. By evacuating the illustrative component 70, the first cover member 72 and the second cover member 74 have collapsed inward toward each other, thereby providing Figure 2B The deformed outer surface 72A of the first cover member 72 shown. Figure 2B The deformation of the schematic component 70 shown is in Figure 3B The best depiction is given in the text.

[0044] Now refer to Figure 3A It depicts Figure 2A The schematic cross-sectional view of component 70 is shown, in which the outer surface 72A of the first cover member 72 and the outer surface 74A of the second cover member 74 are shown in a generally planar configuration between the side members 78 and 76. Figure 3A The configuration shown is an ideal configuration of a vacuum insulation structure after evacuation of the illustrative component 70. However, as mentioned above, when... Figure 2A and Figure 3A When the illustrative component 70 is evacuated, the result is often... Figure 2B and Figure 3B The schematic representation of the deformed component 70 is shown. See details in the attached image. Figure 3B The outer surfaces 72A of the first cover member 72 and 74A of the second cover member 74 are no longer planar, but rather have inwardly deformed outer surfaces with specific indentation deformations 84A-84D caused by the low pressure of the evacuated cavity 80. These indentation deformations pull the first cover member 72 and the second cover member 74 towards each other. The pressure within the evacuated cavity of the plate 70 is expected to be less than 10 millibars compared to 1 atmosphere or 1013.25 millibars of atmospheric pressure.

[0045] To avoid the shown Figures 2A to 3B The schematic component 70 includes a vacuum-deformable arcuate portion, the concept comprising a vacuum-insulated structure having a region configured to undergo controlled deformation, as further described below. Specifically, in Figures 4 to 8 The illustrated embodiment shows a simplified form of the vacuum insulation structure 90, wherein the vacuum insulation structure 90 is intended to represent an application throughout the entire vacuum insulation structure (e.g., at the insulation cavity 24). Figure 1A and Figure 1B The vacuum-insulated cabinet structure 12) employs a controlled deformation technique. Thus, the vacuum-insulated structure 90 is intended to demonstrate an exemplary structure having a controlled deformation technique for providing a substantially planar structure after evacuation. The construction of the vacuum-insulated structure 90 is not intended to limit the scope of this concept in any way. Furthermore, as... Figure 21A and Figure 21B As shown, pre-deformation technology can be applied to the vacuum insulation structure 90B, which specifically relates to the structure of the refrigerator cabinet. Therefore, Figures 2A to 3B The vacuum insulation structure 90 shown can represent Figure 21A and Figure 21B The single sidewall of the vacuum insulated cabinet structure 90B shown, or the opposite outer portions 92A and 92B of the cabinet structure 90B.

[0046] Therefore, according to this concept, in Figures 4 to 8 The vacuum insulation structure 90 is shown. Specifically, Figure 4 A first cover member 92 according to one aspect of this disclosure is shown. Figure 5This is an exploded view of a first cover member 92 and a second cover member 94, spaced apart from each other and configured to couple with a thermal bridge 96 having side members 96A-96D. A evacuation port 98 is shown disposed on the thermal bridge 96, but can be disposed on any part of the vacuum insulation structure 90 to allow access to the cavity 100. Figure 7 ).like Figure 4 and Figure 5 As shown, the first cover member 92 and the second cover member 94 may include opposing outer walls (58 and 60) of the outer cover member 18 and / or corresponding portions of an outer wall and upper lining 20A and lower lining 20B, which are also spaced apart from each other to define Figure 1A The thermally insulating cavity 24 is shown between them. Therefore, the depicted thermal bridge 96 should be understood as illustrative only, such that in the application of the refrigerator outer wrapping 18, the thermal bridge 22 can be represented solely by the side wall 96A, in which the aforementioned openings 25 and 26 are defined for receiving the corresponding lining. In such an application, the remaining side walls 96B-96D may correspond to the top wall 58, bottom wall 60, and rear wall 62 of the wrapping 18.

[0047] The first cover member 92 includes an outer frame 102 disposed inside the periphery 104 of the first cover member 92, the outer frame 102 surrounding the inner region 106. As described above and as... Figure 7 and Figure 8 As best shown, the inner region 106 defines a first horizontal plane P1, and a portion of the outer frame portion 102 extends to a second horizontal plane P2, which is horizontally parallel to and spaced horizontally from the first plane in the axial direction A. As further shown, the outer frame portion 102 includes a first sidewall 102A extending from the first horizontal plane P1 to the second horizontal plane P2, a sidewall 102B extending radially inward along the second horizontal plane P2, and a second sidewall 102C extending from the second horizontal plane P2 to connect with the inner region at the first horizontal plane P1. A peripheral portion 104 is also shown disposed at the first horizontal plane P1. In this way, when the first cover member 92 is in the depicted pre-assembled and pre-emptied state, the inner region 106 is substantially suspended by the outer frame portion 102 at the first horizontal plane P1, including relative to the peripheral portion 104. As further shown, the second cover member 94 can be similarly formed with similar structures and elements, such that, in one aspect, the second cover member 94 can be a mirror image of the first cover member 92.

[0048] The first cover member 92 and the second cover member 94 are contemplated as sheet metal cover members, wherein the outer frame portion 102 is a stamped portion formed by a stamping process that stretches and thins a specific portion of the outer frame portion 102. Specifically referring to the first cover member 92, weakened portions 93A and 93B are shown disposed around the outer frame portion 102 and are contemplated as weakened portions of the first cover member 92 that are stretched and thinned during the stamping process. In the illustrative schematic assembly 90, the first cover member 92 is coupled to a first surface 97 of a thermal bridge 96, while the second cover member 94 is coupled to a second surface 99 of the thermal bridge 96. By coupling the first cover member 92 and the second cover member 94 to the thermal bridge 96, a cavity for a vacuum insulation structure 90 is formed. The cavity is identified as... Figures 5 to 8 The figure shown is referenced to 100 and is intended to represent... Figure 1A Part of the insulation cavity 24 of the vacuum insulated cabinet structure 12 shown.

[0049] Now refer to Figure 6 ,and Figure 5 Compared to the exploded view shown, the vacuum insulation structure 90 is shown in an assembled state. Although Figure 6 The vacuum insulation structure 90 shown is provided during the static or pre-evacuation phase, but structure 90 is still referred to herein as the vacuum insulation structure. In the assembled state, the vacuum insulation structure 90 is shown having a first surface 97 and a second surface 99 connected to a thermal bridge 96. Figure 5 The first cover member 92 and the second cover member 94 are coupled. In this configuration, the inner regions 106 in the first cover member 92 and the second cover member 94 are maintained at the corresponding first plane horizontal level P1. Figure 6 In the assembled state shown, the vacuum insulation structure 90 includes a cavity 100, which is generally accessible through a port 98 located in the thermal bridge 96. Although Figure 6 The illustrated embodiment includes a port 98 disposed on the thermal bridge 96, but it is contemplated that the port 98 can be disposed on any part of the vacuum insulation structure 90, as long as the port provides an entrance to the cavity 100. When assembling the vacuum insulation structure 90, the cavity 100 can be filled with an insulating medium, such as open-cell foam or microporous filler material, which may optionally include particulate reflectors or light-blocking agents, such as aluminum, flakes, or carbon black, to reduce the transmission of radiant energy through the vacuum insulation structure 90. The cavity 100 may also be filled with an insulating material in powder form, the powder comprising pyrolytic silica, glass beads, processed rice husks, or any combination thereof. The insulating material is expected to have a conductivity or thermal conductivity of at least 5 mW / m·K or lower to ensure good insulation properties of the vacuum insulation structure 90. This filler material or insulating material in Figure 7 and Figure 8 It is identified as reference numeral 102 in the attached figure.

[0050] The assembled vacuum insulation structure 90 is then evacuated, wherein a vacuum has been drawn from the cavity 100 through port 98, thereby providing a low-pressure environment within the cavity 100. The low-pressure environment of the cavity 100 may include a reduced internal pressure of less than 10 mbar, but may include other pressure settings obtained by adjusting the filling material used in the vacuum insulation structure 90 and also by adjusting the desired insulation value of the vacuum insulation structure 90.

[0051] Now refer to Figure 7 , showed Figure 6 A cross-sectional view of a vacuum insulation structure 90, wherein the outer frame portions 102 of the first cover member 92 and the second cover member 94 are shown in an undeformed state suspending the inner regions 106 of the respective cover members 92 and 94 at the indicated first horizontal plane P1. The wall surfaces 102A and 102C of the outer frame portions 102 are shown extending along a second horizontal plane P2. When the cavity 100 of the vacuum insulation structure 90 is evacuated, the first cover member 92 and the second cover member 94 are subjected to inwardly pointing forces F1 and F2, respectively, which drive the first cover member 92 and the second cover member 94 toward each other. Due to the weakening of the weakened portions 93A, 93C, 95A, and 95C, these portions of the first cover member 92 and the second cover member 94 are more prone to bending or deflection compared to other portions of the first cover member 92 and the second cover member 94. Therefore, due to the inward forces F1 and F2 caused by the vacuum drawn into the cavity 100, the outer frame portion 102 of the first cover member 92 and the second cover member 94 deforms, in particular, along the face wall 102B, under such forces F1 and F2. This deformation allows the inner region 106 to move away from the first horizontal plane P1 and the second horizontal plane P2 in an axially inward direction.

[0052] Reference Figure 8 The diagram shows the vacuum insulation structure 90 after the evacuation procedure has been performed, such that cavity 100 now represents the evacuated cavity. The outer frame portion 102 is shown deformed by axial inward bending via the facet wall 102B, particularly at a location adjacent to the second sidewall 102C. In this way, the facet wall 102B is angled downwards, causing the second sidewall 102C to have moved relative to the first sidewall 102A along the axial direction A. Figure 8 As shown, this movement facilitates a generally uniform inward movement of the inner region 106 relative to the first plane horizontal P1. In this way, the deformation of the first cover member 92 and the second cover member 94 under vacuum is confined within the outer frame portion 102, thus controlling the overall effect of such deformation. This helps maintain the desired performance of the vacuum insulation structure 90 while preserving its desired aesthetic quality.

[0053] like Figures 4 to 8As further shown, the first cover member 92 and the second cover member 94 include a plurality of ribs 108 arranged in a grid pattern and extending from the outer frame portion 102 across the inner region 106. The ribs 108 include, in a first direction (i.e., in...) Figure 4 The image shown shows a horizontally extending parallel rib group 108A, and in a direction perpendicular to the first direction (i.e., in...). Figure 4 The image shown shows a second parallel rib group 108B extending in a second direction (vertical) to define the aforementioned grid pattern. Rib groups 108A and 108B are also shown as stamping features within the sheet material of the first cover member 92 and the second cover member 94. In this way, they can be formed simultaneously with the outer frame portion 102. Additionally, rib 108 is shown intersecting with a corresponding parallel second surface 102C of the outer frame portion 102. In this way, the second surface 102C provides structural support for rib 108, wherein rib 108 is generally shorter than the second surface 102C, such that the presence of rib 108 does not hinder the aforementioned inward deformation of the faceplate 102B. The stamping nature of the ribs and the generalized grid pattern defined by the intersection of the corresponding parallel rib groups 108A and 108B provide structural support for the inner region 106 to resist deformation of the first cover member 92 and the second cover member 94 within the inner region. In this way, as... Figure 8 As shown, under the deformation of the outer frame 106, the inner region moves inward in a generally uniform manner in the axial direction A as described above. It is worth noting that the inner region 106 may undergo some deformation, including along the rectangular area between the intersecting ribs 108; however, this deformation can be less than 1 mm, making it generally difficult for an observer to perceive, especially when such deformation is visually obscured by the visual features of the first cover member 92 and the second cover member 94. Furthermore, Figure 8 The overall deformation shown may be schematically exaggerated, with the inward movement of the weakened portion 93C and the inward movement of the inner region 106 being less than 2 mm, and in one aspect between 1 mm and 2 mm.

[0054] Now refer to Figures 9A to 16B This illustrates another embodiment of a vacuum insulation structure 90A according to this concept. The vacuum insulation structure 90A includes components similar to... Figure 4 Many features of the vacuum insulation structure 90 shown will be indicated by the same reference numerals. Vacuum insulation structure 90A is also expected to represent Figure 1A This is a part of the vacuum insulated cabinet structure 12 shown. Figures 8 to 9B The concept described in the text is also represented. Figure 21A and Figure 21B Specifically, the vacuum insulated cabinet structure 90B is shown. For example... Figure 17As shown in the exploded view, the vacuum insulation structure 90A includes a first cover member 92 and a second cover member 94. The thermal bridge 96 includes side members 96A-96D and an evacuation port 98 for entering the cavity 100, which is formed when the first cover member 92 and the second cover member 94 are coupled to the thermal bridge 96 at the first surface 97 and the second surface 99. (As described above...) Figure 4 and Figure 5 As discussed in the vacuum insulation structure, the first cover member 92 and the second cover member 94 may include opposing outer walls (58 and 60) of the outer wrapping 18 and / or corresponding portions of an outer wall and upper liner 20A and lower liner 20B, which are also spaced apart from each other to define Figure 1A The thermally insulating cavity 24 is shown positioned between them. Therefore, the depicted thermal bridge 96 should again be understood as illustrative only, such that in the application of the refrigerator outer wrapping 18, the thermal bridge 22 can be represented solely by the side wall 96A, in which the aforementioned openings 25 and 26 receive the corresponding lining. In such an application, the remaining side walls 96B-96D may correspond to the top wall 58, bottom wall 60, and rear wall 62 of the wrapping 18.

[0055] Figures 9A to 16B Various examples of the first cover member 92 according to this embodiment are shown. As shown, each example of the first cover member 92 includes an outer frame portion 102 disposed inside the periphery 104 of the first cover member 92, the outer frame portion 102 surrounding an inner region 106. Figure 9B As shown in one example, the inner region 106 defines a first horizontal plane P1, and a portion of the outer frame portion 102 extends to a second horizontal plane P2, which is horizontally parallel to and spaced horizontally from the first plane in the axial direction A. As further shown, the outer frame portion 102 includes a first stepped section 102A extending from the first horizontal plane P1 to a second stepped section 102B, and a second stepped section 102B extending to the second horizontal plane P2, wherein the stepped sections 102A and 102B are angled to also extend outward from the inner region 106 to a periphery 104 in the radial direction R, the periphery being positioned at the second horizontal plane P2. In this way, when the first cover member 92 is in the depicted pre-assembled and pre-emptied state, the inner region 106 is substantially suspended outward from the periphery 104 by the outer frame portion 102 at the first horizontal plane P1, including relative to the periphery 104. In any assembly using the various first cover members 92 described, the second cover member 94 can be similarly formed with similar structures and elements, such that in one respect, the second cover member 94 can be a mirror image of the first cover member 92.

[0056] The first cover member 92 and the second cover member 94 are contemplated as sheet metal cover members, wherein the outer frame portion 102 is a stamped portion formed by a stamping process that stretches and thins a specific portion of the outer frame portion 102. Specifically referring to the first cover member 92, weakened portions 93A, 93B, and 93C are shown as being disposed between the inner region 106 and the first step segment 102A, between the first step segment 102A and the second step segment 102B, and around the second step segment 102B, and are contemplated as weakened portions of the first cover member 92 that are stretched and thinned during the stamping process. It is understood that... Figures 10A to 16B The various additional cover components shown may differ in the number and construction of the step sections 102A, 102B, ... 102X, as well as the number of the corresponding weakening portions 93A, 93B, ... 93X, for example... Figure 10A and Figure 10B The arrangement shown has an additional step section 102C outside the second step section 102B, and a corresponding additional weakening portion 93D outside the weakening portion 93C between the second step section 102B and the third step section 102C. Furthermore, the depicted first cover member 92 may vary at the corner transition between the horizontal and vertical extensions of the outer frame portion 102. Specifically, Figure 11A and Figure 11B Variations and Figure 12A and Figure 12B Further variations include angled sections 110, which can be used to reinforce the step portions 102A through which they extend. Figure 11A ) or 102B ( Figure 12A ).exist Figures 13A to 16B In the alternative variant, the outer frame portion 102 is shown with rounded corners 112. It will be understood that any additional variants depicted in the referenced figures may be... Figures 17 to 20 The component is replaced to achieve an effect similar to that shown therein and described below.

[0057] In the illustrative schematic component 90, a first cover member 92 is coupled to a first surface 97 of a thermal bridge 96, while a second cover member 94 is coupled to a second surface 99 of the thermal bridge 96. By coupling the first cover member 92 and the second cover member 94 to the thermal bridge 96, a cavity is formed in the vacuum insulation structure 90. This cavity is identified as... Figures 5 to 8 The figure shown is referenced to 100 and is intended to represent... Figure 1A Part of the insulation cavity 24 of the vacuum insulated cabinet structure 12 shown.

[0058] Now refer to Figure 18A ,and Figure 17 Compared to the exploded view shown, the vacuum insulation structure 90 is shown in an assembled state. Although Figure 18A The vacuum insulation structure 90 shown is provided during the static or pre-evacuation phase, but structure 90 is still referred to herein as the vacuum insulation structure. In the assembled state, the vacuum insulation structure 90 is shown having a first surface 97 and a second surface 99 connected to a thermal bridge 96. Figure 17 The first cover member 92 and the second cover member 94 are coupled. In this configuration, the internal regions 106 of the first cover member 92 and the second cover member 94 remain positioned at the corresponding first plane level P1. In the assembled state shown in FIG. 18, the vacuum insulation structure 90 includes a cavity 100, which can be accessed substantially through a port 98 located in the thermal bridge 96 or elsewhere in the structure 90 to evacuate air from the cavity 100, as described above regarding... Figures 6 to 8 As discussed above, when assembling the vacuum insulation structure 90, the cavity 100 can be filled with an insulating medium. Figure 18B As shown, when vacuuming is performed, the inner region 106 moves away from the first horizontal plane P1 and toward the axial inner side of the second horizontal plane P2 by the reversal of the outer frame 102, especially in the step sections 102A, 102B, etc., which promotes the corresponding weakening parts 93A, 93B, etc.

[0059] Now refer to Figure 19 , showed Figure 18A A cross-sectional view of the vacuum insulation structure 90, wherein the outer frame portion 102 of the first cover member 92 and the second cover member 94 is shown in an undeformed state suspending the inner regions 106 of the respective first cover members 92 and the second cover members 94 at the indicated first plane level P1. In this way, the stepped sections 102A, 102B are shown extending axially outward from the periphery 104 (at the second plane level P2) to support the inner regions 106 at the first plane level P1. When the cavity 100 of the vacuum insulation structure 90 is evacuated, the first cover member 92 and the second cover member 94 are subjected to inwardly pointing forces F1 and F2, respectively, which drive the first cover member 92 and the second cover member 94 in one direction. Due to the weakening of the weakened portions 93A, 93B, etc., these portions of the first cover member 92 and the second cover member 94 are more prone to bending or deflection compared to other portions of the first cover member 92 and the second cover member 94. Therefore, due to the inward forces F1 and F2 caused by the vacuum drawn into the cavity 100, the outer frame portion 102 of the first cover member 92 and the second cover member 94 deforms under such forces F1 and F2, particularly along the step sections 102A and 102B. This deformation allows the inner region 106 to move away from the first horizontal plane P1 and through the second horizontal plane in an axially inward direction.

[0060] Reference Figure 20The diagram shows the vacuum insulation structure 90 after the evacuation procedure has been performed, such that cavity 100 now represents the evacuated cavity. The outer frame portion 102 is shown deformed by axial inward bending at the corresponding weakened portions 93A, 93B, and 93C via stepped sections 102A, 102B. In this way, the outer frame 102 is reversed, which facilitates a generally uniform inward movement of the inner region 106 relative to the first plane horizontal P1, as... Figure 20 As depicted in [the original text]. In this way, the deformation of the first cover member 92 and the second cover member 94 under vacuum is confined within the outer frame portion 102, thus controlling the overall effect of such deformation. This helps maintain the desired performance of the vacuum insulation structure 90 while preserving its desired aesthetic quality. Another [description] from [the original text]... Figures 11A to 16B The first cover member 92 will be understood to perform similarly under such conditions in such a component 90A.

[0061] Now refer to Figure 21A The vacuum insulation structure 90C is shown as having the features described above. Figure 18A and Figure 18B The outer cladding 18 and the upper lining 20A are interconnected via thermal bridge 22. Figure 21A In the illustrated embodiment, the vacuum insulation structure 90C is shown having sidewalls 58, 60 and a rear wall 62 of an outer cladding 18 positioned in a straight line with the second horizontal plane P2. Similarly, the first sidewall 34 and second sidewall 36 and rear wall 38 of the upper lining 20A are also shown positioned at the corresponding second horizontal plane P2, such that the vacuum insulation structure 90C is configured in a pre-vacuum state. When a vacuum is drawn from the structure 90C, as... Figure 21B As shown, the internal region 106 of each such plate is aligned with the above... Figure 18A and Figure 18B The similar method described in the text is reversed to the form shown.

[0062] Another aspect of this concept includes a method of manufacturing a vacuum-insulated cabinet structure (e.g., cabinet structures 12 and 90C). The method includes the steps of: 1) assembling a first cover member 92 and a second cover member 94 using a thermal bridge 96, wherein at least the first cover member 92 defines a peripheral portion 104, an outer frame portion 102 defined radially inward of the peripheral portion 104, and an internal region 106 surrounded and supported by the outer frame portion 102. The internal region 106 defines a first horizontal plane P1, and a portion of the outer frame portion 102 extends to a second horizontal plane P2, which is parallel to and spaced outward from the first horizontal plane P1. Assembling the first cover member 92 and the second cover member 94 using the thermal bridge 96 defines a sealed, insulated cavity 100 between them. The method further includes the step of: 2) evacuating the sealed, insulated cavity 100, which causes the outer frame portion 102 to deform, such that the internal region 106 moves axially inward from the second horizontal plane P2 under the vacuum force of the insulated cavity 100.

[0063] The invention disclosed herein is further summarized in the following paragraphs, and is characterized by any and all combinations of the aspects described herein.

[0064] According to another aspect of this disclosure, a vacuum insulation structure includes a first cover member of an integral sheet member defining a peripheral portion, an outer frame portion defined radially inward of the peripheral portion, and an internal region surrounded and supported by the outer frame portion. The internal region defines a first horizontal plane, and a portion of the outer frame portion extends to a second horizontal plane, which is parallel to and axially spaced from the first horizontal plane. The vacuum insulation structure also includes a second cover member of the integral sheet and a thermal bridge that interconnects the first and second cover members at their peripheral portions to define an insulation cavity between them. The insulation cavity is a sealed cavity from which a vacuum is drawn, and deformation of the outer frame portion causes the internal region to move axially inward away from the second horizontal plane under the influence of the vacuum force within the insulation cavity.

[0065] The outer frame portion includes a first sidewall extending horizontally from a first plane to a second plane, a facewall extending radially inward along the second plane, and a second sidewall extending horizontally from the second plane to connect with the interior region at the first plane.

[0066] The outer frame is deformed by bending axially inwards near the second sidewall, causing the second sidewall to move relative to the first sidewall.

[0067] The surrounding area is set at the level of the second plane.

[0068] The internal region is constructed to resist deformation, so that the deformation of the first cover member is mainly within the outer frame portion.

[0069] The interior region defines multiple ribs, which are arranged in a grid pattern and extend from the outer frame across the interior region to provide structural support for the interior region to resist deformation.

[0070] The second cover member defines a peripheral portion, an outer frame portion defined radially inward of the peripheral portion, and an inner region surrounded and supported by the outer frame portion. The inner region defines a third horizontal plane, a portion of the outer frame portion extending to a fourth horizontal plane, the fourth horizontal plane being parallel to and spaced apart from the third horizontal plane in an axially outward direction.

[0071] The outer frame of the second cover component deforms, causing the internal region of the second cover component to move axially inward from the third horizontal plane and the fourth horizontal plane under the action of the vacuum force in the insulation cavity.

[0072] Vacuum insulation structures also include insulation materials placed inside the insulation cavity.

[0073] The outer frame defines multiple stepped sections from the periphery to the interior area, as well as multiple angled sections extending between the stepped sections.

[0074] According to another aspect, a method of manufacturing a vacuum-insulated cabinet structure includes assembling a first cover member and a second cover member using thermal bridges. At least the first cover member defines a peripheral portion, an outer frame portion defined radially inward of the peripheral portion, and an internal region surrounded and supported by the outer frame portion. The internal region defines a first horizontal plane, and a portion of the outer frame portion extends to a second horizontal plane, which is parallel to and spaced outward from the first horizontal plane. The first and second cover members, assembled using thermal bridges, define a sealed insulating cavity between them. The method also includes evacuating the sealed insulating cavity, which causes deformation of the outer frame portion, such that the internal region moves axially inward from the second horizontal plane under the influence of the vacuum force within the insulating cavity.

[0075] The first cover member is an external enclosure structure defining the cabinet structure, and the second cover member is an internal lining structure defining the cabinet structure.

[0076] The first cover member defines a first outer portion, on which a peripheral portion, an outer frame portion, and an inner region are defined, and the first cover member defines a second outer portion, which further defines additional corresponding peripheral portions, outer frame portions, and inner regions.

[0077] The outer frame portion includes a first sidewall extending horizontally from a first plane to a second plane, a facewall extending radially inward along the second plane, and a second sidewall extending horizontally from the second plane to connect with the interior region at the first plane. Vacuuming from the sealed, insulated cavity causes the outer frame portion to deform by bending axially inward through the facewall adjacent to the second sidewall, causing the second sidewall to move relative to the first sidewall.

[0078] The internal region is constructed to resist deformation, such that vacuuming from the sealed, insulated cavity causes the first cover component to deform primarily within the outer frame portion.

[0079] The interior region defines multiple ribs, which are arranged in a grid pattern and extend from the outer frame across the interior region to provide structural support for the interior region to resist deformation.

[0080] The method also includes introducing insulation material into the insulation cavity.

[0081] Thermal insulation materials include pyrolytic silica, glass beads, processed rice husks, and combinations thereof.

[0082] According to another aspect, a refrigerator includes a vacuum-insulated cabinet structure having an outer enclosure having a first side portion defining a peripheral portion, an outer frame portion defined radially inward of the peripheral portion, and an internal region surrounded and supported by the outer frame portion. The internal region defines a first horizontal plane, a portion of the outer frame portion extending to a second horizontal plane parallel to and spaced outward from the first horizontal plane. The refrigerator also includes an inner lining disposed inside the outer enclosure and a thermal bridge that interconnects a first cover member and a second cover member at their peripheral portions to define an insulated cavity between them. The insulated cavity is a sealed cavity from which a vacuum is evacuated, and deformation of the outer frame portion causes the internal region to move axially inward away from the second horizontal plane under the influence of the vacuum force within the insulated cavity.

[0083] Thermal bridges surround an opening leading to the interior cavity of the refrigerator defined by a liner, and the refrigerator also includes at least one door operable to close the opening.

[0084] Those skilled in the art will understand that the construction of the described disclosure and other components is not limited to any particular material. Unless otherwise stated herein, other exemplary embodiments of this disclosure may be formed from a variety of materials.

[0085] For the purposes of this disclosure, the term "coupled" (and all its forms) generally refers to the direct or indirect connection between two components (electrical or mechanical). Such a connection may be fixed or movable in nature. This connection can be achieved by two components (electrical or mechanical) and any additional intermediate members that form a single unit with or with the two components. Unless otherwise stated, such a connection may be permanent or removable or detachable in nature.

[0086] It is equally important to note that the structure and arrangement of the elements of this disclosure shown in the exemplary embodiments are merely illustrative. Although only a few embodiments of the invention have been described in detail in this disclosure, those skilled in the art will readily understand that many modifications can be made (e.g., variations in the size, dimensions, structure, shape and proportion, parameter values, mounting arrangements, use of materials, color, orientation, etc.) of the various elements without substantially departing from the novel teachings and advantages of the described subject matter. For example, an element represented as integrally formed may be composed of multiple parts, or elements represented as multiple parts may be integrally formed; the operation of the interface may be reversed or otherwise altered; the structure and / or the length or width of the system's components or connectors or other elements may be changed; and the nature or number of adjustment positions provided between elements may be changed. It should be noted that the elements and / or components of the system may be made of any of a variety of materials providing sufficient strength or durability, and have any of a variety of colors, textures, and combinations. Therefore, all such modifications should be included within the scope of the invention. Other substitutions, modifications, alterations, and omissions may be made to the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the invention.

[0087] It should be understood that any process described or any step within a described process can be combined with other processes or steps disclosed to form a structure within the scope of this disclosure. The exemplary structures and processes disclosed herein are for illustrative purposes and should not be construed as limiting.

Claims

1. A vacuum insulation structure, comprising: A first cover member of an integral sheet metal member, the first cover member defining a peripheral portion, an outer frame portion defined radially inward of the peripheral portion, and an inner region surrounded and supported by the outer frame portion, the inner region initially defining a first horizontal plane, at least a portion of the outer frame portion extending to a second horizontal plane, the second horizontal plane being parallel to and spaced apart from the first horizontal plane in an axially outward direction. The second cover component of the integral thin plate; as well as A thermal bridge interconnects the first cover member and the second cover member at their peripheral portions to define an insulating cavity between them, wherein the insulating cavity is a sealed cavity from which a vacuum is drawn, and further wherein the outer frame portion deforms such that the inner region moves axially inward horizontally away from the first plane under the action of the vacuum force within the insulating cavity, at least such portion of the outer frame portion remains horizontal to the second plane.

2. The vacuum insulation structure according to claim 1, wherein, The outer frame portion includes a first sidewall extending horizontally from the first plane to the second plane, a facewall extending radially inwardly along the second plane, and a second sidewall extending horizontally from the second plane to connect with the inner region at the first plane.

3. The vacuum insulation structure according to claim 2, wherein, The outer frame portion deforms by bending axially inwards near the second sidewall, causing the second sidewall to move relative to the first sidewall.

4. The vacuum insulation structure according to claim 2 or 3, wherein, The peripheral portion is positioned horizontally on the second plane.

5. The vacuum insulation structure according to any one of claims 1, 2, and 3, wherein, The internal region is configured to resist deformation, such that the deformation of the first cover member is primarily within the outer frame portion.

6. The vacuum insulation structure according to claim 5, wherein, The inner region defines a plurality of ribs arranged in a grid pattern and extending from the outer frame across the inner region to provide structural support for the inner region to resist deformation.

7. The vacuum insulation structure according to claim 1, 2 or 3, wherein, The second cover member defines a peripheral portion, an outer frame portion defined radially inward of the peripheral portion, and an inner region surrounded and supported by the outer frame portion, the inner region defining a third horizontal plane, a portion of the outer frame portion extending to a fourth horizontal plane, the fourth horizontal plane being parallel to and spaced apart from the third horizontal plane in an axially outward direction.

8. The vacuum insulation structure according to claim 7, wherein, The outer frame portion of the second cover member deforms, causing the inner region of the second cover member to move axially inward from the horizontal third plane and the horizontal fourth plane under the action of the vacuum force in the insulation cavity, while at least a portion of the outer frame portion of the second cover member remains horizontal to the fourth plane.

9. The vacuum insulation structure according to claim 1, 2 or 3, further comprising an insulation material disposed within the insulation cavity.

10. The vacuum insulation structure according to claim 1, 2 or 3, wherein, The outer frame portion defines multiple stepped sections from the periphery to the interior region and multiple angled sections extending between the multiple stepped sections.

11. A method for manufacturing a vacuum insulated cabinet structure, comprising: Assemble a first cover member and a second cover member using a thermal bridge, wherein at least the first cover member defines a peripheral portion, an outer frame portion defined radially inward of the peripheral portion, and an internal region surrounded and supported by the outer frame portion, the internal region initially defining a first horizontal plane, at least a portion of the outer frame portion extending to a second horizontal plane parallel to and spaced outward from the first horizontal plane, wherein assembling the first cover member and the second cover member using the thermal bridge defines a sealed, insulating cavity therebetween; and A vacuum is drawn from the sealed insulating cavity, causing the outer frame portion to deform. This causes the inner region to move axially inward from the first horizontal plane and the second horizontal plane under the action of the vacuum force within the insulating cavity, while at least that portion of the outer frame portion remains horizontal to the second plane.

12. The method according to claim 11, wherein: The first cover member is a wrapping structure that defines the exterior of the cabinet structure; and The second cover member is a lining structure that defines the interior of the cabinet structure.

13. The method according to claim 12, wherein: The first cover member defines a first outer portion, on which the peripheral portion, the outer frame portion, and the inner region are defined; and The first cover member defines a second outer portion, which further defines an additional corresponding peripheral portion, an outer frame portion, and an interior region.

14. The method according to claim 11, 12 or 13, wherein: The outer frame portion includes a first sidewall extending horizontally from the first plane to the second plane, a front wall extending radially inwardly along the second plane, and a second sidewall extending horizontally from the second plane to connect with the inner region at the first plane level; and Evacuation from the sealed, insulated cavity causes the outer frame portion to deform axially inward through the face wall adjacent to the second side wall, thereby causing the second side wall to move relative to the first side wall.

15. The method according to claim 11, 12 or 13, wherein, The internal region is configured to resist deformation such that the deformation of the first cover member caused by evacuating from the sealed, insulated cavity is primarily within the outer frame portion.

16. The method according to claim 15, wherein, The inner region defines a plurality of ribs arranged in a grid pattern and extending from the outer frame portion across the inner region to provide structural support for the inner region to resist deformation.

17. The method according to claim 11, 12 or 13, further comprising introducing an insulating material into the insulating cavity.

18. The method according to claim 17, wherein, The insulation material includes one of the following: pyrolytic silica, glass beads, processed rice husks, and combinations thereof.

19. A refrigerator, comprising: The vacuum insulated cabinet structure includes: An outer wrapper having a first side portion defining a peripheral portion, an outer frame portion defined radially inward of the peripheral portion, and an inner region surrounded and supported by the outer frame portion, the inner region initially defining a first horizontal plane, at least a portion of the outer frame portion extending to a second horizontal plane parallel to and spaced apart from the first horizontal plane in an axially outward direction. The lining, which is disposed on the inside of the outer wrapping; and A thermal bridge interconnects the outer casing and the inner lining at their peripheral portions to define an insulating cavity between them, wherein the insulating cavity is a sealed cavity from which a vacuum is drawn, and further, wherein the outer frame portion deforms such that the inner region moves axially inward horizontally away from the first plane under the action of the vacuum force within the insulating cavity, at least such portion of the outer frame portion remains horizontal to the second plane.

20. The refrigerator according to claim 19, wherein, The thermal bridge surrounds an opening leading to an interior cavity of the refrigerator defined by the liner, and the refrigerator also includes at least one door operable to close the opening.

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